Grinding Media Research Articles

Further Results on the Effects of the Grinding Environment on the Flotation of Copper Sulphides

Grinding conditions affect the flotation of copper sulphide minerals as changes in the properties of the grinding media and their interactions with the sulphide minerals, and between sulphide minerals themselves, affect the chemical environment in the flotation pulp. Galvanic interactions between steel grinding media and sulphide minerals, and between sulphide minerals, can lower the pulp potential, decrease the dissolved oxygen concentration in the mineral slurry, and lead to the dissolution of iron and copper from the media and the minerals. As a result, the formation of hydrophilic iron hydroxides and their adsorption on the copper sulphide minerals can be deleterious to copper flotation while pyrite (when present) can be activated to flotation by dissolved copper lowering the grade of the copper concentrate. Electrochemically less active grinding media (e.g., chrome alloy balls rather than mild steel media) can have beneficial effects on flotation performance due to the lower oxidation of the grinding media and consequently the lower production of oxidised iron species in the pulp. Copper activation of pyrite can be decreased by chemical additions to the pulp. In this paper, relevant experimental data published in the last 15 years are discussed.

Working performance of vertical spiral stirred mill based on discrete element method

The main structures and characteristic parameters that affect the working performance of vertical spiral stirred mill were analyzed and studied, and a method for selecting key working parameters was proposed. Based on the discrete element method, a simulation model of vertical spiral stirred mill was established, and the effects of spindle speed, agitator lead and grinding media size distribution on grinding performance were analyzed. A comprehensive grinding performance index was proposed, and orthogonal tests were conducted on each parameter to obtain the quantitative value of the grinding effect, and then the optimal working parameter combination under a specific weight coefficient was obtained, which provided a reference method for the optimal design of the mill.

Stirred media mills of fine and ultrafine grinding for subsequent beneficiation operations

This paper presents a brief review of the designs, characteristics, and operating parameters of Stirred media mills supplied by foreign manufacturers. An analysis of information on Stirred media mills , which are used to improve the efficiency of beneficiation and metallurgical operations, is carried out using available publications. The obtained results indicate the inexpediency of using conventional drum ball mills for flotation separation of ores and concentrates with a fine interpenetration of minerals. The application of conventional mills in extraction of ores and concentrates resistant to cyanidation, where gold is finely disseminated in sulfides, is limited by their high power consumption and the corresponding operating costs. In this work, different types of Stirred media mills are considered, including their vertical and horizontal types. The advantages of Stirred media mills over conventional ball mills, particularly in terms of energy efficiency, are noted. The designs and main characteristics of Stirred media mills , which have received wide application, are presented. According to the data presented in the reviewed publications, the main parameters determining the grinding process in such mills are outlined, including the ratio of bead size to mill feed size, density of grinding medium, density of pulp in the mill, volume loading of beads, stirring speed, etc. The conducted analysis of literature data indicated high efficiency of mills based on agitation of grinding media for fine and ultrafine grinding of ores and concentrates in comparison with conventional ball mills. Given that the volume of ores and concentrates resistant to processing by conventional methods is increasing, the application of Stirred media mills is expected become more widespread, thereby increasing the efficiency of subsequent beneficiation and metallurgical operations.

Insight into the effect of ultrasonic treatment on surface properties and flotation behavior of chalcopyrite after galvanic corrosion of grinding media and chalcopyrite

Ultrasonic treatment is an effective means to promote chalcopyrite flotation. Chalcopyrite needs to be grinded before flotation production. During the grinding process, galvanic corrosion occurs between chalcopyrite and iron grinding media. Galvanic corrosion significantly affects the efficacy of ultrasonic treatment on chalcopyrite flotation. Nonetheless, there is still a lack of research on ultrasonic treatment of chalcopyrite after galvanic corrosion. In this study, micro-flotation tests, SEM-EDS, TOF-SIMS, XPS, ICP-OES and electrochemical tests were used to study the effects of ultrasonic treatment on the surface properties and flotation behavior of chalcopyrite before and after galvanic corrosion under different ultrasonic conditions and galvanic corrosion conditions. The results show that in the absence of galvanic corrosion, short time and low power ultrasonic treatment can improve chalcopyrite floatability. However, when the chalcopyrite after strong galvanic corrosion is subjected to ultrasonic treatment, the increase of galvanic corrosion temperature, galvanic corrosion time, ultrasound power and ultrasound time result in a marked reduction of the flotation recovery of chalcopyrite. The synergistic effect of ultrasonic and galvanic corrosion significantly inhibits the flotation recovery of chalcopyrite, which may provide a new potential way for the inhibition of sulfide ore in flotation production. The research results are helpful to expand the use range of ultrasonic processing for sulfide mineral pretreatment and flotation, and provide a theoretical reference for the application of ultrasonic treatment in sulfide minerals with galvanic corrosion.

