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    Chapter 11 Size Reduction

    Uploaded by

    Charmaine A. Olivas
    Size reduction is the process of cutting, crushing, grinding or milling solid materials to reduce their size without chemically altering them. Common size reduction processes include cutting fruits and vegetables, grinding grains, and milling flour. The size of reduced materials can be characterized using dimensions, sieves or microscopy. Key devices for size reduction include hammer mills, burr mills, crushers and cutter mills. The size of the final product and power requirement depends on factors like the type of mill and materials being processed.

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    © All Rights Reserved
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    Chapter 11 Size Reduction

    Uploaded by

    Charmaine A. Olivas
    65 views50 pages
    Size reduction is the process of cutting, crushing, grinding or milling solid materials to reduce their size without chemically altering them. Common size reduction processes include cutting fruits and vegetables, grinding grains, and milling flour. The size of reduced materials can be characterized using dimensions, sieves or microscopy. Key devices for size reduction include hammer mills, burr mills, crushers and cutter mills. The size of the final product and power requirement depends on factors like the type of mill and materials being processed.

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    Size reduction is the process of cutting, crushing, grinding or milling solid materials to reduce their size without chemically altering them. Common size reduction processes include cutting fruits and vegetables, grinding grains, and milling flour. The size of reduced materials can be characterized using dimensions, sieves or microscopy. Key devices for size reduction include hammer mills, burr mills, crushers and cutter mills. The size of the final product and power requirement depends on factors like the type of mill and materials being processed.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    65 views50 pages

    Chapter 11 Size Reduction

    Uploaded by

    Charmaine A. Olivas
    Size reduction is the process of cutting, crushing, grinding or milling solid materials to reduce their size without chemically altering them. Common size reduction processes include cutting fruits and vegetables, grinding grains, and milling flour. The size of reduced materials can be characterized using dimensions, sieves or microscopy. Key devices for size reduction include hammer mills, burr mills, crushers and cutter mills. The size of the final product and power requirement depends on factors like the type of mill and materials being processed.

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    SIZE REDUCTION

    by

    Engr. Alexis T. Belonio, PAE, Fellow PSAE


    Associate Professor and Chair
    Department of Agricultural Engineering and Environmental
    Management
    College of Agriculture
    Central Philippine University
    Iloilo City
    Email: atbelonio@yahoo.com
    Introduction
     Size reduction is usually refers to cutting,
    crushing, grinding, and milling of solid mass.
     The size reduction in size of the product is
    brought about by mechanical means without a
    change in chemical properties of material and
    the uniformity in size and shape of the individual
    grains and units of the product is usually
    desired.
    Examples of Size Reduction
    Processes
     Cutting of fruits and vegetables for canning
     Shredding of sweet potato for drying
     Chopping corn fodder
     Grinding limestone for fertilizer
     Grinding grains for livestock feed
     Milling flour
     Etc
    Milling
     This is the trade term used relative to the
    reduction of grain into meal or flour.
     The milling process includes
    – Size reduction
    – Hulling
    – Scarifying
    – Polishing
    – Sorting
    – Mixing
    Size Characteristics
     Machine performance in reducing the size
    of material is characterized by the
    following:
    – Capacity
    – Power required per unit of material reduce
    – Size and shape of the product before and
    after reduction
    – Range of size and shape of the resulted
    product
    Classifications of Reduced Materials

