minerals
Article
A Comparison of the Fine-Grinding Performance between
Cylpebs and Ceramic Balls in the Wet Tumbling Mill
Ningning Liao 1 , Caibin Wu 1,2, *, Jianjuan Li 1 , Xin Fang 1 , Yong Li 1 , Zhongxiang Zhang 3 and Wenhang Yin 4
Citation: Liao, N.; Wu, C.; Li, J.; Fang,
X.; Li, Y.; Zhang, Z.; Yin, W. A
Comparison of the Fine-Grinding
Performance between Cylpebs and
Ceramic Balls in the Wet Tumbling
Mill. Minerals 2022, 12, 1007.
https://doi.org/10.3390/min
12081007
Academic Editors: Carlos
Hoffmann Sampaio and Josep Oliva
Received: 15 July 2022
Accepted: 9 August 2022
Published: 11 August 2022
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Copyright: © 2022 by the authors.
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distributed under the terms and
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Attribution (CC BY) license (https://
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4.0/).
Minerals 2022, 12, 1007. https://doi.org/10.3390/min12081007
1 School of Resources and Environmental Engineering, Jiangxi University of Science and Technology,
Ganzhou 341000, China
2 Jiangxi Key Laboratory of Mining Engineering, Jiangxi University of Science and Technology,
Ganzhou 341000, China
3 Betterwear New Material Co., Ltd., Jingdezhen 333000, China
4 Goldpro New Material Co., Ltd., Handan 057650, China
* Correspondence: caibin.wu@jxust.edu.cn
Abstract: This study investigated the effect of grinding media on the fine-grinding performance in the
wet tumbling mill. Comparative experiments between cylpebs and ceramic balls were conducted in a
laboratory wet ball mill under various conditions, such as different total masses, total surface areas,
and total numbers. The results indicated that ceramic balls produce a slightly smaller instantaneous
breakage rate than cylpebs due to their small bulk density at the same charge volume. However, a
larger instantaneous breakage rate can be obtained by ceramic balls with the same total mass due to
the larger surface area. According to experiments related to the total surface area and total number of
ceramic balls, it was found that the fine grinding of ceramic balls also needs to meet a certain break
force, which is mainly determined by the diameter of the ceramic balls. Moreover, two models were
developed to use ceramic balls instead of cylpebs as fine-grinding media in the wet tumbling mill
based on the ball size and the ratio of the total mass of cylpebs. Cylpebs can be replaced by ceramic
balls with 1.16–1.75 times the diameter of cylpebs, taking up only 76%–83% of the total weight of
cylpebs. When the charge volume of cylpebs is between 20% and 35% in the wet ball mill, cylpebs
can be replaced by ceramic balls of the same single mass, with the total weight of the ceramic balls
being only 74%–77% of that of the cylpebs.
Keywords: cylpebs; ceramic balls; wet tumbling mill; total mass; ball sizes
1. Introduction
In mineral-processing plants, grinding is a process of particle size reduction that
consumes a large amount of energy: about 50% of the total energy consumption in com-
minution [1]. Therefore, enhancing the energy efficiency in the grinding process helps to
save the operation cost of the concentrator.
In order to improve the energy efficiency in the grinding process of tumbling mills,
many researchers have studied the effect of different operating conditions on the energy
efficiency of existing tumbling mills [2,3]. The grinding media have been reported to be a
critical parameter in the grinding process of tumbling mills. Because the types of grinding
media have an important effect on the product size distribution and the cost of the grinding
operation due to energy and media consumption, balls and rods, as traditional grinding
media, have been widely used in tumbling mills [4,5]. Other types of grinding media,
including cylpebs [6–8], hexagons [9], pebbles [10,11], worn balls [12,13], and ceramic
balls [14], have also been studied by many researchers. The significant influence of the types
of grinding media on the grinding performance in terms of the loading behavior [13,15],
contact mechanism [6], grinding kinetics [16,17], and mill powder [18] has been reported
in detail by Shahbazi et al. [19]. Cylpebs with a greater surface area have been used as
fine-grinding media in the mineral [3] and cement clinker [20] industries. Shi [6] reported
https://www.mdpi.com/journal/minerals
Minerals 2022, 12, 1007 2 of 15

that, with cylpebs as grinding media, the product size distribution showed slightly less
oversize but the same fine size compared with balls with the same specific energy, which
may be because cylpebs have a larger surface area than steel balls. Other researchers have
also found that cylpebs have a faster breakage rate than balls with the same total mass [3,21].
Pebbles can be used as grinding media in stirred mills [22,23] and tumbling mills [10,11].
Research has shown that it saves 25% steel and 15% energy in consumption by adding a
25% volume ratio of pebbles instead of steel balls as the grinding media in the secondary
grinding mill. Ceramic balls are usually used as fine-grinding media in vertical stirred
mills for regrinding [24]. In recent years, ceramic balls have reportedly been applied in
secondary overflow ball mills by our research group for feed particle sizes of −0.5 mm,
which, compared with cylpebs, saves 38.5% energy in the industry. In addition, ceramic
balls have better wear resistance than cylpebs. Under the condition that the grinding
throughput is satisfied, the consumption of ceramic balls is only 40% of that of cylpebs [14].
An analysis of the influence of ceramic balls and cylpebs on the fine-grinding perfor-
mance proves that the energy saving of the wet tumbling mill is necessary. However, the
effect of ceramic balls and cylpebs on the fine-grinding performance of wet tumbling mills
has not yet been systematically studied. The main purpose of this study was to compare
the differences in the fine-grinding performance between ceramic balls and cylpebs in a
laboratory batch wet ball mill. In addition, a new method of replacing cylpebs with ceramic
balls as grinding media in the tumbling mill based on the ball size and the ratio of the total
mass is presented.

2. Theoretical Background
The comminution process is satisfactorily described using the grinding kinetics ap-
proach. The population balance model (PBM) has been widely used to describe the particle
breakage behavior in the ball mill [16,25]. The population balance model includes two
functions: the breakage-rate function (Si ) and the breakage-distribution function (bij ). The
two parameters can be obtained from batch grinding tests with monosize-fraction feed.
The breakage-rate function (S1 ) for the top size can be expressed as follows:
dw1 (t)
= −S1 (t)w1 (t) (1)
dt

where S1 (t) is the breakage rate for the top size; w1 is the weight fraction of the material with
the top size; t is the grinding time (min). If the breakage rate (S1 (t)) does not change with
time and follows the first-order kinetics, Equation (2) can be given in the following form:
logw1 (t) S (t)
=− 1 (2)
logw0 2.3

Gupta [26] found that the actual specific breakage rate (S1 ) for different grinding-time
intervals is defined as follows:
logw1 (t1 ) S ( t − t1 )
= 1 2 (3)
logw1 (t2 ) 2.3

If the breakage follows the first-order grinding kinetics, then the instantaneous break-
age rate (S1 ) for different grinding-time intervals can be presented as follows:
logw1 (t1 ) S ( t − t0 )
= 1 1 (4)
logw1 (t0 ) 2.3

The ball size is a critical parameter that affects the breakage rate and grinding perfor-
mance. The relationship between the maximum ball size (D) and maximum particle size
(Xm ) has been investigated by various researchers [16,27–30]:
Xm = kD2 (5)
 ramic balls with the same quality as 11 mm steel balls were 10 × 10 mm and 14 mm,
spectively. According to Equation (5), the constants (k) of the cylpebs and ceramic b
were 1.5 × 10−3 and 0.77 × 10−3, respectively.