Effect of Grinding Media Grading on Liner Wear and Load Behavior in a Ball Mill by Using Rocky DEM

The liner is a wear-prone component in ball mills, subject to continuous impacts, squeezing, and abrasion from the grinding media during operation. Its service performance directly affects the working efficiency of the ball mill. The service life of mining ball mill liners is about 8 months, and frequent downtimes occur due to liner wear and loss of effectiveness, with liner replacement accounting for about 6% of the total cost, resulting in huge economic losses. This paper focuses on a Φ305 mm × 150 mm experimental ball mill, using the discrete element software Rocky Discrete Element Method (DEM) (software version number Rocky 2022 R2) for simulation modeling analysis. With Φ10 mm and Φ20 mm mono-size particle simulations serving as reference groups, this study investigates the motion states and liner abrasion patterns under different liner heights for both sizes of grinding media in Equilibrium Quality Manufacturer (EQM) and Original Equipment Manufacturer (OEM) gradations. The results indicate that the impact of liner height on the wear of the ball mill liners is related to the size and gradation of the grinding media. The degree of liner wear from highest to lowest is as follows: EQM > Φ20 mm > OEM > Φ10 mm. Due to the effect of the cylinder end cap, the wear at the axial center of the ball mill liner is more severe than at both ends, and the wear on the facing side of the liner is more severe than on the backside. A thorough study of the influence of ball mill grinding media gradation on the wear pattern of liners is of great theoretical significance for optimizing liner structures, improving grinding efficiency, and promoting energy saving and cost reduction in ball mills. This study provides theoretical guidance for understanding the mechanisms behind liner wear in ball mills and predicting the liner lifespan.

Optimization and Experimental Study of Iron Ore Grinding Medium Parameters Using EDEM Discrete Element Software.

Energy savings and consumption reduction of ball mills are crucial for industrial production. The grinding medium is an important component of a ball mill. In theory, using higher-density grinding media can yield better grinding results. However, for materials with varying grindability, employing grinding media of different densities can reduce energy consumption while maintaining the same grinding effect. This study simulates the motion of the grinding media in the mill using three different densities of balls and the same material (iron ore). The results reveal that balls with densities of 5.8 g/cm3 and 7.8 g/cm3 achieve faster grinding of materials into finer particles, but balls with a density of 5.8 g/cm3 consume less energy. Therefore, replacing a ball with a density of 5.8 g/cm3 in a ball mill can significantly reduce energy consumption. This study will assist in selecting the optimal grinding medium density for different materials, ultimately contributing to energy savings and reduced carbon emissions.

Understanding the Energy-Saving mechanism of ceramic balls in tumbling mills

This study investigates why ceramic balls achieve superior grinding performance compared to steel balls at lower densities and lower energy consumption. Particle motion analysis shows that increasing the filling level significantly improves the velocity distribution of the grinding media. The energy input from the mill is mainly converted into the kinetic and potential energy of the media, with potential energy being dominant. As the filling level increases, the efficiency of kinetic energy conversion improves. Collisions between media and mineral particles dominate energy transfer, and lower media density enhances collision energy distribution uniformity. Reducing media density decreases grinding energy consumption while maintaining the same grinding effect.

The effects of processing parameters on the shape of particle size distribution and grinding rate in a stirred mill

The study of particle size distribution (PSD) of materials is a crucial aspect of mineral processing. It not only determines the appropriate beneficiation process and equipment but also has a significant impact on the grade and recovery of concentrate. This study utilizes a pin-stirred mill for the wet fine grinding of limonite to examine four different widths of PSD functions and compares their quantitative descriptions of the PSD. Skewness is a parameter introduced to quantitatively describe the asymmetry of the PSD. This study aims to investigate the effect of the stirrer speed, the density and the size of the grinding media on the shape of the PSD and on the grinding rate. The results show that a lower stirrer speed and a lower density of the grinding media result in a narrower and a more symmetrical PSD of the grinding products. Moreover, the time-dependent approach succeeds in simulating and proving the evolution behavior of the median particle size. It was found that the optimum mixing ratio of the grinding media can effectively adjust the shape of the PSD and improve the grinding efficiency.

