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Experimental and DEM Simulation Study on the Grinding Behavior of Ceramic Balls in a Vertical Stirred Mill
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1  School of Resources and Environmental Engineering, Jiangxi University of Science and Technology, Ganzhou 341000, China
Academic Editor: Zhiyong Gao

Abstract:

This study focuses on the grinding behavior and efficiency optimization of ceramic ball media in vertical stirred mills. By combining experimental methods with discrete element method (DEM) simulations, it systematically investigates the effects of stirring shaft speed, media filling rate, and media size on the grinding performance of specific-sized magnetite. This experimental research employs particle size distribution models, grinding rates, and the t10-Ecs model to analyze and quantitatively evaluate the impact of different parameter conditions on the grinding efficiency and product characteristics of ceramic media from multiple perspectives. Meanwhile, DEM simulations provide a microscopic-level analysis, examining key factors such as the kinetic energy changes of ceramic ball media, particle velocity distribution patterns, motion trajectories and stratification phenomena, collision energy intensity and distribution among different collision types, and the proportion of effective collisions and energy utilization efficiency between grinding media and mineral particles, offering detailed insights into the mechanisms of ceramic ball motion and grinding behavior. The results show that for the specific-sized magnetite tested, higher stirring shaft speeds, filling rates, and larger media sizes generally lead to better grinding performance under the same conditions. However, adjusting parameter ranges can help to improve energy utilization efficiency while maintaining grinding effectiveness, thereby achieving energy-saving and consumption-reducing goals. This research clarifies the dominant grinding mechanisms of ceramic media and provides theoretical and practical strategies for optimizing energy-efficient grinding processes.

Keywords: Ceramic ball, Vertical stirred mill, Discrete Element Method (DEM), Grinding behavior, Magnetite

 
 
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