Minerals 2022, 12, 1007 3 of 15

3. Materials and Methods
3.1. Materials
−3 in Kelsall (1965) studies [30].
The tested
where samples,
k is a constant, andtungsten
the value ofores, were
k is 1.25 taken
× 10 from the underflow of the indust
In this study, the maximum particle
second-stage classification in Shizhuyuan Nonferrous size was 0.15 mm, whichCo.,
Metal wasChenzhou,
calculated byChina.
substituting the constant of Kelsall into Equation (5), and the diameter of the steel ball
XRD analysis of tungsten ores in Figure 1 shows that scheelite, wolframite, molybden
was 10.95 mm. Consequently, a diameter close to 11 mm was selected as a follow-up
bismuthinite,
reference. Influorite, and the
order to meet hematite are valuable
requirements minerals,
of the breakage force, and quartz
the sizes of theiscylpebs
mainly gang
The and
chemical
ceramiccompositions of the
balls with the same tungsten
quality as 11 mm ores
steelanalyzed
balls were by
10 ×XRF
10 mm areand
presented
14 mm, in Ta
respectively.
1, which indicatesAccording
that WOto Equation
3 (0.279),(5),
Mo the(0.066),
constantsBi(k) of the cylpebs
(0.110), and ceramic
Fe2O3 (14.130), andballs
CaO (28.3
were 1.5 × 10−3 and 0.77 × 10−3 , respectively.
are the main valuable elements, and SiO2 is the main impurity.
3. Materials and Methods
Table 1. Materials
3.1. Chemical compositions of tungsten ores (wt/%).
The tested samples, tungsten ores, were taken from the underflow of the industrial
Constituents WO3 Mo Bi F SO3 Zn K2O TiO2 Cu
second-stage classification in Shizhuyuan Nonferrous Metal Co., Chenzhou, China. The
Content (%) of tungsten
XRD analysis 0.279 ores0.066 0.110
in Figure 1 shows4.880 2.270 wolframite,
that scheelite, 0.050 1.260 0.190 0.03
molybdenite,
bismuthinite, fluorite,
Constituents Rb2and
O hematite
Fe2O3 areSiO valuable
2 Alminerals,
2O3 CaOand quartz
MgOis mainly
MnOgangue.
Na2O Othe
The chemical compositions of the tungsten ores analyzed by XRF are presented in Table 1,
Content (%) 0.068 14.130 34.410 9.250 28.320 1.070 1.180 0.840 1.59
which indicates that WO3 (0.279), Mo (0.066), Bi (0.110), Fe2 O3 (14.130), and CaO (28.320)
are the main valuable elements, and SiO2 is the main impurity.
3500

F S1--Siniarite
3000 S2--Scheelite
W--Wolframite
2500
B--Bismuthinite
F--Fluorite
Intensity (counts)

H--Hematite
2000 Q--Quartz
S1 M--Molybdenite
S2
1500 Q

1000 B

Q M F
500 Q H Q
H B B Mw M F

0
0 10 20 30 40 50 60 70 80

2θ/°

Figure 1. XRD analysis of tungsten ores.

Figure 1. XRD analysis of tungsten ores.
Table 1. Chemical compositions of tungsten ores (wt/%).
3.2. Grinding Media
Constituents WO3 Mo Bi F SO3 Zn K2 O TiO2 CuO
Cylpebs and ceramic
Content (%) 0.279 balls were
0.066 0.110 used
4.880in the experiments
2.270 0.050 performed
1.260 0.190 to determine
0.034
effect of the grinding
Constituents media.
Rb2 O Fe2 OTo
3 be
SiOmore
2 Al2specific,
O3 CaOthe MgO
grindingMnOmedia used
Na2 O for the exp
Others
Content (%) 0.068 14.130 34.410 9.250 28.320 1.070 1.180 0.840 1.593
ments were cylpebs sized 14 × 16 mm, 12 × 12 mm, and 10 × 10 mm, provided by Gold
New3.2.Material
GrindingCo.,
MediaLtd., Handan, China, and ceramic balls with diameters of 25 mm
mm, 17 mm, Cylpebs15 and
mm,ceramic
14 mm, and
balls 10 mm,
were manufactured
used in the experiments byperformed
Betterwear New Material C
to determine
Ltd.,the
Jingdezhen, China. The
effect of the grinding media. compositions and physical
To be more specific, properties
the grinding of for
media used thethe cylpebs
experiments were cylpebs sized 14 × 16 mm, 12 × 12 mm, and 10 × 10 mm, provided
by Goldpro New Material Co., Ltd., Handan, China, and ceramic balls with diameters
of 25 mm, 21 mm, 17 mm, 15 mm, 14 mm, and 10 mm, manufactured by Betterwear
New Material Co., Ltd., Jingdezhen, China. The compositions and physical properties
of the cylpebs and ceramic balls used in the experiments are presented in Tables 2 and 3,
respectively. The photographs of the grinding media used are shown in Figure 2.
Minerals 2022, 12, 1007 4 of 15

Table 2. Composition properties of grinding media.

Composition (%)
Grinding Media
C Mn Si Cr P S Others
Cylpebs 0.80 0.92 0.27 0.65 0.03 0.03 97.30
Composition (%)
Grinding Media
Al2 O3 Fe2 O3 SiO2 Others
Ceramic balls 70.50 10.50 9.60 9.40

Table 3. Physical properties of grinding media.

Grinding Media Ceramic Balls

Dimension (mm) 25 21 17 15 14 10
Mass (g) 30.00 17.50 9.50 6.50 5.50 2.05
Surface area (cm2 ) 19.63 13.45 9.08 50.24 7.07 3.14
Specific surface (cm2 /g) 0.65 0.77 0.96 1.09 1.12 1.53
Specific density(g/cm3 ) 3.70 3.70 3.70 3.70 3.70 3.70
Bulk density (g/cm3 ) 2.20 2.20 2.20 2.20 2.20 2.20
Grinding Media Cylpebs
Dimension (mm) 14 × 16 12 × 12 10 × 10
Minerals 2022, 12, x FOR PEER REVIEW 4 of 15
Mass (g) 17.6 9.5 5.6
Surface area (cm2 ) 10.11 6.78 4.71
Specific surface (cm2 /g) 0.58 0.71 0.87
Specific density(g/cm 3) 7.00 7.00 7.00
ceramic balls used in the experiments are presented in Tables 2 and 3, respectively. The
Bulk density (g/cm 3) 4.40 4.40 4.40
photographs of the grinding media used are shown in Figure 2.

Figure2.2.Photographs
Figure Photographsof
ofthe
thegrinding
grindingmedia.
media.

Table
3.3. 2. Composition
Experimental properties of grinding media.
Methods
3.3.1. Media Charge Conditions Composition (%)
Grinding
The media Media
mass, mediaCsurface area, Mn and number
Si of media
Cr were
P usedSas the media
Others
charge conditions
Cylpebs to compare
0.80the differences
0.92 in the
0.27 fine-grinding
0.65 performance
0.03 0.03 between
97.30
cylpebs and ceramic balls.
Composition (%)
Tables 3–6Media
Grinding present the media conditions when the charge volume (22.5%), total mass,
total surface area, and totalAl 2O3
number Femedia
of 2O3
areSiO 2
kept theOthers
same, respectively.
Ceramic balls 70.50 10.50 9.60
Table 4 presents the media charge-volume conditions, 9.40
which were used as the base
case for the comparison. Table 5 presents the ceramic balls’ charge with the same total
Tableas
mass 3. 12
Physical properties
× 12 mm of grinding
cylpebs. Table 6 media.
presents ceramic balls with the same total number as
12 × 12 mm cylpebs. Table
Grinding Media 7 presents the ceramic balls’ charge with the
Ceramic same total surface
Balls
area but less total mass than that of the 12 × 12 mm cylpebs. Table 8 presents the media
Dimension (mm) 25 21 17 15 14 10
conditions’ change with the charge volume.
Mass (g) 30.00 17.50 9.50 6.50 5.50 2.05
Surface area (cm2) 19.63 13.45 9.08 50.24 7.07 3.14
Specific surface (cm2/g) 0.65 0.77 0.96 1.09 1.12 1.53
Specific density(g/cm3) 3.70 3.70 3.70 3.70 3.70 3.70
Bulk density (g/cm ) 3 2.20 2.20 2.20 2.20 2.20 2.20
Minerals 2022, 12, 1007 5 of 15

Table 4. Ceramic balls and cylpebs with the same charge volume (%).