Effect of the Solvent Composition in Catalyst Inks on Viscosity, Catalyst Layer Morphology, and PEMFC Performance

The solvent composition in a catalyst ink is a key parameter in fabricating cathode catalyst layers (CCLs) to reach high-performance proton exchange membrane fuel cells (PEMFCs). In general, an optimized solvent composition in a catalyst ink (e.g., the H2O-to-alcohol ratio) can yield reasonably uniform and thin ionomer structures covering the catalyst surface, leading to better proton and oxygen transport resistances of the CCLs.1,2 While the impact of solvent composition on the morphology of ionomer or catalyst in both solvent dispersion and CCLs was widely investigated, those results could vary significantly and remain inconclusive in between different studies.3 This is likely due to complex interactions between the solvent system, the ionomer, and the catalyst, and additional experimental parameters (e.g., the solvent composition in the ionomer stock dispersion, or the ink mixing method) that were not controlled. Minor changes in the fabrication process can alter the final morphology of the components in a CCL and thus vary its PEMFC performance.4 To the best of our knowledge, there are only a few systematic studies correlating the effect of the solvent system on ionomer dispersions and catalyst inks to the CCL micromorphology and PEMFC performance.In this study, we systematically examined the impact of the ratio of two commonly used solvents, 1-propanol (1-PA) and H2O, on the viscosity of ionomer dispersions (without catalysts), on the viscosity of catalyst inks (using Pt supported on a Vulcan and a Ketjenblack carbon support), on the crack formation in CCLs, and on the single-cell PEMFC performance (using 5 cm2 active area single-cell testing under differential-flow conditions). The occurrence of cracks in the CCLs was rationalized based on the rheology of the catalyst inks, the surface tension of the solvent mixtures, and the change in solvent composition during the drying process. Moreover, the influence of the ionomer stock dispersion on the viscosity of catalyst inks was investigated. This analysis shows that catalyst inks with identical compositions can have significantly different viscosities and crack formation in CCLs, depending on the ionomer stock dispersion used in the catalyst ink preparation, which highlights the importance of the processing history of the ionomer. An exemplary result is given in Figure 1, comparing the photographs of two CCLs coated on a PTFE substrate prepared with catalyst inks of identical composition. Both CCLs were fabricated with 10/90 wt% 1-PA/H2O in the catalyst inks, but different ionomer stock dispersions were used: One stock dispersion was prepared with 100 wt% H2O (Fig. 1A), and the other with a 60/40 wt% 1-PA/H2O mixture (Fig. 1B). Furthermore, we show that the shear force due to the grinding media used during the mixing of catalyst inks can trigger a gelation process of the ionomer, which strongly affects the viscosity and processibility of the catalyst ink. Finally, the impact of the solvent composition of catalyst inks on the PEMFC performance (in H2/O2 and H2/air configuration), the proton conduction resistance, and the oxygen transport resistance of the CCL were compared. Based on those results, we highlight the importance of the processing history for the fabrication of CCLs. References T. van Cleve, S. Khandavalli, A. Chowdhury, S. Medina, S. Pylypenko, M. Wang, K. L. More, N. Kariuki, D. J. Myers, A. Z. Weber et al., ACS applied materials & interfaces 2019, 11, 46953.A. Orfanidi, P. J. Rheinländer, N. Schulte, H. A. Gasteiger, J. Electrochem. Soc. 2018, 165, F1254-F1263.S. A. Berlinger, S. Garg, A. Z. Weber, Current Opinion in Electrochemistry 2021, 29, 100744.S. Khandavalli, J. H. Park, N. N. Kariuki, D. J. Myers, J. J. Stickel, K. Hurst, K. C. Neyerlin, M. Ulsh, S. A. Mauger, ACS applied materials & interfaces 2018, 10, 43610. Acknowledgment This work has been supported by the Fuel Cells and Hydrogen 2 Joint Undertaking under grant agreement No. 826097 (GAIA). This Joint Undertaking receives support from the European Union’s Horizon 2020 research and innovation program, Hydrogen Europe, and Hydrogen Europe Research. Figure 1

Quantifying pyrrhotite superstructures in copper-gold ore flotation through synchrotron X-ray diffraction analysis