    Class Size

    Dimension Range Size 1/8 in or more

    Sieve Range 0.125 to 0.0029 in

    Microscopic Range less than 0.0029


    Sieves
     These are the
    simplest method of
    classifying granular
    materials by passing
    the them into series
    of Tyler sieves
    Tyler Standard Screen Sieve
    Mesh No. Openings to Diameter of Wire, in. Size of Opening
    in.
    - 0.1050 0.5250
    3 0.0700 0.2630
    6 0.0360 0.1310
    8 0.0320 0.0930
    10 0.0350 0.0650
    14 0.0250 0.0460
    20 0.0172 0.0328
    28 0.0125 0.0232
    35 0.0122 0.0164
    48 0.0092 0.0116
    65 0.0072 0.0082
    100 0.0042 0.0058
    150 0.0026 0.0041
    200 0.0021 0.0029
    Fineness Modulus
     This indicates the uniformity of grind in the
    resultant product.
     It is the sum of the weight fractions retained
    above each sieve divided by 100.
     Sieve used are: 3/8-, 4-, 8-, 14-, 28, 48-, and
    100-in mesh
     Standard samples is 250 grams oven dried to
    constant weight to 100 C and shaken to Ro-Tap
    for 5 minutes.
    Determine the fineness modulus for the following data obtained
    using a hammer mill:

    Mesh Size of Opening Percent of Material Multiplied by


    Retained
    3/8 0.371 0.0 7= 0
    4 0.185 3.7 6 = 22.2
    8 0.093 20.4 5 = 10.7
    14 0.046 36.1 4 = 144.4
    28 0.0232 17.8 3 = 53.4
    48 0.0116 10.1 2 = 20.2
    100 0.0058 7.0 1 = 7.0
    Pan 4.9 0= 0
    257.9

    Fineness Modulus = 257.9 / 100


    = 2.57
    Particle Size

    D = 0.0041 (2) FM

    where:
    D - average grain size, inches
    FM - fineness modulus, dmls

    Using the data above, the particle diameter D = 0.0041 (2) 2.57
    is 0.024 inch
    Size Reduction Procedure
     Cutting – It is a separation or reduction
    which produce by pushing or forcing a thin,
    sharp knife through the materials to be
    reduce.
     Crushing – This is the reduction by applying
    a force to the unit to be reduced in excess
    of its strength.
     Shearing – This is the combination of
    cutting and crushing. This can be done
    either singly or in combination.
    Cutting
     Minimum deformation and rupture of the reduce
    particles.
     New surfaces produce by this sharp knife are
    relatively undamaged.
     Well adopted to fruits and vegetables.
     Knife of extreme sharpness and as thin as
    possible is the most satisfactory cutting device.
     Knife with edge that has sawing component
    provides a smoother cut with probably less
    energy.
    Crushing
     Characteristics of the new surfaces are irregular
    in size and shape.
     The characteristics of the new surfaces and
    particles are dependent upon the type of
    material and the method of force application.
     Crushing by means of rigid roll or bed are
    example of static force application.
     Hitting the product with hammer is example of
    dynamic force application.
    Shearing
     It is usually used for reducing materials of
    a tough fibrous nature where some
    crushing may be advantageous and the
    resulting units are of large uniform size.
     For beast performance, the clearance
    between the bar and the knife should be
    small as possible and the knife as sharp
    and thin as possible.
    Size Reducing Devices
     Hammer Mill – reduction caused by impact
    – Fixed Hammer
    – Swinging Hammer
     Attrition Mill or Burr Mill or Plate mill – reduction caused
    by twisting pressure
     Crushers – reduction cause by simple normal pressure
    – Jaw
    – Gyratory
    – Roller mill
     Cutter Mill - reduction cause by cutting
    Hammer Mill
     It consist essentially of a
    rotating beater and heavy
    perforated screen.
     The material is introduced
    into the housing and the
    beater that rotates 1500
    to 4000 rpm beats and
    pounds the material until
    it is small enough to pass
    through the screen.
     The fineness of the
    material is controlled
    mainly by the size of holes
    of the screen.
     Hammers are rigidly
    fixed to the shaft or
    swing.
     The striking edge of
    the hammer is
    designed in great
    many ways.
     The swinging hammer
    are usually reversible.
    Advantages of Hammer Mill
     Simplicity
     Versatility
     Freedom from significant damage due to
    foreign objects
     Freedom from damage when operating
    empty
     Hammer wear does not materially reduce
    its efficiency
    Disadvantages of Hammer Mill
     Inability to produce uniform grind
     High power requirement
    Attrition, Burr, or Plate Mill
     It consists essentially of two
    roughened plates, one
    stationary and other rotating.
     The material is fed between
    the plates and is reduced by
    crushing and shear.
     Over feeding reduces the
    effectiveness of the grinder
    and excessive heating results.
     Operating speed is usually less
    than 1200 rpm.
     The fineness of reduction is controlled by
    the type of plates and by the spacing.
     It is heavy –duty precision used for
    preparation of feed and food.
     Each burr rotates and is driven
    independently, speed are much higher,
    and design and construction are more
    precise.
    Advantages of Burr Mill
     Low initial cost
     Product may be relatively uniform
     Power requirement are very low
    Disadvantages of Burr Mill
     Foreign objects may cause breakage
     Operating empty may cause excessive
    burr wear
     Worn burrs yield poor results.
    Crushers
     It reduce the material by pressing or
    squeezing it until the material breaks.
     Crushers includes the following:
    – jaw crusher – cheaper and slower used for
    smaller operation.
    – gyratory crusher – cone in shape smoother
    operation and capacity is higher
    – roll crusher – Used for primary reduction of
    material following attrition or hammer mill.
    Roller Mills Used for Slicing Noodles into Sizes
    Cutter Mill
     It is best for reducing the size of fibrous
    materials like forages, straws, and weeds
    Performance Characteristics
     Product uniform as to size
     Minimum temperature size during
    reduction
     Minimum power requirement
     Trouble free operation
    Product Size
    Hammer Mill Vary the size of screen opening

