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382–388
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Abstract
Based on the motion of the grinding media in stirred media mills with disc stirrer different grinding mechanisms are possible: product
particles can be stressed by grinding media which are accelerated from the stirrer shaft towards the grinding chamber wall ŽA., which are
pressed against the chamber wall because of the centrifugal acceleration ŽB. and which move in tangential direction with high velocities
and collide with grinding media with lower velocities ŽC.. The importance of the three different grinding mechanisms can be determined
by evaluating the respective stress intensity and the respective number of stress events per unit time. The theoretical investigations
showed, that the product particles are broken mainly by stress mechanism C. This finding was confirmed by experimental investigations
concerning the comminution of limestone in a stirred media mill.
´ ´
Resume
´´
Du fait du mouvement des elements broyeurs dans un broyeur a` billes avec agitateur a` disques, trois phenomenes
´ ` de broyage peuvent
ˆ identifies.
etre ´ ´ Les particules peuvent etre ˆ soumises a` contraintes par des billes, qui sont soit accelerees
´ ´ ´ depuis l’agitateur vers la paroi de
la chambre de broyage ŽA., soit comprimees ´ contre la paroi du fait de l’acceleration
´´ centrifuge ŽB. ou par des billes a` grande vitesse en
mouvement tangentiel heurtant des billes de vitesse plus faible ŽC.. L’importance de ces trois phenomenes ´ ` ˆ determinee
peut etre ´ ´ en
´
evaluant l’intensite´ respective des contraintes ainsi que la frequence
´ ´
respective des efforts. Les etudes ´
theoriques montrent que les
´
particules cassent essentiellement du fait des contraintes resultant ´
du cas C. Ces resultats ´ experimentalement
furent confirmes ´ dans le cas
du broyage de calcaire dans un broyeur agite´ a` billes. q 1999 Elsevier Science S.A. All rights reserved.
Keywords: Stirred media mill; Grinding mechanism; Stress intensity; Stress number
0032-5910r99r$ - see front matter q 1999 Elsevier Science S.A. All rights reserved.
PII: S 0 0 3 2 - 5 9 1 0 Ž 9 9 . 0 0 1 6 2 - X
A. Kwader Powder Technology 105 (1999) 382–388 383
4. Estimation of stress intensities A P , can be used. For the calculation, the centrifugal force
at the outer circumference of the disc was taken:
The intensity of grinding media mills can be described FC 1
either by the force acting on a grinding medium or by the s VGM Ž rGM y r Susp . bC
kinetic energy of a grinding medium w1,2x. According to AP AP
the investigations described above, in stirred media mills 2
usually only one particle is stressed intensively between 4 d GM d GM
two grinding media Žas long as the particles are not much
smaller than 1 mm andror the solids concentration is not
s
3 ž / ž /Ž
x dD
2
rGM y r Susp . ÕGM Ž 3.
extremely high.. Therefore, the stress intensity acting on a In case of mechanism C, grinding media with different
particle between two grinding media can be described velocities collide. Since the tangential velocities are usu-
either by the energy related to the particle volume or by ally much higher than the axial and radial velocities, in the
the force related to the cross-sectional particle area. following, only the tangential direction is considered. Two
In case of mechanism A, the media is accelerated in the grinding media, which move with different tangential ve-
vicinity of the disc from the stirrer shaft towards the locities ÕGM ,1 and ÕGM,2 Ž ÕGM,1 ) ÕGM,2 ., have different
grinding chamber wall. Thereby, the media take up kinetic kinetic energies. For the evaluation of the stress intensity,
energy, which can be used for comminution when the it is assumed that the impacts are straight and inelastic and
media collides with media which are based on the chamber that the faster medium is decelerated from the velocity
wall and, thus, which have no or nearly no radial velocity. ÕGM ,1 to the velocity of the slower medium, ÕGM,2 . The
This process is comparable to the one in a tumbling ball difference between the energies of the faster medium
mill, in which grinding media are dropped from the upper before and after the collision, D E kin , is used for stressing
part of the grinding cylinder and fall on the bulk media in the captured particle:
the lower part of the grinding cylinder. According to
w2,3x, in this case, the stress intensity is deter- VGM rGM
¨
Schonert D E kin s 2
Ž ÕGM 2
,1 y ÕGM ,2 . Ž 4.
mined by the kinetic energy of the medium and the volume 2
of the captured product particle, V P . A measure for the
The energy difference D E kin represents the maximum
kinetic energy is the potential energy of the medium,
energy available for stressing the captured particle because
which is accelerated from the stirrer shaft Ž r s d Sr2. to
under the assumptions stated above no energy is consumed
the outer circumference of the discs Ž r s d D r2. with a
for the acceleration of the slower grinding medium. The
centrifugal acceleration bc of r v GM . Considering the lift-
velocities ÕGM ,1 and ÕGM,2 can be estimated using fluid
ing force acting on the media and neglecting the coriolis
velocity gradients. Under the assumptions, that the velocity
force the specific energy E V,GM , which is related to the
of the media corresponds to the velocity of the fluid and
volume VP of the captured particle, can be calculated:
that the velocity gradient is independent on the value of
0.5d D 2
the velocity, the following equation can be given based on
H0.5d VGM Ž rGM y r Susp . r v GM dr Fig. 4:
S
E V ,GM s
Vp Õmax
ÕGM s Ž l 0 y l . Ž 5.
l0
2 3
1 dS d GM
s
2 ž 1y
ž / /ž / Ž
dD x
2
rGM y r Susp . ÕGM
Ž 2.