Grinding Media Ceramic Balls

Dimension (mm) 25 21 17 15 14 10
Charge volume (%) 22.50 22.50 22.50 22.50 22.50 22.50
Number of media 33 57 104 152 180 483
Total mass (g) 990 990 990 990 990 990
Total surface area (cm2 ) 647.63 761.11 945.67 1076.05 1107.79 1516.39
Grinding Media Cylpebs
Dimension (mm) 14 × 16 12 × 12 10 × 10
Charge volume (%) 22.50 22.50 22.50
Number of media 113 208 367
Total mass (g) 1980 1980 1980
Total surface area (cm2 ) 1137.47 1413.59 1727.00

Table 5. Ceramic balls with the same total mass as cylpebs (12 × 12 mm).

Grinding Media Ceramic Balls

Dimension (mm) 25 21 17 14 10
Charge volume (%) 45.00 45.00 45.00 45.00 45.00
Number of media 66 113 208 360 966
Total mass (g) 1980 1980 1980 1980 1980
Total surface area (cm2 ) 1295.25 1522.22 1891.34 2215.58 3032.78

Table 6. Ceramic balls with the same total number as cylpebs (12 × 12 mm).

Grinding Media Ceramic Balls

Dimension (mm) 17 14 10
Charge volume (%) 45.00 26.05 29.56
Number of media 208 208 208
Total mass (g) 1980 1146 427
Total surface area (cm2 ) 1891.34 1282.71 654.44

Table 7. Ceramic balls with the same total surface area as cylpebs (12 × 12 mm).

Grinding Media Ceramic Balls

Dimension (mm) 21 17 15 14 10
Charge volume (%) 40.60 33.63 29.56 28.73 20.99
Number of media 102 156 200 230 451
Total mass (g) 1786 1480 1301 1264 924
Total surface area (cm2 ) 1413.59 1413.59 1413.59 1413.59 1413.59

Table 8. Comparison of ceramic balls and cylpebs with different charge volumes.

Grinding Media Ceramic Balls

Dimension (mm) 17 17 17 17 17 17 17
Charge volume (%) 20.00 25.00 30.00 35.00 40.00 45.00 50
Number of media 93 116 139 162 185 208 232
Total mass (g) 880 1100 1320 1540 1760 1980 2200
Total surface area (cm2 ) 840.59 1050.74 1260.89 1471.04 1681.19 1891.34 2101.49
Grinding Media Cylpebs
Dimension (mm) 12 × 12 12 × 12 12 × 12 12 × 12 12 × 12 12 × 12 12 × 12
Charge volume (%) 20.00 25.00 30.00 35.00 40.00 45.00 50
Number of media 185 232 278 324 371 417 463
Total mass (g) 1760 2200 2640 3080 3520 3960 4400
Total surface area (cm2 ) 840.59 1050.74 1260.89 1471.04 1681.19 1891.34 2101.49
 3.3.2. Experimental Details
This experiment was carried out in a small-scale laboratory mill with a size of 132
mm × 90 mm, a volume of 2000 cm3, and a set speed of 170 rev/min. In each test, 200 g of
Minerals 2022, 12, 1007 6 of 15
−0.15 + 0.075 mm single-sized feed was used, and a volume of 100 mL of tap water was
then added to the mill charge in order to make a 67 wt.% solids concentration. The illus-
tration of the grinding equipment between the rolls is shown in Figure 3.
3.3.2. Experimental Details
Afterward, the ground products under various conditions were sieved using a Taylor
This experiment was carried out in a small-scale laboratory mill with a size of
standard sieve set ranging from 0.075 mm to 0.038 mm. In the case of wet screening, the
132 mm × 90 mm, a volume of 2000 cm3 , and a set speed of 170 rev/min. In each test, 200 g
weight of the product after sieving for 1 min was less than 1% of the original screening
of −0.15 + 0.075 mm single-sized feed was used, and a volume of 100 mL of tap water
weight.
was thenFinally,
added tothe
thedata were processed
mill charge in order to in batches
make by Excel
a 67 wt.% solidstoconcentration.
obtain the particle-size-
The
distribution data of the final grinding product.
illustration of the grinding equipment between the rolls is shown in Figure 3.

Figure
Figure 3.3.Schematic
Schematicofof grinding
grinding equipment
equipment usedused
in theingrinding
the grinding process.
process.

Afterward, the ground products under various conditions were sieved using a Taylor
In order to verify that the breakage behavior follows the first-order kinetics, first, in
standard sieve set ranging from 0.075 mm to 0.038 mm. In the case of wet screening, the
the comparative experiments between 17 mm ceramic balls and 12 × 12 mm cylpebs under
weight of the product after sieving for 1 min was less than 1% of the original screening
the sameFinally,
weight. chargethevolume, theprocessed
data were ceramic balls and cylpebs
in batches by Excel were firstthe
to obtain ground for 2, 4, and 6
particle-size-
min. Then, the comparative experiments
distribution data of the final grinding product. of the total surface area, number, and mass of
ceramic ballstowere
In order verifyconducted, with the
that the breakage grinding
behavior time
follows theoffirst-order
the otherkinetics,
sizes offirst,
ceramic
in balls
and cylpebs kept at 2 min.
the comparative experiments between 17 mm ceramic balls and 12 × 12 mm cylpebs under
the same chargetovolume,
In order the ceramic
determine balls and
that ceramic cylpebs
balls havewere
the first
same ground for 2, 4, and
fine-grinding 6 min.
performance as
Then, the comparative experiments of the total surface area, number, and
cylpebs within the range of the charge volume, 17 mm ceramic balls and 12 × 12 mm mass of ceramic
balls were conducted, with the grinding time of the other sizes of ceramic balls and cylpebs
cylpebs were selected as the grinding media. The mass of the tested sample, the solids
kept at 2 min.
concentration, and the grinding time were kept constant with comparative tests.
In order to determine that ceramic balls have the same fine-grinding performance
as cylpebs within the range of the charge volume, 17 mm ceramic balls and 12 × 12 mm
4. Results
cylpebs wereand Discussion
selected as the grinding media. The mass of the tested sample, the solids
concentration,
4.1. The Effect and the
of the grinding
Media Sizetime were
on the Finekept constant
Grinding of with comparative
Tungsten Ores tests.
Figure
4. Results and4 Discussion
shows the first-order plots for the −0.15 + 0.075 mm feed size of tungsten
ores ground
4.1. The bythe12Media
Effect of × 12 Size
mmon cylpebs
the Fineand 17 mm
Grinding ceramicOres
of Tungsten balls at the same charge volume
of 22.5%.
Figure R24isshows
the statistical termplots
the first-order for the
forcorrelation
the −0.15 +coefficient,
0.075 mm feed which
sizeprovides a measure
of tungsten
of how
ores wellbythe
ground 12 observed outcomes
× 12 mm cylpebs aremm
and 17 replicated by the
ceramic balls regression
at the model.
same charge volume of R =1
When 2

this indicates
22.5%. R2 is thethat the two
statistical sets
term forof data
the are exactly
correlation matched.
coefficient, whichAsprovides
is shown in Figure
a measure of4, the R2
for
how12 × 12
well themm cylpebs
observed and 17are
outcomes mm ceramicby
replicated balls
the are 0.992 and
regression 0.995,
model. When 2
respectively,
R = 1, this both of
indicates that the two sets of data are exactly matched. As is shown in Figure 4, the R2 for
12 × 12 mm cylpebs and 17 mm ceramic balls are 0.992 and 0.995, respectively, both of which
are close to 1, which indicates that the breakage of the −0.15 + 0.075 mm single-sized feed
generally follows the first-order grinding kinetics, and the value of the Si can be determined
by the slope of the straight line of the first-order plots. The specific breakage rates of cylpebs
and ceramic balls, calculated by Equations (2) and (4), are presented in Table 9.

