Effect of grinding media shape on the particle size distribution of UG2 ore using the response surface methodology central composite design

Abstract

In this study, the effects of truncated ellipsoids and cubes on the particle size distribution of a UG2 ore were compared to the spheres using the response surface methodology for experimental design, modeling, and optimization. The response surface methodology demonstrated that it can be useful in optimizing grinding operations. It provides lenses to see and analyze the behavior of the ball filling, interstitial filling, and % solids parameters which are complex and interactive, and their effects on the production of the desired product (−75 µm) for different grinding media. Spherical grinding media outperformed truncated ellipsoids and cubes, producing the highest amount of the desired size class (82.58%), followed by 80.41% for truncated ellipsoids and 77.07% for cubes. Spheres also consumed the least power followed by cubes and lastly truncated ellipsoids. The differences in optimal grinding conditions were attributed to different contact mechanisms, surface area, and load behavior of the grinding media.