Size reduction Comminution

See also Minerals recovery/processing Minerals recovery/processing, 16 595-668. See also Minerals concentration Minerals processing classification in, 16 618-622 economic aspects of, 16 606-609 environmental aspects of, 16 609—610 flow sheets in, 16 603-605 materials handling in, 16 660-663 from ocean waters, 17 695—697 ores, 16 598-603 process control in, 16 663-665 size reduction (comminution) in, 16 610-615... 

A kind of mechanical impact mill or jet mill for size reduction (comminution) that also incorporates a particle classifier. 

A surfactant used in froth flotation to adsorb onto solid particles, make them hydrophobic, and thus facilitate their attachment to gas bubbles. See also Froth Flotation. A high-shear mixing device used to prepare colloidal dispersions of particles or droplets by size reduction (comminution). Also termed dispersion mill . 

Colloid Mill A high-shear mixing device used to prepare colloidal dispersions of particles or droplets by size reduction (comminution). Also termed dispersion mill. 

Energy demands are heavy in gas compression, size reduction (comminution), and in those separations operations involving vaporization, evaporative concentration, drying and distillation. 

The raw ROM (run of mine) ore is reduced in size from boulders of up to 100 cm in diameter to about 0.5 cm using jaw cmshers as weU as cone, gyratory, or roU-type equipment. The cmshed product is further pulverized using rod mills and ball mills, bringing particle sizes to finer than about 65 mesh (230 p.m). These size reduction (qv) procedures are collectively known as comminution processes. Their primary objective is to generate mineral grains that are discrete and Hberated from one another (11). Liberation is essential for the exploitation of individual mineral properties in the separation process. At the same time, particles at such fine sizes can be more readily buoyed to the top of the flotation ceU by air bubbles that adhere to them. 

Flow Sheets. AH minerals processing operations function on the basis of a flow sheet depicting the flow of soHds and Hquids in the entire plant (6,13,14). The complexity of a flow sheet depends on the nature of the ore treated and the specifications for the final product. The basic operations in a flow sheet are size reduction (qv) (comminution) and/or size separation (see Separation, size), minerals separation, soHd—Hquid separation, and materials handling. The overaH flow sheet depends on whether the specification for the final mineral product is size, chemical composition, ie, grade, or both. Products from a quarry, for example, may have a size specification only, whereas metal concentrates have a grade specification. 

Size reduction (qv) or comminution is the first and very important step in the processing of most minerals (2,6,10,20—24). It also involves large expenditures for heavy equipment, energy, operation, and maintenance. Size reduction is necessary because the value minerals are intimately associated with gangue and need to be Hberated, and/or because most minerals processing/separation methods require the ore mass to be of certain size and/or shape. Size reduction is also required in the case of quarry products to produce material of controlled particle size (see Size measurement of particles). In some instances, hberation of valuables or impurities from the ore matrix is achieved without any apparent size reduction. Scmbbers and attritors used in the industrial minerals plants, eg, phosphate, mtile, glass sands, or clay, ate examples. 

Many crystalline products, including fine chemicals, foodstuffs and pharmaceuticals, require a final particle size that is significantly smaller than that produced during the crystallization or precipitation step. One way of achieving the required particle size is to employ a subsequent size-reduction step using some form of comminution device, frequently a mill. 

Institution of Chemical Engineers, 1975. In Comminution, Institution of Chemical Engineers Working Party concerned with the theory and practice of the size reduction of solid materials. Ed. V.C. Marshall, Institution of Chemical Engineers, Rugby, 83pp. 

The major purposes of comminution or size reduction operations can be summarized in four categories as shown in Table 2.2. Comminution is almost invariably performed in two or more stages. It starts with the crude mined or quarried product this is progressively taken to the desired final size by a step-by-step process. As the process of fracture is involved throughout this procedure, a brief discussion on the fracture of materials is appropriate at this point. 

Separation processes, as could be seen from Figure 2.1, position themselves at the back end of the sequence in operations in the mineral processing flowsheet. The front-end operations has been found virtually to terminate with the liberation or the size-reduction processes involving crushing and grinding. It is important to limit the amount of size reduction to that at which adequate liberation is accomplished. The term adequacy is related to the cost involved in comminution and to performance of the concentration methods that follows. The concentration is obtained by separation processes which rely on differences in the properties of the particles, the physical and physico-chemical characteristics of minerals. In this context, it will only be relevant to refer to Table 2.5 which presents a summary of the processes along with the properties of the minerals that are exploited. 

Modeling ofBubble-Induced Attrition. Merrick and Highley (1974) have modeled bubble-induced attrition as a comminution process. According to Rittinger s law of size reduction by abrasion (cfi, Perry, 1973), the rate of creation of new surface area AS Al is proportional to the rate of energy input Ah. At... 

In the materials processing industry, size reduction or comminution is usually carried out in order to increase the surface area because, in most reactions involving solid particles, the rate of reactions is directly proportional to the area of contact with a second phase. Thus the rate of combustion of solid particles is proportional to the area presented to the gas, though a number of secondary factors may also be involved. For example, the free flow of gas may be impeded because of the higher resistance to flow of a bed of small particles. In leaching, not only is the rate of extraction increased by virtue of the increased area of contact between the solvent and the solid, but the distance the solvent has to penetrate into the particles in order to gain access to the more remote pockets of solute is also reduced. This factor is also important in the drying of porous solids, where reduction in size causes both an increase in area and a reduction in the distance... 

Comminution, or particle size reduction of solids, is considerably different from that of the breakup of one liquid by dispersal as small droplets in another. Particle size reduction is generally achieved by one of four mechanisms (1) compression, (2) impact, (3) attrition and (4) cutting or shear. Equipment for particle size reduction or milling includes crushers (which operate by compression, e.g., crushing rolls), grinders (which operate principally by impact and attrition, although some compression may be involved, e.g.,... 

Impact Milling Particle size reduction by high-speed mechanical impact or impact with other particles (also known as milling, pulverizing, or comminuting)... 

Characteristics of the main common types of size reduction equipment are listed in Table 12.3, including size of feed, size of product, capacity, power consumption, and average reduction ratio. Coarse comminuters perform with reduction ratios less than 10, fine ones with ratios of 100 or more. From very large to very fine may require several operations in series, as in the flowsketch of Figure 12.4(b), where three stages of crushing and two of classification are shown. 

Nanoparticle size, as accomplished by size reduction techniques, has been an area of focus using wet milling comminution processes to achieve submicron particle nm (Liversidge et al.,... 

In industrial and laboratory settings the subdivision process more commonly involves the comminution of large particles or aggregates into smaller sizes, either dry with subsequent dispersion (size reduction to the order of a few pm) or directly in a slurry (size reduction to as small as a few tenths of pm). Examples of comminution machines include agitator ball mills, colloid mills, cutting mills, disk mills, homogenizers, jet mills, mechanical impact mills, ring-roller mills, and roll crushers. 

A machine for the comminution, or size reduction, of minerals or other materials. Such machines crush the input material by wet grinding in a cylindrical rotating bin containing grinding balls. These mills can produce colloidal-sized particles. 

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