Minerals 2022, 12, 1007
which are close to 1, which indicates that the breakage of the −0.15 + 0.075 mm single-sized
feed generally follows the first-order grinding kinetics, and the value of the Si can be de-
termined by the slope of the straight line of the first-order plots. The specific breakage
rates of cylpebs and ceramic balls, calculated by Equations (2) and (4), are presented 7in of 15
Table 9.

Weight fraction remaining in top size (%)

1

0.1

R2
Cyplebs (12×12 mm):0.992
Ceramic balls(17 mm):0.995

Cyplebs （12×12 mm）

Ceramic balls (17 mm)
0.01
0 2 4 6
Grinding time (min)

Thefirst-order
Figure4.4.The
Figure first-orderplots
plotsfor
forcylpebs
cylpebsand
and ceramic
ceramic balls
balls at at
thethe same
same charge
charge volume.
volume.

Table9.9.AAcomparison
Table comparisonofofthe
thespecific
specificbreakage
breakagerates
ratesbetween
betweenEquations
Equations(2)(2)
andand (4).
(4).

Grinding Media Media

Grinding EquationEquation
(2) (2) Equation (4)
Equation (4)
Cylpebs
Cylpebs 0.115 0.115 0.147
0.147
Ceramic balls balls
Ceramic 0.101 0.101 0.123
0.123

AsAsshown
shownininTableTable9,9,thethecalculation
calculationresults resultsofofEquations
Equations (2)(2)
andand(4)(4)
share
share thethe
same
same
pattern,
pattern,presenting
presentingthat thatthethespecific
specificbreakage
breakagerate rateofof
cylpebs
cylpebs is is
greater
greaterthan
thanthat
thatof ceramic
of ceramic
balls
ballsunder
underthethesame
samecharge
chargevolume
volume(22.5%).(22.5%).Therefore,
Therefore, thetheinstantaneous
instantaneous breakage
breakage rate
rate
can
canbe beused
usedtotocompare
comparethe thefine-grinding
fine-grindingperformance
performance ofofcylpebs
cylpebs andandceramic
ceramic balls, thus
balls, thus
simplifying
simplifyingthe theexperiment
experimentprocess.
process.
The
The instantaneous breakagerate
instantaneous breakage rateofofceramic
ceramic balls was
balls was compared
compared with
withthat
thatof of
cylpebs
cylpebs
atatthe
Minerals 2022, 12, x FOR PEER REVIEW thesame
samecharge
chargevolume,
volume,asasshown shownininFigure Figure5,5,which
which shows
shows that
thatthetheinstantaneous
instantaneous
8 of 15
breakage
breakagerate rateofofceramic
ceramicballs
ballsofofallallsizes
sizesis is
smaller
smaller than
thanthat
thatof of
cylpebs.
cylpebs.The Theinstantaneous
instantaneous
breakage
breakagerate rateobtained
obtainedby byusing
usingceramic
ceramicballs ballsatatgrinding
grinding periods
periods of of
2 min
2 min is smaller
is smaller than
than
that
thatobtained
obtainedby byusing
usingcylpebs
cylpebsininallallcases.
cases.This
Thismaymay reflect
reflectthethefact that
fact ceramic
that ceramic balls have
balls have
cylpebs
less
less totalhave
total massthe
mass than best
than grinding
cylpebs
cylpebs under effect
under the among
thesame
samechargecylpebs,
charge and 17
volume.
volume. mm
Therefore,ceramic
Therefore, thethe balls
total have
impact
total the
impact
best
force grinding
forceofofceramic effect
ceramicballs among ceramic
ballsisisinferior
inferiortotothat balls for grinding
thatofofcylpebs.
cylpebs. −0.15 + 0.075 mm tungsten ores.
In addition, an interesting observation in Figure 5 is that when the diameter of ce-
0.18
ramic balls is larger than 17 mm, the instantaneous breakage rate is less than that pro-
Ceramic balls
duced0.16by using 17 mm ceramic balls. The single masses of the 25 mm and 21 mm ceramic
Cylpebs
Instantaneous breakage rate (%)

0.147
balls are larger than that of the 17 mm ceramic 0.14 balls, which means that the larger the balls,
0.14
the larger the impact break force, and few numbers 0.127 of balls are used for the break, which
0.121 0.123 0.119 0.12
means0.12 that
0.114the probability of collision
0.117 is smaller. On the premise of meeting the break
force, the smaller the impact force, the larger the number of balls applied to the break, and
0.10
the better the fine-grinding performance. It was also observed that when the diameter of
ceramic
0.08 balls is less than 14 mm, although the number and surface area of the 10 mm
ceramic balls are larger than those of the 14 mm ceramic balls, the break force is insuffi-
0.06
cient, and thus the fine-grinding performance will be weakened. In general, 12 × 12 mm
0.04

0.02

0.00
25 21 17 15 14 10 14×16 12×12 10×10

Media Size (mm)

Figure 5. Instantaneous breakage rates of the grinding media at
at the
the same
same charge
charge volume.
volume.

4.2. The Effect of the Total Mass of Media on the Fine Grinding of Tungsten Ores
In order to deeply investigate the differences in the fine-grinding performance be-
tween ceramic balls and cylpebs, batch grinding tests using ceramic balls with the same
total mass as 12 × 12 mm cylpebs were conducted. The instantaneous specific breakage
 best grinding effect among ceramic balls for grinding −0.15 + 0.075 mm tungsten ores.

0.18
Ceramic balls
0.16 Cylpebs

Instantaneous breakage rate (%)

Minerals 2022, 12, 1007 0.147 8 of 15
0.14
0.14
0.127
0.121 0.123 0.12
0.12 0.119 0.117
0.114
In addition, an interesting observation in Figure 5 is that when the diameter of ceramic
0.10
balls is larger than 17 mm, the instantaneous breakage rate is less than that produced by
0.08 17 mm ceramic balls. The single masses of the 25 mm and 21 mm ceramic balls are
using
larger
0.06
than that of the 17 mm ceramic balls, which means that the larger the balls, the larger
the impact break force, and few numbers of balls are used for the break, which means that
the0.04
probability of collision is smaller. On the premise of meeting the break force, the smaller
the0.02
impact force, the larger the number of balls applied to the break, and the better the
fine-grinding performance. It was also observed that when the diameter of ceramic balls
0.00 than 14 mm, although the number and surface area of the 10 mm ceramic balls are
is less
25 21 17 15 14 10 14×16 12×12 10×10
larger than those of the 14 mm ceramic balls, the break force is insufficient, and thus the
fine-grinding performance Mediawill
Sizebe
(mm)
weakened. In general, 12 × 12 mm cylpebs have the
best grinding effect among cylpebs,
Figure 5. Instantaneous breakage rates of and
the17 mm ceramic
grinding balls
media at the have
same the best
charge grinding effect
volume.
among ceramic balls for grinding −0.15 + 0.075 mm tungsten ores.
4.2. The Effect of the Total Mass of Media on the Fine Grinding of Tungsten Ores
4.2. The Effect of the Total Mass of Media on the Fine Grinding of Tungsten Ores
In order to deeply investigate the differences in the fine-grinding performance be-
In order to deeply investigate the differences in the fine-grinding performance between
tween ceramic balls and cylpebs, batch grinding tests using ceramic balls with the same
ceramic balls and cylpebs, batch grinding tests using ceramic balls with the same total mass
total mass as 12 × 12 mm cylpebs were conducted. The instantaneous specific breakage
as 12 × 12 mm cylpebs were conducted. The instantaneous specific breakage rates of the
rates of the ground products are shown in Figure 6.
ground products are shown in Figure 6.
0.20
Ceramic balls
0.18 0.177 0.176 Cylpebs
Instantaneous breakage rate (%)

0.164 0.163
0.16
0.151 0.147
0.14

0.12

0.10

0.08

0.06

0.04

0.02

0.00
25 21 17 14 10 12×12
Media Size (mm)
ground products
Figure 6. Instantaneous breakage rates of the ground products at
at the
the same
same total
total mass.
mass.

