Mechanistic modeling and simulation of grinding iron ore pellet feed in pilot and industrial-scale ball mills

Carvalho, Rodrigo M. de; Campos, Túlio Moreira; Faria, Patrícia Mundim Campos; Tavares, Luís Marcelo

doi:10.1016/j.powtec.2021.07.030

Cited by 16 publications

(11 citation statements)

References 39 publications

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“…According to a semi-theoretical analysis (Hayashi and Tanaka, 1972), the impact force for free-falling balls scales with D 0.5 . A recent advanced DEM simulation study (De Carvalho et al, 2021) provides a more fundamental explanation. Their DEM simulations point out a significant expansion of the collision frequency-collision energy envelope as the ball milling is carried out at larger scales: from batch to pilot and then to industrial mills.…”

Section: Virtual Scale-up With the Kk Modelmentioning

confidence: 99%

On the Similarity of Austin Model and Kotake–Kanda Model and Implications for Tumbling Ball Mill Scale-Up

Bilgili

2023

KONA

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The aim of this theoretical investigation is to seek any similarities between the Austin model and the Kotake-Kanda (KK) model for the specific breakage rate function in the population balance model (PBM) used for tumbling ball milling and assess feasibility of the KK model for scale-up. For both models, the limiting behavior for small particle size-to-ball size ratio and the extremum behavior for a given ball size are described by "power-law." Motivated by this similarity, specific breakage rate data were generated using the Austin model parameters obtained from the labscale ball milling of coal and fitted by the KK model successfully. Then, using the Austin's scale-up methodology, the specific breakage rate was scaled-up numerically for various mill diameter scale-up ratios and ball sizes of 30-49 mm and coal particle sizes of 0.0106-30 mm. PBM simulations suggest that the KK model predicts identical evolution of the particle size distribution to that by the Austin model prior to scale-up. Upon scale-up, the differences are relatively small. Hence, modification of the exponents in the Austin's scale-up methodology is not warranted for scale-up with the KK model. Overall, this study has established the similarity of both models for simulation and scale-up.

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Section: Virtual Scale-up With the Kk Modelmentioning

confidence: 99%

On the Similarity of Austin Model and Kotake–Kanda Model and Implications for Tumbling Ball Mill Scale-Up

Bilgili

2023

KONA

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“…At 80% of the critical speed, there is more liner wear because more grinding media will be hitting the liners. According to experiments conducted, it has been observed that prolonging the grinding time results in particles being broken effectively by abrasion [66]. This is because as the grinding time increases, more fine particles are produced, which can be effectively ground by abrasion.…”

Section: Motion Of Grinding Media In a Ball Millmentioning

confidence: 99%

Grinding Media in Ball Mills-A Review

Matsanga¹,

Nheta²,

Chimwani³

2023

Preprint

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Comminution is a very important and result-determining step in mineral processing. This is because further downstream processes in the beneficiation chain depend entirely on it. Comminution includes the blasting, crushing, and grinding of ore to liberate valuable mineral particles. It consumes most of the energy used in mineral processing plants with grinding using up to 50% of the provided energy. Tumbling mills are an old technology that is still commonly used for grinding. One of the most used tumbling mills is the ball mill. This paper reviews different types of grinding media that have been developed and improved over the years and their properties. Also reviewed are the effects of grinding media on various aspects such as energy consumption, mill efficiency, minerals liberation and grinding rate. A comparison of the grinding media is given together with the knowledge gaps that still need to be bridged to improve the quality and performance of grinding media used in ball mills. Despite various research conducted on ball mills, the grinding process is still a very energy inefficient process. This creates a great opportunity for further research to improve the process because just a slight improvement in the process efficiency significantly reduces the production costs and provides a lot of environmental benefits.

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“…( 10) is to back-calculate them from batch grinding tests, assuming that predictions using the UFRJ mechanistic mill model (Tavares and Carvalho, 2009;Carvalho and Tavares, 2013) are strictly accurate. This approach has been used to estimate breakage parameters of an iron ore from batch milling data (Carvalho et al, 2021) as well as of limestone to stirred milling data (Oliveira et al, 2020). In these cases, the parameters from Eqns.…”

Section: Breakage Testing and Model Fittingmentioning

confidence: 99%

Review and Further Validation of a Practical Single-Particle Breakage Model

Tavares

2022

KONA

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Particle breakage occurs in comminution machines and, inadvertently, in other process equipment during handling as well as in geotechnical applications. For nearly a century, researchers have developed mathematical expressions to describe single-particle breakage having different levels of complexity and abilities to represent it. The work presents and analyses critically a breakage model that has been found to be suitable to describe breakage of brittle materials in association to the discrete element method, either embedded in it as part of particle replacement schemes or coupled to it in microscale population balance models. The energy-based model accounts for variability and size-dependency of fracture energy of particles, weakening when particles are stressed below this value, as well as energy and size-dependent fragment size distributions when particles are stressed beyond it, discriminating between surface and body breakage. The work then further validates the model on the basis of extensive data from impact load cell and drop weight tests. Finally, a discussion of challenges associated to fitting its parameters and on applications is presented.

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Mechanistic modeling and simulation of grinding iron ore pellet feed in pilot and industrial-scale ball mills

Cited by 16 publications

References 39 publications

On the Similarity of Austin Model and Kotake–Kanda Model and Implications for Tumbling Ball Mill Scale-Up

On the Similarity of Austin Model and Kotake–Kanda Model and Implications for Tumbling Ball Mill Scale-Up

Grinding Media in Ball Mills-A Review

Review and Further Validation of a Practical Single-Particle Breakage Model

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