The length l corresponds to the distance between the
center of the grinding medium and the position of the
maximum velocity Õmax Že.g., at the disc surface.. Based
where VGM is the volume and rGM the density of the
grinding media, r Susp is the density of the suspension and
ÕGM is the tangential velocity of the grinding media.
In case of mechanism B, the grinding media in the vicinity
of the chamber wall have no radial velocity. Because of
the centrifugal force they are based on the grinding cham-
ber wall. Comminution takes place by a combined normal
and shear force between the grinding media. The normal
force which can be assumed to be the decisive force w2,3x,
corresponds to the centrifugal force, which acts on the
media and which is reduced by the lifting force. As a
measure for the stress intensity the centrifugal force, FC ,
related to the cross-sectional area of the captured particle, Fig. 4. Gradient of the tangential velocity.
386 A. Kwader Powder Technology 105 (1999) 382–388
D E kin
D E V ,kin s
VP
3 2 2
1 d GM l 0 y l1 l0 y l2
s
2 ž / x
2
rGM Õmax
ž l0 / ž y
l0 /
Ž 6.
The result that at a circumferential speed of 10 mrs the of Bunge w6x, the average number of revolutions of a
stress intensity of glass beads with diameters less than 300 grinding medium in tangential direction is approximately
mm is too low to break limestone particles with a size of half of the number of revolutions of the stirrer. Therefore,
50 mm was confirmed by comminution tests with lime- every four stirrer revolutions a single medium moves
stone in a stirred media mill w7,8x. The experimental results through the zone near the stirrer disc and collides with
show, that at a circumferential speed of 9.6 mrs glass NC,R other grinding media. Based on this, the number of
beads with a size of 96 and 219 mm are not able to break media contacts can be described as follows:
feed particles with a median size of approximately 60 mm n n VGC wGM Ž 1 y ´ .
Ž x 10 f 40 mm and x 90 f 80 mm.. Using glass beads with NC s NC ,R tNGM s NC ,R t Ž 8.
4 4 p 3
sizes of 399, 515 and 661 mm, the feed particles are d
broken after comminution times of 16 min Ž399 mm., 4 6 GM
min Ž515 mm. and 2 min Ž661 mm.. According to Fig. 5, where n is the number of revolutions of the stirrer per unit
glass beads with these sizes have just or just not the stress time, NGM the number of grinding media inside the cham-
intensity to break limestone particles with sizes between ber, t the comminution time, VGC the volume of the
40 and 80 mm. Since the stress intensity of glass beads grinding chamber, wGM the filling ratio of the grinding
with a size of 399 mm is too small to break the larger feed media and ´ the porosity of the bulk grinding media. The
particles in one stress event, more stress events are neces- number of product particles is equal to the ratio of the
sary and, therefore, a longer comminution time is required overall volume of the product particles and the average
to break all feed particles. If the glass beads are larger than volume of the product particles:
661 mm, most of the feed particles are broken in less than
1 min, because the stress intensity is high enough to break
V P ,ges Ž 1 y wGM Ž 1 y ´ . . c V
NP s s VGC p Ž 9.
limestone particles of a size of 100 mm. VP x3
The comminution tests with limestone showed further, 6
that the optimum stress intensity or the optimum media where c V is the volume solids concentration of the product
size, which is required to produce a certain product fine- suspension and x the average particle size of the product.
ness with a minimum specific energy, depends on the Presuming that the probability PS is 1 Žmaximum value.
product fineness. At low specific energy inputs and, thus, the following expression for the number of stress events
small product fineness the optimum bead size at a circum- can be derived:
ferential speed of 9.6 mrs corresponds to the bead size 3
required to break the largest feed particles Ži.e., media size n wGM Ž 1 y ´ . x
of approximately 800 mm.. At higher specific energy
SN s NC ,R
4
t
Ž 1 y wGM Ž 1 y ´ . . c V ž /
d GM
Ž 10 .
inputs the optimum media size decreases and corresponds
For usual values of the operating parameters Ž Õt s 10 mrs,
to the media size, which is necessary to break feed parti-
n s 1592 miny1 , wGM s 0.8, ´ s 0.4, c V s 0.2, d GM s
cles with an average size Ži.e., media size of approximately
1000 mm. and an average particle size x of 50 mm the
500–600 mm..
number of stress events of a single particle within 1 min
can be calculated as given in Table 1, in which the stress
number is given for different numbers of media contacts
5. Estimation of number of stress events within one passage through the zone of high power den-
sity.
