Search Results (27)

To mitigate the entanglement, agglomeration, and unstable conveying of high-moisture rice residues during stubble crushing for field incorporation, a discrete element method (DEM)-based modeling and optimization framework was developed to enhance the performance of a stubble-crushing device under wet paddy-field conditions. The device structure and kinematics were first analyzed, and the physical and mechanical properties of the residues were obtained through field measurements. A hollow wet–flexible straw model was then proposed to account for both mechanical breakage and moisture-induced adhesive interactions. Key contact and material parameters were calibrated using DEM simulations coupled with laboratory shear and three-point bending tests, showing good agreement with experimental trends. The validated model was subsequently extended to the device scale to characterize the cyclic capture–acceleration–throwing behavior of residues inside the crushing chamber. The individual and interactive effects of rotor speed, forward speed, and throwing-chamber clearance on comminution efficiency and conveying stability were investigated. A multi-objective response surface optimization identified an optimal parameter combination of 2000 rpm rotor speed, 0.87 m s⁻¹ forward speed, and 10.5 cm clearance. Under these conditions, the comminution rate reached 96.94%, and the coefficient of variation in throwing uniformity was 8.71%. Field validation further confirmed the reliability of the simulation results, with relative errors below 6%. Overall, the proposed framework provides an effective tool for the design optimization and parameter selection of wet-residue comminution equipment. Full article

This study proposes a data-driven framework to predict the rock mass-specific fracture energy distributions using microstructural descriptors extracted from SEM-EDS automated characterization images. Ore textures were encoded through unsupervised k-means clustering to identify six representative mineralogical patterns. The resulting cluster proportions were then used as input features for supervised machine learning models, which seek to estimate the parameters of the log-normal distribution (median and standard deviation) adjusted to the experimental fracture energy data. Both models (XGBoost and decision tree regressor) were validated through Leave-One-Out cross-validation and showed high accuracy ($R^2$ of 0.80 and 0.91, respectively) and predict over 85% of the energy distributions matched the experimental ones according to Kolmogorov–Smirnov and Cramér–von Mises tests. The proposed method outperforms traditional empirical approaches by incorporating mineralogical variability and predicting the complete distribution of fracture behavior, representing a step toward more efficient, texture-aware comminution practices. Full article

Urban leaf litter represents an underutilized biomass resource with potential applications in sustainable building materials. This study investigates the suitability of dried, comminuted leaves collected from municipal green areas as a loose-fill thermal insulation material. The material was characterized in terms of thermal conductivity, settlement behavior, fire reaction, resistance to mold growth, water vapor diffusion, hygroscopic sorption, and short-term water absorption. Tests were conducted following relevant DIN and ISO standards, with both untreated and flame-retardant-treated samples examined. Results indicate that the thermal conductivity of leaf-based insulation (λ = 0.041–0.046 W/m·K) is comparable to other bio-based loose-fill materials such as cellulose and wood fiber. Optimal performance was achieved for particles sized 2–16 mm, showing settlement below 1%. All variants, including untreated material, fulfilled the fire resistance requirements of class E, while selected treatments further improved fire resistance. The material exhibited moderate vapor permeability (μ ≈ 4–5), low water absorption, and moisture buffering behavior similar to that of other bio-based insulation materials. Resistance to mold growth was satisfactory under standardized conditions. Overall, the results demonstrate that leaf litter can serve as an effective and environmentally favorable loose-fill insulation material, offering an innovative recycling pathway for urban green waste. Full article

In the mining industry, particle size reduction is the most energy-demanding activity. Blasting represents the first stage of comminution. Experimental and field observations have demonstrated that blasting produces two main effects on rock: (i) macroscopic fracturing and fragmentation, and (ii) microscopic fracturing, consisting of a network of microfractures that weaken the rock, reduce the specific Work Index, and make the material less resistant to crushing and milling. The present work represents an initial investigation into the relationship between blast-induced microfracturing, fragment size, and mechanical resistance. Blasted rock was analyzed using three approaches: macroscopic testing via point load tests, laboratory grinding tests using a Bond ball mill to determine the blasted Work Index, and microscopic optical observation of microfractures. The results show that macroscopic testing is unable to detect microscopic weakening, as no correlation was observed between point load strength and particle size. In contrast, laboratory ball mill tests and microscopic optical observations indicate a preliminary relationship between particle size and the internal weakening of particles. These results allow the formulation of a new hypothesis: that the Work Index may not be constant within a given volume of blasted rock and could depend on the particle size distribution. Full article

The integration of high-pressure grinding roller (HPGR) with pre-concentration techniques and stirred mills is recognized for its energy efficiency. Studies have suggested that the feed with a P₈₀ around 1 mm is acceptable for stirred mills or coarse particle flotation. Nonetheless, published experimental data characterizing the comminution behavior of single-stage HPGR circuits configured with a 1 mm screen aperture remain scarce. Moreover, extant research remains confined to laboratory scale. Consequently, critical performance metrics, including production capacity, screening efficiency, and process continuity, have not been substantively documented in the literature. In this paper, the HPGR performance in an industrial-scale HPGR/tower mill comminution circuit was assessed and optimized by laboratory and industrial tests. The research meticulously analyzed the impact of feed rate on the industrial-scale flip-flow screen and HPGR performance and found that the HPGR featuring two studded rolls with a diameter of 800 mm and a width of 400 mm, operating in a reverse classification circuit with a scalped feed by a 14.64 m² flip-flow screen while running continuously 24 h per day, is capable of producing a −1 mm comminution product suitable for tower mill feed. Under the optimal operating conditions identified, it achieved a specific energy consumption of 4.57 kWh/t with a feed rate of 27.08 t/h. Full article

