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

Important advances have been made in the last 60 years or so in the modeling of ball mills using mathematical formulas and models. One approach that has gained popularity is the population balance model, in particular, when coupled to the specific breakage rate function. The paper demonstrates the application of this methodology to optimize solids concentration in ball milling of an iron ore from Brazil. The wet grinding experiments were conducted in bench (0.25 m diameter) and pilot-scale mills (0.42 m diameter), and surveys in a full-scale industrial (5.2 m diameter) mill. It is first demonstrated that the successful application of the model required recognizing the non-normalizable nature of the breakage function of the particular ore. It is then demonstrated how the model can be used to predict results of pilot-scale grinding tests under different conditions (overflow/grate discharge) based on data from batch grinding tests. Finally, the model is used to predict the effect of changing solids concentration inside the industrial mill, with good correspondence between the pilot plant and full-scale results, which demonstrated the benefit of reducing solids concentration to values between 76 and 80% in weight for the ore of interest from the 83% that was originally used in the operation.