Compared with with 1212×× 1212mm mm cylpebs,

cylpebs, 17 mm
17 mm ceramic
ceramic ballsballs
havehave the same
the same singlesingle
mass,
mass, total number of grinding media, and total mass, but a larger
total number of grinding media, and total mass, but a larger total surface area. As total surface area. As
illus-
illustrated in Figure − 1
trated in Figure 7, the7,instantaneous
the instantaneous breakage
breakage rate (0.177
rate (0.177 min )min
−1 of 17 mm) of 17 mm ceramic
ceramic balls is
balls −1 × 12 mm
largeristhan
larger
thatthan that
(0.147 min (0.147
−1) ofmin
12 × 12) of
mm 12cylpebs. cylpebs.
This This the
may reflect may reflect
fact the fact
that ceramic
that
ballsceramic balls have
have a larger a largerarea
total surface totalthan
surface area than
cylpebs, which cylpebs, which
is beneficial toisfine
beneficial
grindingtowith
fine
grinding with the same total charge mass and same
the same total charge mass and same total number of charges. total number of charges.
Compared
Compared with 12 ×
with 12 12 mm
× 12 mm cylpebs,
cylpebs, 2121 mm
mm ceramic
ceramic balls
balls have
have the
the same
same total
total mass,
mass,
larger total surface area, larger single mass, and less total number of charges.
larger total surface area, larger single mass, and less total number of charges. As shown As shown
in Figure 7, the instantaneous breakage rate (0.164 min−1 ) of 21 mm ceramic balls is still
larger than that of 12 × 12 mm cylpebs. According to Table 4, 21 mm ceramic balls have
0.54 times less total number, 1.07 times larger total surface area, and 1.84 times larger
single mass than 12 × 12 mm cylpebs, which is also beneficial to fine grinding at the same
total charge mass. However, when the size of the ceramic ball continues to increase to
25 mm, the instantaneous breakage rate (0.144 min−1 ) of 25 mm ceramic balls is smaller
than that of 12 × 12 mm cylpebs. The weight of one single 25 mm ceramic ball is 3.15 times
heavier than that of 12 × 12 mm cylpebs, which also shows that the impact break force of
ceramic balls is greater than that of cylpebs, and the total number and total surface area of
Minerals 2022, 12, 1007 9 of 15

25 mm ceramic balls are only 0.32 times and 0.92 times smaller, respectively, than those of
Minerals 2022, 12, x FOR PEER REVIEW
12 ×12 mm cylpebs. 9 of 15

When the size of the ceramic ball continues to decrease to 14 mm, the instantaneous
breakage rate (0.177 min−1 ) of 14 mm ceramic balls is larger than that of 12 × 12 mm cylpebs.
Although
in Figure the weight
7, the of one single
instantaneous 14 mm rate
breakage ceramic
(0.164ballmin
is only
−1) of0.58 timesceramic
21 mm lighter than
balls that of
is still
12 × 12 mm cylpebs, the total number and total surface area of
larger than that of 12 × 12 mm cylpebs. According to Table 4, 21 mm ceramic balls have 14 mm ceramic balls are
1.73
0.54 times
times and
less 1.57
totaltimes larger,
number, 1.07respectively,
times largerthan totalthose
surfaceof 12 × 12
area, andmm1.84cylpebs. When sin-
times larger the
size of thethan
gle mass ceramic
12 × ball
12 mm continues
cylpebs, to which
decrease to 10beneficial
is also mm, the instantaneous
to fine grinding breakage rate
at the same
(0.163 min−1mass.
total charge ) of 10However,
mm ceramic when balls
theissize
lessofthan that of 12
the ceramic × 12
ball mm cylpebs.
continues Although
to increase to 25
the weight of one single 10 mm ceramic ball is 0.22 times lighter
mm, the instantaneous breakage rate (0.144 min ) of 25 mm ceramic balls is smaller than
−1 than that of 12 × 12 mm
cylpebs, the total number of 10 mm ceramic balls is 4.64 times more
that of 12 × 12 mm cylpebs. The weight of one single 25 mm ceramic ball is 3.15 times than that of 12 × 12 mm
cylpebs, and the total surface area is 2.15 times larger than that of
heavier than that of 12 × 12 mm cylpebs, which also shows that the impact break force of 12 × 12 mm cylpebs.
Therefore,
ceramic balls is itgreater
is submitted that,
than that ofin the process
cylpebs, and theof fine grinding,
total number the andimpact break force
total surface area
does
of 25 not
mmneed to beballs
ceramic too are
large, and
only a larger
0.32 timessurface
and 0.92 area andsmaller,
times greater respectively,
number of media than could
those
be more
of 12 × 12conducive
mm cylpebs. to fine grinding.
When the size of the ceramic ball continues to decrease to 14 mm, the instantaneous
4.3. The Effect of the Total Number of Media on the Fine Grinding of Tungsten Ores
breakage rate (0.177 min−1) of 14 mm ceramic balls is larger than that of 12 × 12 mm
3 when the 17 mm
Because
cylpebs. the bulk
Although the density
weight ofof one
the ceramic
single 14balls
mmwas onlyball
ceramic 2.2 g/cm
is only, 0.58 times lighter
ceramic
than thatballs
of 12(single
× 12 mm mass equalthe
cylpebs, to 12 × number
total 12 mm cylpebs)
and totalwith the area
surface sameoftotal
14 mm mass were
ceramic
used, the charge volume reached 45%. Considering that the charge volume in the ball mill
balls are 1.73 times and 1.57 times larger, respectively, than those of 12 × 12 mm cylpebs.
is generally not higher than 50%, the diameter of 17 mm was selected as the maximum
When the size of the ceramic ball continues to decrease to 10 mm, the instantaneous break-
ceramic-ball size used in the experiment to compare with 12 × 12 mm cylpebs of the same
age rate (0.163 min−1) of 10 mm ceramic balls is less than that of 12 × 12 mm cylpebs. Alt-
total number. Figure 7 shows the effect of the total number of ceramic balls on the particle
hough the weight of one single 10 mm ceramic ball is 0.22 times lighter than that of 12 ×
size distributions and instantaneous breakage rates of the ground products. When the
12 mm cylpebs, the total number of 10 mm ceramic balls is 4.64 times more than that of 12
size of ceramic balls is less than 17 mm, despite having the same total number of grinding
× 12 mm cylpebs, and the total surface area is 2.15 times larger than that of 12 × 12 mm
media, a smaller charge mass and total surface area could lead to a poorer fine-grinding
cylpebs.
performance. Therefore, the instantaneous breakage rate of the ground product using
Therefore, it is submitted that, in the process of fine grinding, the impact break force
14 mm or 10 mm ceramic balls as the grinding media is less than that of 12 × 12 mm
does not need to be too large, and a larger surface area and greater number of media could
cylpebs. Despite having the same total number as cylpebs, only when ceramic balls have
be more conducive to fine grinding.
the same single mass as cylpebs can an equal fine-grinding performance be achieved.
0.20
Ceramic balls
0.18 0.177 Cylpebs
Instantaneous breakage rate (%)

0.16
0.147
0.14
0.13
0.12
0.102
0.10

0.08

0.06

0.04

0.02

0.00
17 14 10 12×12
Media Size (mm)
Figure 7.
Figure 7. Instantaneous
Instantaneous breakage
breakage rates
rates of
of the
the ground
ground products
products at
at the
the same
same total
total number.
number.