In batch mode, the average number of stress events of Experimental investigations show w7,8x that under the
each product particle, SN, is determined by the number of operating parameters given above within 1 min 90% by
media contacts, NC , by the probability that a particle is volume of feed particles which have a average size of 50
caught and sufficiently stressed at a media contact, PS , and mm are smaller than 15 mm. Therefore, under the condi-
by the number of product particles inside the mill, NP : tions, that at any media contact a particle is intensively
stressed and broken Ž PS s 1. and that all original feed
NC PS
SN s Ž 7. particles are broken before particle fragments are broken
NP further, the number of stress events per feed particle in the
first minute is about 1. According to Table 1, for this stress
The number of media contacts can be assumed to be
proportional to the number of revolutions in the radial–
axial plane and therefore to the passages through the zone Table 1
of high power density near the stirrer disc Žstress intensity Number of stress events of a single particle within 1 min
at the chamber wall usually too small to break a particle.. Number of media contacts NC,R 1 2 4 8 16
According to Blecher w5x, a grinding medium needs two Number of stress events of one 0.2 0.5 0.9 1.8 3.7
revolutions in tangential direction for one revolution in the particle within a minute SN
radial–axial plane. Moreover, according to investigations
388 A. Kwader Powder Technology 105 (1999) 382–388
number, the number of media contacts at a passage through ated in radial direction taking up kinetic energy and col-
the zone of high power density is about 4. Since in reality lides with a medium which is based on the chamber wall.
the probability PS is smaller than 1, fragments of the feed Therefore, usually mechanism A occurs only once during a
particles will be stressed further before all feed particles complete revolution in the radial–axial plane. Against that
are stressed once and not all grinding media pass the zone media collisions because of velocity gradients in tangential
of high power density at the disc within each revolution in direction can occur several times during one revolution
the radial–axial plane, the number of media contacts within and, thus, during one passage through the zone near the
a passage through the zone of high power density will be disc Žmechanism C.. Therefore, most of the particles are
clearly higher than 4 in reality. broken by mechanism C in the zone near the stirrer disc,
especially if coarser feed particles have to be ground. This
finding was confirmed by experimental investigations con-
6. Conclusions cerning comminution of limestone in a stirred media mill.
Since media collisions in circumferential direction are
The investigations showed that the number of particles mainly responsible for the grinding effect of stirred media
captured by two media depends above all on the media and mills with disc stirrer geometry, stirred media mills with
the particle size as well as on the solids concentration of annular gap geometry are also very efficient, although
the suspension. As long as the particles are sufficiently nearly no radial and axial movement occurs. This was
larger than 1 mm and the solids concentration is not too confirmed by the results of Muller¨ w9x, who investigated
high, only single particles Žno particle bed. are stressed. If the comminution in stirred media mills with annular gap
more than one single particle is stressed, usually only the geometry. By measuring the media velocities, Muller ¨
particle stressed first can be broken completely. Probably, showed that the breakage energy necessary for coarser
the other particles are only reduced in size by breaking off particles can only be produced by media collisions in
edges. circumferential direction.
The importance of the three grinding mechanisms A, B
and C for the comminution result can be evaluated based
on the theoretical considerations and the comparison of
theoretical with experimental results. The considerations
regarding the stress intensity show that by grinding media References
which are pressed against the chamber wall because of the
centrifugal acceleration even with large grinding media w1x K. Schonert,
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w2x K. Schonert,
¨ in: K.V.S. Sastry, M.C. Fuerstenau ŽEds.., Challenges in
broken completely Žmechanism B.. Moreover, the velocity
Mineral Processing, Society of Mining Engineers, Littleton, 1989, p.
gradients in tangential direction are clearly smaller at the 151.
chamber wall than near the disk. Therefore, because of the w3x K. Schonert,
¨ Aufbereitungstechnik 32 Ž1991. 487.
clearly higher stress intensity the zone near the stirrer disc w4x D.G. Bosse, Off. Dig. 3 Ž1958. 251.
is much more important than the zone at the chamber wall, w5x L. Blecher, Dissertation, TU Braunschweig, 1993.
w6x F. Bunge, Dissertation, TU Braunschweig, 1992.
especially if particles larger than 10 mm have to be
w7x A. Kwade, Dissertation, TU Braunschweig, 1996, and Verlag Shaker,
ground. Aachen, 1997.
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high power density near the disc, the medium is acceler- w9x H. Muller,
¨ ¨
Dissertation, VDI-Verlag, Dusseldorf, 1991.