Modelling and simulation of ball mill wear

Abstract

In the mineral processing industry, ball mills are used to reduce ore from one size distribution to another. Ball mill wear occurs as a result of the violent interactions within the ball charge. In the present article, a mathematical description of wear has been added to a ball charge motion model. Wear is associated with the comminution mechanisms found in the ball charge profile. It is assumed that ball mill wear occurs in each of three comminution zones, with adhesive wear found in the crushing and tumbling zones and abrasive wear arising in the grinding zone. Wear rates are proportional to the energy dissipated in these zones as predicted by the charge motion model. Three laboratory case studies are investigated followed by one full-scale example in a wet milling context. Simulation results are compared with experimental data from which real-system predictions are presented. The use of these results provides the possibility of optimizing ball mill performance while including the wear rate factor.