Optimizing key parameters for grinding energy efficiency and modeling of particle size distribution in a stirred ball mill

Fine grinding using a stirred ball mill can enhance ore liberation but incurs high energy consumption, which can be minimized by optimizing operating conditions. This study explores the impact of key operational parameters-grinding time, stirrer tip speed, solid concentration, and feed size-on grinding efficiency, evaluated using specific energy inputs, in stirred milling of Egyptian copper ore. The particle size distribution (PSD) of ground products was simulated using the Gates-Gaudin-Schuhmann model (GGS) and the Rosin-Rammler-Benne (RRB) function. Taking minimum energy consumption into account, the finest particles (100% ~1 μm) were achieved at the maximum stirrer speed of 500 rpm and a moderate solid concentration of 33.3% after 17 h of grinding, consuming approximately 1225 kWh/t. Experimental data demonstrated a linear correlation between the natural logarithm of the cumulative retained fraction and particle size (µm). The proposed model accurately describes PSDs across different solid concentrations and grinding durations.