Optimization of Solids Concentration in Iron Ore Ball Milling through Modeling and Simulation

Faria, Patrícia Mundim Campos; Rajamani, Raj K.; Tavares, Luís Marcelo

doi:10.3390/min9060366

Cited by 20 publications

(6 citation statements)

References 11 publications

(24 reference statements)

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“…Over the past decades, several studies have been carried out for the development of phenomenological grinding kinetic models. The so-called population balance model (PBM) can be used for the design, optimization, and control of grinding circuits due to its ability to take into account the breakage mechanism [19][20][21]. The PBM, also referred to as the linear time-invariant (LTINV) model, which considers that the breakage rate remains constant during grinding has been adopted by many researchers [22][23][24][25], while in other studies a deviation from the linear kinetic approach has been experimentally observed [26][27][28].…”

Section: Introductionmentioning

confidence: 99%

Effect of Grinding Media Size on Ferronickel Slag Ball Milling Efficiency and Energy Requirements Using Kinetics and Attainable Region Approaches

Petrakis

Komnitsas

2022

Minerals

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The aim of this study is to evaluate the effect that the size of grinding media exerts on ferronickel slag milling efficiency and energy savings. A series of tests were performed in a laboratory ball mill using (i) three loads of single size media, i.e., 40, 25.4, and 12.7 mm and (ii) a mixed load of balls with varying sizes. In order to simulate the industrial ball milling operation, the feed to the mill consisted of slag with natural size distribution less than 850 μm. Grinding kinetic modeling and the attainable region (AR) approach were used as tools to evaluate the data obtained during the ball milling of slag. Particular importance was given to the determination of the specific surface area of the grinding products, the identification of the grinding limit, and the maximum specific surface area which could be achieved when different grinding media sizes were used. The results showed that, in general, the breakage rates of particles obey non-first-order kinetics and coarse particles are ground more efficiently than fines. The AR approach proved that there is an optimal grinding time (or specific energy input) dependent on the ball size used for which the volume fraction of the desired size class is maximized. The use of either 25.4 mm balls or a mixed load of balls with varying sizes results in 31 and 24% decrease in energy requirements, compared to the use of balls with small size (12.7 mm).

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Section: Introductionmentioning

confidence: 99%

Effect of Grinding Media Size on Ferronickel Slag Ball Milling Efficiency and Energy Requirements Using Kinetics and Attainable Region Approaches

Petrakis

Komnitsas

2022

Minerals

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“…Currently, these issues are beginning to attract more attention. For example, [50] presents the results of a study to find the optimal value of slurry density corresponding to the optimal performance of a ball mill [51] shows application of the methodology to optimize the concentration of solid particles in an iron ore ball mill. The study, conducted under industrial conditions, shows the need to reduce the solids concentration from 83%, as observed in the tests, to 76-80% by weight for the specific ores in the experiment.…”

Section: Resultsmentioning

confidence: 99%

Study of rock fracture patterns for obtaining the basis for energy-efficient ore ball milling

Kondratets,

Matsui,

Brovko

et al. 2024

IOP Conf. Ser.: Earth Environ. Sci.

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The study is conducted using methods of analysis (in proving the possibility of assessing the disintegration of rocks by energy consumption), methods of free vibration theory (to determine the motion of a falling ball over an elastic connection), methods of energy balance, methods of theoretical mechanics and material resistance (to study amplitude characteristics of mechanical systems), methods of rock fracture theory (to determine fracture work), physical modeling (to design test benches) and experimental methods (to find relationships between parameters). The strength of bulk crushed material in the first stages of ore preparation is practically independent of its coarseness and solid form, which allows the estimated volume of disintegrated ore (particle concentration) to be determined by the energy expended, translated into other physical quantities. Results of experimental studies support the theoretical dependences. The proposed approach of automatic stabilisation of solid concentration in the ball mill pulp at the optimum level allows to increase the productivity of ore preparation on the finished grade in the first stages by 10% at reduction of specific power consumption for ore grinding.

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“…Two functions must be known in order to solve the resulting system of differential equations: b ij and S i,k . Campos et al (2019a) and Faria et al (2019) observed that, for some Brazilian iron ores, the non-normalizable breakage function proposed by King (2001) was required to describe their response, being given by:   1 for…”

Section: Proposed Hybrid Modelmentioning

confidence: 99%

A Hybrid PBM-DEM Model of High-Pressure Grinding Rolls Applied to Iron Ore Pellet Feed Pressing

Rodriguez

Campos

Barrios

et al. 2023

KONA

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Mathematical models of high-pressure grinding rolls (HPGR) have attracted great attention, owing to their role in optimization of operating machines as well as in the design and selection of new ones. Although population balance models (PBM) and the discrete element method (DEM) have been used in this task, both suffer from important limitations. Whereas PBMs have challenges associated to the prediction of operating gap and to the validity of several of its assumptions in different formulations in the literature, application of DEM has its own challenges, in particular when fed with distributions containing large amounts of fines. This work proposes a hybrid approach in which the coupling of DEM to particle replacement models and multibody dynamics is used to predict operating gap, throughput and power, as well as providing information along the rolls length that is used in PBM to predict the product fineness. The hybrid approach is then compared to both DEM and a PBM (Modified Torres and Casali), demonstrating similar results to the later when applied to simulating a pilot-scale machine operating under different conditions, but improved prediction when applied in scale-up to an industrial-scale HPGR.

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Optimization of Solids Concentration in Iron Ore Ball Milling through Modeling and Simulation

Cited by 20 publications

References 11 publications

Effect of Grinding Media Size on Ferronickel Slag Ball Milling Efficiency and Energy Requirements Using Kinetics and Attainable Region Approaches

Effect of Grinding Media Size on Ferronickel Slag Ball Milling Efficiency and Energy Requirements Using Kinetics and Attainable Region Approaches

Study of rock fracture patterns for obtaining the basis for energy-efficient ore ball milling

A Hybrid PBM-DEM Model of High-Pressure Grinding Rolls Applied to Iron Ore Pellet Feed Pressing

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