    Burr Mill Vary spring pressure on the burrs

    Roller Mill Vary opening between roll

    Cutter Mill Vary the rate of feed of material


    with respect to the cutter rpm
    Uniformity of the Product
     Attrition mill does not significantly produce
    a more uniform product than hammer mill.
    Power Requirement
     Affected by the type of materials, moisture
    content, fineness of grinding, rate of
    feeding, type and condition of mill, etc.
     Fibrous materials requires more power
    than crystalline materials.
     Moist grain are difficult to grind than dried
    grains.
     The power required to operate empty
    increases swiftly are the speed of the mill
    increases.
     Capacity of hammer mill is limited by the
    power available.
    Energy Requirement of Feed Grinding
    (kW-hr/ton)
    Material Hammer Mill Burr Mill

    Shelled Corn 7.4 3 – 5.8

    Oats 11.5 – 14 5 – 14

    Barley 9 – 14 4 – 10

    Ear Corn 6–8 -

    Hay 8 - 16 -
    Temperature Rise
     The energy for grinding is dissipated as heat
    energy and raises the temperature of the ground
    product , the mill and the ambient air.
     Some heat is lost in vaporizing moisture.
     Temperature may rise higher when grinding
    fibrous materials particularly when producing fine
    materials.
     Hammer mill produces a cooler product because it
    uses air for conveying the materials.
     High temperature contributes to decomposition of
    ground materials especially if the moisture
    content is high.
    Material Temperature Rise During Grinding
    Material Type of Grinder Fineness Temp
    Modulus Elevation
    Oats Burr 2.73 50

    Hammer 2.70 18

    Barley Burr 3.66 8

    Hammer 3.66 2

    Shelled Corn Burr 3.96 7

    Hammer 3.13 10

    Ear Corn Burr 3.07 14

    Hammer 3.05 13
    References
     Henderson, S. M, and R. L. Perry. 1976.
    Agricultural Process Engineering. Third
    Edition. The AVI Publishing Company,
    Inc. Westport Connecticut. 442pp.
     Hunt, D. Farm Power and Machinery
    Management. Iowa State University
    Press. Ames, Iowa. 365pp
    Thank you very much
    and God bless!!!

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