Pyrrhotite, a significant sulfide mineral in base metal sulfide deposits, exists in various superstructures including magnetic (4C) and non-magnetic (5C and 6C) types. Identifying and quantifying pyrrhotite superstructures in an ore sample has been a challenge, hindering efforts to improve pyrrhotite rejection in copper–gold flotation. This study employed synchrotron X-ray powder diffraction (S-XRPD) analysis to quantify pyrrhotite superstructures in the concentrates obtained from flotation of a copper–gold ore after grinding with forged steel and 30% chromium grinding media. S-XRPD demonstrated a superior capability in detecting characteristic peaks of 4C, 5C and 6C pyrrhotite superstructures compared to conventional XRPD. Utilizing the Rietveld refinement method, the identified pyrrhotite superstructures were quantified. These findings were successfully validated through independent X-ray fluorescence analysis on elemental compositions. The quantification work demonstrated that 30% chromium grinding media enhanced the floatability of all pyrrhotite superstructures over forged steel grinding media and each pyrrhotite superstructure in the copper–gold ore resembled a copper sulfide mineral rather than pyrite in response to grinding media during flotation. This research highlights the potential of S-XRPD as an effective technique for identifying and quantifying pyrrhotite superstructures in ore samples and determining their flotation behaviors.

Performance analysis of vertical stirred mill based on multi-coupling method

To improve vertical mill performance, a vertical stirred mill is used as the research object. Firstly, an electromechanical multi-body dynamic model (EMBD) of the vertical stirred mill is established, followed by the establishment of a discrete element method (DEM) analysis model of the grinding media, and then the DEM-EMBD coupling model is formed. The feasibility of the DEM-EMBD coupling model is verified through experiments. On this basis, the stress distribution state of the helical agitator is analysed based on the coupling method of the discrete element method and finite element method (DEM-EMBD-FEM). The DEM-EMBD coupling model can better reflect the dynamic characteristics of the vertical stirred mill by comparing it with the DEM model and the coupling method of discrete element method and computational fluid dynamics (DEM-CFD) respectively. Finally, the effects of vertical stirred mill structural parameters, operating parameters and grinding media size on mill performance are investigated by the DEM-EMBD and DEM-EMBD-FEM coupling models. The approach then provides insights into the structural design of vertical stirred mills, motor selection, and the welding process between the helical blades and screw.

Comparison of surface physicochemical properties of spodumene and feldspar using different grinding media: Implications for flotation separation

Grinding processing after crushing is a common practice in mineral processing circuits involving flotation, and achieving selective liberation of target minerals by grinding is a prerequisite for successful flotation. In this study, the surface characteristics and the floatability of spodumene and feldspar particles produced by laboratory ball and short cylinder mills were determined by XRD, SEM, AFM, XPS analysis, DFT calculation, and flotation experiment. Compared with ball-milled particles, spodumene ground with short cylinder media had more exposed {110} cleavage planes, while feldspar under the same condition had more exposed {110} and {201} cleavage planes. Additionally, the amount of Al sites and the roughness of spodumene and feldspar after grinding by short cylinder media were higher than those of ball-milled particles. Micro-flotation experiments and XPS analysis further indicated that, although the co-adsorption of NaOL/DDA on the surface of spodumene is stronger than feldspar under both milling media, the flotation separation efficiency of spodumene and feldspar remained higher with short cylinder grinding media. Therefore, this study is expected to provide more reference value and theoretical guidance for the development of selective flotation separation of spodumene and feldspar from the perspective of grinding.

Mechanochemical synthesis and catalysis of dinuclear Cu (II) complexes in C–S coupling

This study introduces a mechanochemical approach for synthesizing dinuclear Cu (II) complexes and applying them directly in C–S coupling reactions, offering a sustainable alternative to traditional solvent‐based syntheses. The mechanochemical method, recognized for its environmental advantages and efficiency, was employed to synthesize the Cu (II) complex [CuL(μ‐Cl)Cl2] (I) and the metal–organic salt 2L.2[CuCl4]2− (II), thereby minimizing solvent use and waste production. The synthesized complex I exhibited superior catalytic activity in C–S coupling, achieving a 96% yield within 20 min with methanol serving as a grinding medium. The mechanochemical process was further refined and confirmed for its environmental sustainability, with an E‐factor of 0.460 and an EcoScale score of 78. This synthetic method not only shortens reaction times and reduces solvent use but also streamlines the operational procedure, providing a more environmentally benign and economically viable route for C–S coupling. The research highlights the potential of mechanochemistry in simplifying synthetic processes and enhancing their sustainability, paving the way for future advancements in green synthetic strategies.