4.3. The
4.4. The Effect
Effect of the Total
of the Total Surface
NumberArea
of Media on the
of Media on Fine Grinding
the Fine of Tungsten
Grinding OresOres
of Tungsten
Because
The theofbulk
effect density
the total of thearea
surface ceramic balls
on the was only 2.2
fine-grinding g/cm , whenisthe
3
performance 17 mm
shown in
ceramic balls (single mass equal to 12 × 12 mm cylpebs) with the same total
Figure 8. As presented in Table 5, 17 mm ceramic balls have the same total surface area, mass were
used,
but thetimes
0.75 charge volume
less reached
the total number 45%. Considering
of charges that mass
and total the charge volume
compared in 12
with the×ball mill
12 mm
is generally not higher than 50%, the diameter of 17 mm was selected as
cylpebs. Moreover, Figure 8 shows that, when the 17 mm ceramic balls shared the same the maximum
ceramic-ball size used in the experiment to compare with 12 × 12 mm cylpebs of the same
total number. Figure 7 shows the effect of the total number of ceramic balls on the particle
size distributions and instantaneous breakage rates of the ground products. When the size
of ceramic balls is less than 17 mm, despite having the same total number of grinding
 single mass as cylpebs can an equal fine-grinding performance be achieved.

4.4. The Effect of the Total Surface Area of Media on the Fine Grinding of Tungsten Ores
The effect of the total surface area on the fine-grinding performance is shown in Fig-
Minerals 2022, 12, 1007 ure 8. As presented in Table 5, 17 mm ceramic balls have the same total surface area, but
10 of 15
0.75 times less the total number of charges and total mass compared with 12 × 12 mm
cylpebs. Moreover, Figure 8 shows that, when the 17 mm ceramic balls shared the same
total surface area as 12 × 12 mm cylpebs, an equal instantaneous breakage rate of the
total surface area as 12 × 12 mm cylpebs, an equal instantaneous breakage rate of the
ground product could be obtained. This interesting phenomenon may indicate that, when
ground product could be obtained. This interesting phenomenon may indicate that, when
using ceramic balls with an equal single mass instead of cylpebs, the total mass of the
using ceramic balls with an equal single mass instead of cylpebs, the total mass of the
ceramic balls can be less than that of the cylpebs. When the size of the ceramic ball is larger
ceramic balls can be less than that of the cylpebs. When the size of the ceramic ball is larger
than 17 mm and up to 21 mm, the instantaneous breakage rate of the ground product is
than 17 mm and up to 21 mm, the instantaneous breakage rate of the ground product is
larger than that produced by 12 × 12 mm cylpebs. This is because, when the total surface
larger than that produced by 12 × 12 mm cylpebs. This is because, when the total surface
area is kept the same, the weight of a single 25 mm ceramic ball is 1.86 times heavier than
area is kept the same, the weight of a single 25 mm ceramic ball is 1.86 times heavier than
that of 12 × 12 mm cylpebs, and, hence, the break force of 25 mm ceramic balls is greater
that of 12 × 12 mm cylpebs, and, hence, the break force of 25 mm ceramic balls is greater
than that of 12 × 12 mm cylpebs. Although the total number of 25 mm ceramic balls is only
than that of 12 × 12 mm cylpebs. Although the total number of 25 mm ceramic balls is
0.54 times
only smaller
0.54 times than that
smaller thanof 12 of
that × 12
12mm × 12cylpebs, whichwhich
mm cylpebs, also shows that a that
also shows larger break
a larger
force makes up for the lack of collision probability, the former still demonstrates
break force makes up for the lack of collision probability, the former still demonstrates a a better
effect of
better the of
effect fine
thegrinding. WhenWhen
fine grinding. the sizetheofsize
ceramic balls is
of ceramic lessisthan
balls less 17 mm,
than despite
17 mm, hav-
despite
ing the same total surface area and a larger total number, the single mass
having the same total surface area and a larger total number, the single mass and total mass and total mass
are both
are both less
less than
than those
those ofof 12
12 ×
× 12
12 mm
mm cylpebs.
cylpebs. Therefore,
Therefore, the
the effect
effect ofof the
the fine
fine grinding
grinding of of
14 mm and 10 mm ceramic balls is inferior to that of 12 × 12
14 mm and 10 mm ceramic balls is inferior to that of 12 × 12 mm cylpebs. mm cylpebs.

0.20
Ceramic balls
0.18
Instantaneous breakage rate (%)

Cylpebs
0.16
0.16
0.146 0.147
0.14 0.132 0.133 0.129
0.12

0.10

0.08

0.06

0.04

0.02

0.00
21 17 15 14 10 12×12

Media Size (mm)

ground products
Figure 8. Instantaneous breakage rates of the ground products at
at the
the same
same total
total surface
surface area.
area.

4.5. The Overall Relationship between the Optimum Composition and Various
Various Parameters
Parameters
It was shown that the optimum fine-grinding performance of the wet ball mill was
indeed affected
affected by various parameters.
parameters. The three most sensitive parameters of the ceramic
balls are the total
total mass,
mass,total
totalsurface
surfacearea,
area,and
andtotal
totalnumber.
number.Figure
Figure 9 shows
9 shows thethe effects
effects of
of three
three different
different parameters
parameters ofofthe
theceramic
ceramicballs
balls(the
(thetotal
totalmass,
mass, total
total surface
surface area, total
number) on the the distribution
distributionof ofthe
thepercentage
percentagepassing
passing0.075
0.075mm
mm inin the
the ground
ground product.
product. It
It was observed that the distribution of the percentage passing 0.075 mm first
was observed that the distribution of the percentage passing 0.075 mm first increased till increased
till
the the
sizesize of the
of the ceramic
ceramic ballsballs reached
reached 17 mm,
17 mm, andand
thenthen decreased
decreased withwith the in
the rise risethe
in size
the
size of the ceramic balls. It also shows that 17 mm ceramic balls have the best effect of fine
grinding for feed sized −0.15 + 0.075 mm. As shown in Figure 9a, the distribution of the
percentage passing 0.075 mm in the ground product increased with the total mass when the
charge volume of the ceramic balls was less than 50%. When the total mass of the ceramic
balls reached 2000 g, the ceramic balls performed the best in fine grinding. As presented in
Figure 9b, the distribution of the percentage passing 0.075 mm in the ground product first
increased with the total surface area till the latter reached 1900 cm2 , and it then started to
decrease. This is mainly because the total surface area of 10 mm ceramic balls is larger than
that of cylpebs when the total mass of the two is the same, but the break force of the former
is insufficient, which weakens its effect of fine grinding. From Figure 9c, it is observed that
the distribution of the percentage passing 0.075 mm in the ground product increased as the
total number of ceramic balls went up when using ceramic balls of a uniform size. When
 balls is larger than that of cylpebs when the total mass of the two is the same, bu
force of the former is insufficient, which weakens its effect of fine grinding. Fr
9c, it is observed that the distribution of the percentage passing 0.075 mm in t
product increased as the total number of ceramic balls went up when using cer
of a uniform size. When the size of the ceramic balls is between 14 and 21 m
Minerals 2022, 12, 1007 moderate total number of ceramic balls is used, which also suggests that the tot
11 of 15
of ceramic balls is not the more the better. This should be considered, togethe
size of the ceramic balls, to find the best condition for fine grinding.
In general, the fine-grinding performance of ceramic balls is mainly dete
the size of the ceramic ballstheistotal
between 14 and
mass and 21 mm,
the size of theonly a moderate
ceramic balls. When total number
the size of theofceramic bal
ceramic balls is used, whichthealso suggests
same, that
the total the total
surface area,number of ceramic
charge volume, andballs
total is not theincrease w
number
more the better. This should be considered,
crease together
in the total mass. When with
the the
totalsize
massofisthe ceramic
constant, theballs,
total to
surface area
find the best condition for fine
numbergrinding.
of ceramic balls change with the size of the ceramic balls.

