Predicting the effect of operating and design variables on breakage rates using the mechanistic ball mill model

Batch grinding tests have been a very good tool to aid in understanding the effect of design and operating variables in ball milling, as well as in providing data for a couple of successful scale-up methods. Recently, a mechanistic model of the ball mill has been proposed, and the present paper describes its application in the simulation of batch mills operating under a range conditions. First-order breakage rates have been estimated using data from these simulations, and used to investigate the effect of operating and design variables in milling. Predictions using the mechanistic model are then compared to those using the scale-up relationships proposed by Austin and collaborators and Herbst and Fuerstenau. The trends predicted using the mechanistic model are in general agreement with the empirical models. Good correlation has also been observed between the simulated specific breakage rates and the specific mill power, which is in agreement with the scale-up method proposed by Herbst and Fuerstenau.

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► The mechanistic ball mill model combines DEM, PBM and breakage models.
► Simulations using the mechanistic ball mill model have been conducted.
► The effect of design and operating variables has been analyzed.
► Simulated specific breakage rates were proportional to specific mill power.