THE MECHANICALLY ACTIVATED COMPOSITES BASED ON TUNGSTEN DISULFIDE: SYNTHESIS AND PROPERTIES

In this work, the physicochemical properties of mechano-activated composites (hereinafter referred to as the mechanocomposites) obtained by mechanical activation of commercial tungsten disulfide powder in a planetary mill were studied. Mechanical activation was carried out for 2, 4 and 8 h, but this work presents the results for the last two experiments. The acceleration of the grinding media was controlled through frequency adjustment; a frequency value of 15.5 Hz, according to calculations, corresponds to an acceleration of the grinding media of 50 m/s2 or 5G. The material of the balls from which the grinding balls are made is stainless steel. Due to the relatively low acceleration values, the problem of contamination of the sample with stainless steel components does not occur as a result of surface erosion that occurs when the balls collide with each other and with the walls of the grinding bowl. Mechanical activation was carried out in an inert argon environment, since these were preliminary studies and therefore there was a need to minimize the environmental parameters taken into account. However, the oxidation process will occur during the process of discharging the sample from the grinding bowl of the planetary mill. The resulting mechanocomposites are precursors for the synthesis of monocomponent catalysts for the processing of heavy oil residue. For this purpose, it is necessary to obtain mechanocomposites containing tungsten trioxide and tungsten disulfide. The results of an experimental study of the influence, mainly, of the duration of mechanical activation on the production of tungsten mechanocomposites are presented. The resulting compounds were characterized by X-ray phase analysis (XRD), IR spectroscopy, scanning electron microscopy (SEM), thermogravimetry (TGA) and simultaneous thermal analysis (STA). For citation: Akimov Al.S., Zhirov N.A., Sudarev E.A., Akimov A.S. The mechanically activated composites based on tungsten disulfide: synthesis and properties. ChemChemTech [Izv. Vyssh. Uchebn. Zaved. Khim. Khim. Tekhnol.]. 2024. V. 67. N 8. P. 36-43. DOI: 10.6060/ivkkt.20246708.2t.

Design and Characterization of a Continuous Melt Milling Process Tailoring Submicron Drug Particles

Solid crystalline suspensions (SCSs) containing submicron particles were introduced as a competitive solution to increase dissolution rates and the bioavailability of poorly water-soluble drugs. In an SCS, poorly water-soluble drug crystals are finely dispersed in a hydrophilic matrix. Lately, melt milling as an adapted wet milling process at elevated temperatures has been introduced as a suitable batch manufacturing process for such a formulation. In this work, the transfer from batch operation to a two-step continuous process is demonstrated to highlight the potential of this technology as an alternative to other dissolution-enhancing methods. In the first step, a powder mixture of a model drug (griseofulvin) and a carrier (xylitol) is fed to an extruder, where a uniform suspension is obtained. In the second step, the suspension is transferred to a custom-built annular gap mill, where comminution down to the submicron region takes place. The prototype’s design was based on batch grinding results and a narrow residence time distribution, intended to deliver large quantities of submicron particles in the SCS. The throughput of the mill was found to be limited by grinding media compression. By inclining the mill at an angle, the grinding media position was manipulated, such that compression was avoided. Different states of the grinding media in the grinding chamber were identified under surrogate conditions. This strategy allows the maintenance of an energy-optimized comminution without adaption of the associated process parameters, even at high throughputs. Using this new process, the production of an SCS with 80–90 % submicron particles in a single passthrough was demonstrated.

A New Approach to the Calculation of Bond Work Index with Mixed Grinding Media

A New Approach to the Calculation of Bond Work Index with Mixed Grinding Media

Study on the Population Balance Dynamics Simulation of Grinding under Impact Crushing