Figure 9. The effects of different parameters on the fine-grinding performance: (a) total mass of
ceramic balls; (b) total surface area of ceramic balls; (c) total number of ceramic balls.

In general, the fine-grinding performance of ceramic balls is mainly determined by the

total mass and the size of the ceramic balls. When the size of the ceramic balls remains the
same, the total surface area, charge volume, and total number increase with the increase in
the total mass. When the total mass is constant, the total surface area and total number of
ceramic balls change with the size of the ceramic balls.

4.6. A New Approach to Using Ceramic Balls Instead of Cylpebs as Fine-Grinding Media
In Sections 4.1 and 4.5, it is shown that 14–21 mm ceramic balls and 12 × 12 mm
cylpebs have better performances of the fine-grinding process. However, because the
bulk specific gravity of ceramic balls is only 0.5 times that of cylpebs, the fine-grinding
performance of ceramic balls is inferior to that of cylpebs at the same charge volume. In
order to yield the same fine-grinding performance achieved by cylpebs in the wet ball
mill, we proposed a method using ceramic balls instead of cylpebs under the premise that
the ceramic balls would reach a certain total mass and size. The relationship between the
distribution of the percentage passing 0.075 mm and the ratio of the total mass of cylpebs
can be defined as follows:
y = kx + b (6)
 y = kx + b
where y is the distribution of the percentage passing 0.075 mm in the ground produc
is the ratio of the total mass of 12 × 12 mm cylpebs; k and b are the slope and intercep
the fitting line, respectively. The size of ceramic balls can be calculated as follows:
Minerals 2022, 12, 1007 X =k D 12 of 15

where D is the maximum ball size (mm), Xm is the maximum particle size (mm), and k
a constant for ceramic balls. In this study, 14–21 mm ceramic balls were suitable for f
where y is the distribution
grinding in the of the percentage
mill. Therefore,passing
the k1 is0.075
0.34 ×mm 10−3in the ×ground
~0.77 10−3. product; x is
the ratio of the total Asmass of 12 × 12 mm cylpebs; k and b are the slope
shown in Figure 10a, when the distribution of the percentage and intercept passing
of the 0.075 m
fitting line, respectively. The size of ceramic balls can be calculated as follows:
of 21 mm ceramic balls is the same as that of 12 × 12 mm cylpebs (25.41%), the total m
of the 21 mm ceramic balls Xmis =
only 0.83
k1 D 2 times that of the 12 × 12 mm cylpebs. In Figure 1
(7)
when the distribution of the percentage passing 0.075 mm of the 17 mm ceramic ball
the same asball
where D is the maximum thatsize
of the 12 ×X12
(mm), m mmis thecylpebs
maximum (25.41%), the size
particle total(mm),
mass of andthek117ismm ceram
balls is only 0.76 times that of the 12 × 12 mm cylpebs.
a constant for ceramic balls. In this study, 14–21 mm ceramic balls were suitable for fine Moreover, in Figure 10c, when
distribution of the percentage passing
grinding in the mill. Therefore, the k1 is 0.34 × 10 ~0.77 × 10 . − 3 0.075 mm of− the
3 14 mm ceramic balls is the same
As shown in Figure 10a, when the distribution of the percentage passing 0.075 mm ofballs is o
that of the 12 × 12 mm cylpebs (25.41%), the total mass of the 14 mm ceramic
21 mm ceramic0.77 ballstimes
is thethat
sameof the 12 × of
as that 12 12
mm × cylpebs.
12 mm cylpebs (25.41%), the total mass of
the 21 mm ceramic balls is only 0.83 times that of the performance
Therefore, when the fine-grinding is the same,
12 × 12 mm cylpebs. less total
In Figure 10b,weight is
when the distribution of the percentage passing 0.075 mm of the 17 mm ceramic balls isballs, wh
quired compared with cylpebs due to the larger total surface area of ceramic
the same as thatexplains
of the 12 the×reason
12 mmwhy ceramic
cylpebs balls could
(25.41%), the totalsave
massmore of energy
the 17 mm thanceramic
cylpebs in seco
stage fine grinding in industrial applications [14].
balls is only 0.76 times that of the 12 × 12 mm cylpebs. Moreover, in Figure 10c, when the
Because thepassing
distribution of the percentage charge0.075
volumemmofofball themills
14 mm is usually
ceramicbelowballs 50%,
is thein order
same asto promp
that of the 12 × 12 mm cylpebs (25.41%), the total mass of the 14 mm ceramic balls is only we carr
better replacement of cylpebs with ceramic balls as the fine-grinding media,
0.77 times that ofoutthe
expanded
12 × 12 research
mm cylpebs. on the charge volume and found a suitable charge-volume ran

30 30

25

Mass passing 0.075 mm ( % )

25
Mass passing 0.075 mm ( % )

20 20

15 15

R2=0.958 R2=0.983
10 y=13.67x+14.10 10 y=16.07x+13.28
Experimental data Experimental data
21 mm ceramic balls 17 mm ceramic balls
5 Linear fitting 5 Linear fitting
21 mm ceramic balls 17 mm ceramic balls

0
Minerals 2022, 12, x FOR PEER REVIEW 0 13 o
0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2

A ratio of total mass ( % ) A ratio of total mass ( % )

(a) 21 mm ceramic balls (b) 17 mm ceramic balls
30

25
Mass passing 0.075 mm ( % )

20

15

R2=0.987
10 y=17.16x+12.27
Experimental data
14 mm ceramic balls
5 Linear fitting
14 mm ceramic balls

0
0.0 0.2 0.4 0.6 0.8 1.0 1.2

A ratio of total mass ( % )

(c) 14 mm ceramic balls
Figure 10. The
Figure 10. The relationship relationship
of the of the
distribution distribution
of the of the
percentage percentage
passing passing
0.075 mm 0.075
in the mm in the gro
ground
product and the ratio of the total mass of 12 × 12 mm cylpebs at the
product and the ratio of the total mass of 12 × 12 mm cylpebs at the same charge volume. same charge volume.

Therefore, whenAs shown

the in Figureperformance
fine-grinding 11a, when compared with
is the same, thetotal
less 20%weight
chargeisvolume
requiredof 12 × 12 m
compared with cylpebs, for 17
cylpebs due tomm ceramic
the larger balls
total to have
surface theof
area same grinding
ceramic balls,performance,
which explainsit only requ
the reason whythat the ratio
ceramic ballsofcould
the total
savemass
moreof ceramic balls cylpebs
energy than to cylpebs in be 0.75:1, and afine
second-stage charge volu
larger than 30% (1.5 times
grinding in industrial applications [14]. that of 12 × 12 mm cylpebs). In Figure 11b, when compared w
the 25% charge volume of 12 × 12 mm cylpebs, it only demands that the ratio of the m
of ceramic balls to cylpebs be 0.77:1, and a charge volume larger than 38.5% (1.54 tim
that of 12 × 12 mm cylpebs). In Figure 11c, when compared with the 30% charge volu
of 12 × 12 mm cylpebs, it only requires that the ratio of the mass of ceramic balls to cylp
be 0.74:1, and a charge volume larger than 44.4% (1.48 times that of 12 × 12 mm cylpe
In Figure 11d, when compared with the 35% charge volume of 12 × 12 mm cylpebs, it o
requires that the ratio of the mass of ceramic balls to cylpebs be 0.76:1, and a charge v
 5 Linear fitting
14 mm ceramic balls

0
0.0 0.2 0.4 0.6 0.8 1.0 1.2

A ratio of total mass ( % )

(c) 14 mm ceramic balls
Minerals 2022, 12, 1007 13 of 15
Figure 10. The relationship of the distribution of the percentage passing 0.075 mm in the gro
product and the ratio of the total mass of 12 × 12 mm cylpebs at the same charge volume.

