840 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
J. Menacho et al. provides zero order wear rate mecha-
nism for grinding mill, where the wear mechanism induced
by the mill operating condition has been evaluated math-
ematically in real time mill operation [1,2]. Here, the
first-order partial differential equation along with spatial
population balance mechanism representing the model for
ball wear which solved by the method of characteristics of
Lagrange and good agreement has been found between pre-
dictions with the model and experimentally obtained ball
size distribution in three industrial ball mills. In the subse-
quent of literature survey, Geoming HU et al provides an
approach for the optimization of grinding performance for
tumbling ball mill, where the derived governing formulation
for motions, impact parameters and grindability have been
established and use as objective and constraints functions for
the optimization of grinding operational parameters which
causes high wear rate of media [3]. Mishra and Rajamani
have developed a simulation of charge motion in ball mill
by using discrete elemental method, which pivotal on media
segregation with mill speed, distribution of ball collision as a
function of collision energy and friction among ball charge
[4]. K.R Raju has reported a brief analysis of orders of wear
law and appropriate testing criteria to determine wear of
media, in this context different order of wear kinetics has
been established which will be helpful in determining an
accurate duration of media wear while mill operation [5].
These works provide useful information about mill optimi-
zation and wear kinetics of media for ball mill operation.
Present work represented an approach to anticipate
grinding media wear rates in industrial ball mills through
a computational framework. Leveraging first principles
techniques, the unique mathematical model resolves media
wear kinetics, enabling precise predictions. The model,
rooted in fundamental principles i.e., abrasion wear and
collision wear, provides unprecedented insights into wear
behaviour of media and quantify the mass losses for the
same. This method ensures continual monitoring and pro-
vide recommendation for timely media top up to maintain
optimal volumetric mill filling. The relatively high hard
ore causes high abrasion and impact forces to get ground
in desired size, resulting high wear rate of grinding media.
The in-built control analogy in this integrated method sug-
gests optimal motor drive RPM to reduces the media wear
rate if hard ore is anticipated in mill for grinding operation.
Application of this model within a plant context yielded sig-
nificant benefits by optimizing ball mill operating param-
eters. By controlling media charge at optimal throughput,
the plant witnessed enhanced efficiency and cost savings.
This approach marks a paradigm shift in predictive mainte-
nance strategies, ensuring sustainable and optimized indus-
trial grinding processes.
MATERIALS, METHODOLOGY AND
SIMULATION
Materials
The iron ore fines sourced from Tata Steel Noamundi mines
as a run of mines (ROM) concentrate, which consist dif-
ferent physical and chemical characteristic, predominantly
fragile and hard iron ore which characteristic is represent
in Table 1 as ROM A and ROM B respectively. Such ore
undergo initial treatment in a dryer to remove the surface.
Subsequently, the dried iron ore along with fluxed
and other additives is directed to a grinding mill unit. This
grinding mill unit operates in a closed-circuit configura-
tion with Air classifier. Within this setup, the coarse prod-
uct is redirected for recirculation back to the grinding mill
for regrinding. Meanwhile, the fine product is conveyed to
storage bins. The Table 2 depicts the performance of ball
Figure 1. Grinding phenomenon of ball mill
J. Menacho et al. provides zero order wear rate mecha-
nism for grinding mill, where the wear mechanism induced
by the mill operating condition has been evaluated math-
ematically in real time mill operation [1,2]. Here, the
first-order partial differential equation along with spatial
population balance mechanism representing the model for
ball wear which solved by the method of characteristics of
Lagrange and good agreement has been found between pre-
dictions with the model and experimentally obtained ball
size distribution in three industrial ball mills. In the subse-
quent of literature survey, Geoming HU et al provides an
approach for the optimization of grinding performance for
tumbling ball mill, where the derived governing formulation
for motions, impact parameters and grindability have been
established and use as objective and constraints functions for
the optimization of grinding operational parameters which
causes high wear rate of media [3]. Mishra and Rajamani
have developed a simulation of charge motion in ball mill
by using discrete elemental method, which pivotal on media
segregation with mill speed, distribution of ball collision as a
function of collision energy and friction among ball charge
[4]. K.R Raju has reported a brief analysis of orders of wear
law and appropriate testing criteria to determine wear of
media, in this context different order of wear kinetics has
been established which will be helpful in determining an
accurate duration of media wear while mill operation [5].
These works provide useful information about mill optimi-
zation and wear kinetics of media for ball mill operation.
Present work represented an approach to anticipate
grinding media wear rates in industrial ball mills through
a computational framework. Leveraging first principles
techniques, the unique mathematical model resolves media
wear kinetics, enabling precise predictions. The model,
rooted in fundamental principles i.e., abrasion wear and
collision wear, provides unprecedented insights into wear
behaviour of media and quantify the mass losses for the
same. This method ensures continual monitoring and pro-
vide recommendation for timely media top up to maintain
optimal volumetric mill filling. The relatively high hard
ore causes high abrasion and impact forces to get ground
in desired size, resulting high wear rate of grinding media.
The in-built control analogy in this integrated method sug-
gests optimal motor drive RPM to reduces the media wear
rate if hard ore is anticipated in mill for grinding operation.
Application of this model within a plant context yielded sig-
nificant benefits by optimizing ball mill operating param-
eters. By controlling media charge at optimal throughput,
the plant witnessed enhanced efficiency and cost savings.
This approach marks a paradigm shift in predictive mainte-
nance strategies, ensuring sustainable and optimized indus-
trial grinding processes.
MATERIALS, METHODOLOGY AND
SIMULATION
Materials
The iron ore fines sourced from Tata Steel Noamundi mines
as a run of mines (ROM) concentrate, which consist dif-
ferent physical and chemical characteristic, predominantly
fragile and hard iron ore which characteristic is represent
in Table 1 as ROM A and ROM B respectively. Such ore
undergo initial treatment in a dryer to remove the surface.
Subsequently, the dried iron ore along with fluxed
and other additives is directed to a grinding mill unit. This
grinding mill unit operates in a closed-circuit configura-
tion with Air classifier. Within this setup, the coarse prod-
uct is redirected for recirculation back to the grinding mill
for regrinding. Meanwhile, the fine product is conveyed to
storage bins. The Table 2 depicts the performance of ball
Figure 1. Grinding phenomenon of ball mill