During the grinding process, the crushing of minerals mainly depends on the impact action of the grinding medium. Based on the JK drop weight test data of quartz and pyrrhotite and the research results of their impact crushing characteristic parameters, this paper calculates the specific crushing energy (Ecs) of mineral samples subjected to impact in a ball mill using the grinding medium motion theory and then calculates the cumulative particle size distribution under screening under any mesh size using the JK drop weight test method. On this basis, the breakage distribution function of mineral samples is calculated, and a selection function is obtained based on grinding experiments. Finally, using Matlab programming and function-fitting mathematical methods, as well as a particle size population balance dynamics simulation of grinding, the particle size distribution characteristics of the grinding products of the two mineral samples in the mill that are only subjected to impact action are calculated. The results show that the selection function of quartz and pyrrhotite decreases overall with the prolongation of the grinding time, and the selection function of the coarse particle size changes more significantly than that of the fine particle size. At the same time, the selection function decreases with the decrease in feed particle size, and the smaller the feed particle size, the lower the probability of impact crushing. The Ecs values of quartz and pyrrhotite at each particle level in the mill are different, and the degree of mineral crushing is closely related to the impact energy, feed particle size, and mineral properties.

Milling efficiency and wear behavior of silicon grinding media in autogenous stirred media milling

This study investigates the wear mechanisms and milling efficiency of silicon as grinding media for autogenous stirred media milling. Fresh autogenous grinding media (aGM) showed an exponentially decreasing wear rate first, while becoming constant at longer grinding times. The wear rate of used aGM was constant throughout the whole milling experiment. Shape and size analysis revealed that chipping and abrasion mechanisms dominate the wear behavior. These mechanisms led to spheroidization of the aGM. The grinding media concentration was introduced as measure for the energy transfer from the stirrer to the product particles. This concept was used for weighting the specific energy consumption. Nanoparticles of around 150 nm were obtained with similar weighted specific energy consumptions, while used aGM performed most efficiently due to their spheroidized shape. Finally, spheroidized aGM still consumed more weighted specific energy than conventional grinding media. However, a direct comparison was difficult due to the different material properties of the grinding media.

Preparation and Performance Study of SiC-Reinforced Fe-Based Wear-Resistant Composite Grinding Media.

During industrial and laboratory processes involving material grinding, the grinding media endure prolonged high-collision and friction environments, resulting in substantial wear. Consequently, this study adopts the hot-pressing sintering technique in powder metallurgy to prepare SiC-reinforced Fe-based wear-resistant composite grinding media, aiming to increase wear performance. For this purpose, Fe with 10 wt% SiC powders were milled for the fabrication of the composite. Then, sintering was performed by hot press at 1100 °C in a furnace. Scanning electron microscopy (SEM) and X-ray diffraction were employed to investigate the microstructures and phase of SiC-reinforced Fe-based matrix composite. Subsequently, comparative performance evaluations of the newly developed grinding media and traditional chromium-based media were conducted in terms of wear rate and grinding efficiency. The wear resistance tests revealed that the SiC-reinforced composite media displayed significantly superior wear resistance across various abrasives compared to the chromium-containing alternatives. Specifically, the composite media achieved a wear rate reduction of 2.9 times against standard sand over 1 h, and 2.3 and 2.4 times against sandstone and iron slag, respectively. Moreover, extended grinding for 3 hours further enhanced these reductions to 3.1, 2.4, and 2.7 times, respectively. Additionally, efficiency assessments indicated that at a 1:1 material ratio, the composite media outperformed the chromium-containing media in grinding efficiency by 7.5%, 12.5%, and 10.3% for standard sand, sandstone, and iron slag, respectively. Further increasing the material ratio to 3:1 resulted in efficiency improvements of 7.4%, 17.5%, and 11.3%, correspondingly.

Scaling Energy Transfer in Ball Mills: A Scale-Agnostic Approach through a Universal Scaling Constant

Ball mills are widely used for size reduction in mineral processing, but effective scaling from laboratory to industrial scale remains challenging. This study introduces a novel scaling constant approach to replicate energy transfer to ore during milling across different scales by adjusting rotational speed and grinding medium size distribution. The scaling constant encapsulates parameters like the number of balls per working area, rotational speed, and an average ball’s maximum potential and kinetic energies. Experiments were conducted using a laboratory ball mill with interchangeable drum sizes (300, 400, and 500 mm) and a Design of Experiments methodology. Statistical analysis revealed that the scaling constant was more effective at maintaining consistent specific energy and energy per rotation across scales than size reduction, especially in dry milling. Wet milling results showed no significant differences in all metrics across scales. The dominant charge motion shifted from centrifuging to cascading as the mill diameter increased, highlighting the complex scaling dynamics. While the scaling constant shows promise for maintaining energy utilization, additional factors like charge motion and particle breakage mechanisms should be considered. The findings provide insights for improving ball mill design and optimization in mineral processing.