Analyzing the influence of lifter design and ball mill speed on grinding performance, particle behavior and contact forces

Abstract

Ball mills are the foremost equipment used for grinding in the mineral processing sector. Lifters are placed on the internal walls of the mill and are designed to lift the grinding media (balls) to a higher position. In the calculation of energy consumption in ball mills, classical theories mainly consider factors like the charge fill level, lifter dimensions, the number of lifters, and the rotational speed of the mill. This research recognizes the significance of lifter geometry and proposes a new lifter design aimed at optimizing the energy consumption and efficiency of ball mills. Simulation results by discrete elements obtained in this study were validated using experimental results. By conducting this comparative analysis, the aims of the study was to examine the impact of the new lifter's geometry and rotational speed of the mill on torque, power draw, particles behavior, and contact forces. The findings indicate that when the pitch of the lifters is increased, there is a reduction of 3.30% in torque and power consumption. Additionally, this change leads to an increase in the number of cataracting particles and a 6 to 7% increase in contact forces compared to lifters with a straight shape.