Because the charge volume

As shown of ball11a,
in Figure mills is usually
when compared belowwith50%,
the in
20%order to prompt
charge volume ofa 12 × 12 m
cylpebs,
better replacement for 17 with
of cylpebs mm ceramic
ceramic balls
balls to
ashave the same grinding
the fine-grinding media,performance, it only requ
we carried out
expanded researchthat on
thethe
ratio of thevolume
charge total massandoffound
ceramic balls tocharge-volume
a suitable cylpebs be 0.75:1, and a charge volu
range.
As shown in larger
Figurethan 30%
11a, (1.5 times
when that ofwith
compared 12 × the
12 mm20%cylpebs). In Figure
charge volume 12 ×
of11b, when compared w
12 mm
the 25%
cylpebs, for 17 mm charge
ceramic volume
balls to have of 12
the× same
12 mm cylpebs,performance,
grinding it only demands thatrequires
it only the ratio of the m
that the ratio ofof
theceramic balls of
total mass to ceramic
cylpebs balls
be 0.77:1, and a charge
to cylpebs volume
be 0.75:1, and alarger
charge than 38.5% (1.54 tim
volume
that of 12 × 12 mm cylpebs). In Figure 11c, when compared
larger than 30% (1.5 times that of 12 × 12 mm cylpebs). In Figure 11b, when compared with with the 30% charge volu
the 25% charge volume of 12 × 12 mm cylpebs, it only demands that the ratio of the mass to cylp
of 12 × 12 mm cylpebs, it only requires that the ratio of the mass of ceramic balls
of ceramic balls be 0.74:1, and
to cylpebs a charge
be 0.77:1, andvolume larger
a charge than larger
volume 44.4% than
(1.48 38.5%
times that
(1.54oftimes
12 × that
12 mm cylpe
of 12 × 12 mm cylpebs). In Figure 11c, when compared with the 30% charge volume cylpebs,
In Figure 11d, when compared with the 35% charge volume of 12 × 12 mm of it o
requires that the ratio of the mass of ceramic balls to cylpebs
12 × 12 mm cylpebs, it only requires that the ratio of the mass of ceramic balls to cylpebs be 0.76:1, and a charge v
be 0.74:1, and a ume
chargelarger than larger
volume 53.2% (1.52
than times
44.4%that(1.48oftimes
12 × 12that
mmofcylpebs).
12 × 12 mm cylpebs).
In Figure 11d, when As a result,with
compared for fine
thegrinding
35% charge in the wet ball
volume mill,
of 12 × when
12 mmthe chargeitvolume
cylpebs, only of cylp
requires that the ratio of the mass of ceramic balls to cylpebs be 0.76:1, and a charge volume In this c
is 20%–35%, cylpebs can be replaced by ceramic balls of the same single mass.
larger than 53.2%the(1.52
totaltimes
mass that
of ceramic
of 12 ×balls is only
12 mm about 0.74–0.77 times that of cylpebs.
cylpebs).
30 30

25 25

Mass passing 0.075 mm ( % )

Mass passing 0.075 mm ( % )

20 20

15 15
R2=0.962 R2=0.968
y=15.37x+2.21 y=20.93x+0.78
10 δ=20% 10
Experimental data δ=25%
17 mm ceramic balls Experimental data
5 Linear fitting 5 17 mm ceramic balls
17 mm ceramic balls Linear fitting
17 mm ceramic balls
0 0
Minerals 2022, 12, x FOR
0.4 PEER0.6REVIEW
0.8 1.0 1.2 1.4 1.6 0.4 0.6 0.8 1.0 1.2 14 o
A ratio of total mass ( % ) A ratio of total mass ( % )
(a) (b)
30 30

25 25
Mass passing 0.075 mm ( % )
Mass passing 0.075 mm (% )

20 20

15 15
R2=0.970 R2=0.950
y=27.36x-0.84 y=29.46x-0.74
10 10
δ=30% δ=35%
Experimental data Experimental data
5 17 mm ceramic balls 5 17 mm ceramic balls
Linear fitting Linear fitting
17 mm ceramic balls 17 mm ceramic balls
0 0
0.4 0.6 0.8 1.0 0.4 0.6 0.8 1.0

A ratio of total mass (% ) A ratio of total mass ( % )

(c) (d)
Figure 11. The
Figure 11. The relationship relationship
of the of the
distribution distribution
of the percentageof the percentage
passing passing
0.075 mm 0.075
in the mm in the gro
ground
product
product and the ratio andtotal
of the the mass
ratio of
ofthe
12 ×total
12 mass of 12 × 12
mm cylpebs in mm cylpebs
a wider in avolume:
charge wider charge
(a) J =volume:
20%; (a) J = 2
(b) J = 25%; (c) J = 30%; (d) J = 35%.
(b) J = 25%; (c) J = 30%; (d) J = 35%.

As a result,5.for
Conclusions
fine grinding in the wet ball mill, when the charge volume of cylpebs
is 20%–35%, cylpebsThis can study investigated
be replaced the fine-grinding
by ceramic balls of the performance of ceramic
same single mass. balls
In this in compari
case,
with cylpebs. According to the test data, the fine-grinding
the total mass of ceramic balls is only about 0.74–0.77 times that of cylpebs. performance is mainly depe
ent on the ball size and total mass. The single mass of ceramic balls is 0.58–1.84 times t
5. Conclusionsof cylpebs, and the size of ceramic balls is 1.07–1.5 times that of cylpebs. Due to the lar
This studysurface area ofthe
investigated ceramic balls, theperformance
fine-grinding same grinding performance
of ceramic balls can be obtained only wh
in comparison
the total mass of ceramic balls is 0.76–0.83 times that of cylpebs.
with cylpebs. According to the test data, the fine-grinding performance is mainly dependent An innovative appro
for using ceramic balls instead of cylpebs as grinding media in the wet ball mill based
the ball size and the ratio of the total mass of cylpebs was proposed. Therefore, cera
balls can be used in wet tumbling mills to replace cylpebs as fine-grinding media. T
result has also been verified in industrial applications. It should be noted that this n
method requires further verification with different feed sizes and media.
Minerals 2022, 12, 1007 14 of 15

on the ball size and total mass. The single mass of ceramic balls is 0.58–1.84 times that of
cylpebs, and the size of ceramic balls is 1.07–1.5 times that of cylpebs. Due to the larger
surface area of ceramic balls, the same grinding performance can be obtained only when
the total mass of ceramic balls is 0.76–0.83 times that of cylpebs. An innovative approach
for using ceramic balls instead of cylpebs as grinding media in the wet ball mill based on
the ball size and the ratio of the total mass of cylpebs was proposed. Therefore, ceramic
balls can be used in wet tumbling mills to replace cylpebs as fine-grinding media. This
result has also been verified in industrial applications. It should be noted that this new
method requires further verification with different feed sizes and media.

Author Contributions: Conceptualization, N.L. and C.W.; methodology, N.L.; validation, J.L., Y.L.
and X.F.; formal analysis, J.L.; investigation, N.L.; data curation, J.L.; writing—original draft prepara-
tion, N.L.; writing—review and editing, C.W.; resources, Z.Z.; supervision, funding acquisition, C.W.
and W.Y. All authors have read and agreed to the published version of the manuscript.
Funding: This work was financially supported by the Projects of the National Natural Science
Foundation of China (grant number 51964016), and the Industrial Innovation and Entrepreneurship
Team of Hebei Province, China (grant number 215A7606D).
Acknowledgments: The authors would also like to thank the Jiangxi Key Laboratory of Mining
Engineering and Hunan Shizhuyuan Nonferrous Metals Co., Ltd., China, for their support. Yuqing
Wang from the Jiangxi University of Science and Technology is also gratefully acknowledged.
Conflicts of Interest: The authors declare no conflict of interest.

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