This study investigates the impact of two comminution technologies—Vertical Shaft Impactors (VSI) and High-Pressure Grinding Rolls (HPGR)—on gold flotation performance, using ore samples from the Ballarat Gold Mine, Australia. The motivation stems from the growing need to improve energy efficiency and flotation recovery in mineral processing, particularly under increasing economic and environmental constraints. Despite the widespread use of HPGR and VSI in the industry, limited comparative studies have explored their effects on downstream flotation behavior. Laboratory-scale experiments were conducted across particle size fractions (300–600 µm) using two collector types—Potassium Amyl Xanthate (PAX) and DSP002 (a proprietary dithiophosphate collector) to assess differences in flotation recovery, concentrate grade, and specific energy consumption. The results reveal that HPGR produces more fines and micro-cracks, enhancing liberation but also increasing gangue entrainment and energy demand. Conversely, VSI produces coarser, cubical particles with fewer slimes, achieving higher flotation grades and recoveries at lower energy input. VSI at 600 µm demonstrated the highest flotation efficiency (4241) with only 9.79 kWh/t energy input. These findings support the development of hybrid or tailored comminution strategies for improved flotation selectivity and sustainable processing. Full article

This study examines the conversion of an overflow ball mill into a new discharge system via Discrete Element Method (DEM) and Smoothed Particle Hydrodynamics (SPH) simulations, demonstrating significant performance improvements. The methodology integrates SPH to assess the effects of the slurry on energy dissipation, power loss, breakage rates, and material transport. The findings highlight significant operational inefficiencies in the overflow setup, extensive dead zones, and excessive charge volume that hinder milling efficiency by limiting grinding media interaction with the ore and reducing energy for comminution. Additionally, slurry pooling shifts the center of gravity, causing torque losses and direct material bypass to the discharge zone. Our simulations replicate these challenges and benchmark them against industrial-scale operations, identifying critical charge excesses that constrain throughput and elevate power consumption. The new proposed discharge system decouples the filling charge from the evacuation mechanism, releasing the effective volume in the mill, in addition to tackling common issues in the traditional grate discharge setups like backflow and carry-over. This arrangement substantially improved grinding efficiency, as demonstrated by enhanced breakage rates and diminished specific energy consumption. The results provide a robust framework for mill design and operational optimization, underscoring the value of integrated slurry behavior analysis in mill performance enhancement. Full article

Slags containing critical minerals concentrated in artificial phases, so-called engineered artificial minerals (EnAMs), are a novel source of critical raw materials. To liberate the EnAMs, the slags need to be comminuted, reducing the size of the particles. This work investigated the dependence of the breakage behavior on particle size and mineral structure during the comminution of an EnAM-containing slag. Piston-die experiments were performed for particles in the 3 mm to 5 mm size range. Nanoindentation and two-roller breakage tester experiments were performed for those in the 50 µm to 200 µm size range. The investigations were accompanied by X-ray computed tomography (XCT) and scanning electron microscope/energy dispersive X-ray spectroscopy (SEM/EDX) measurements as well as a micro X-ray fluorescence analysis to examine the mineral microstructure. It was found that the commonly assumed exponential connection between particle size and strength differed in the two size ranges. This behavior can be linked to different grain and cluster sizes, which were found in the investigation of the mineral microstructure. In addition to particle size, it was found that mineral structure plays an important role when characterizing the breakage behavior. Full article

Grinding is an important process of ore beneficiation that consumes a significant amount of energy. Pretreating ore before grinding has been proposed to improve ore grindability, reduce comminution energy, and enhance downstream operations. This paper investigates hybrid thermal mechanical pretreatment to improve iron ore grinding behavior. Thermal pretreatment was performed using conventional and microwave approaches, while mechanical pretreatment was conducted with a pressure device using a piston die. Results indicate that conventional (heating rate: 10 °C; maximum temperature: 400 °C), microwave (2.45 GHz, 1.7 kW, 60 s), and mechanical (14.86 MPa, zero delay time) pretreatments improved the studied iron ore grindability by 4.6, 19.8, and 15.4%, respectively. Meanwhile, conventional-mechanical and microwave-mechanical pretreatments enhanced the studied iron ore grindability by 19.2% and 22.6%, respectively. These results suggest that stand-alone mechanical pretreatment or microwave pretreatment may be more beneficial in improving the grinding behavior of the studied fine-grain iron ore sample. The results of the mechanical pretreatment obtained in this study may be used in a simulation of the HPGR system for grinding operations of similar iron ore Full article

The increasing world population and the development of technology have boosted the demand for electrical and electronic equipment (EEE). Equipment that has completed its life cycle causes serious damage to the environment due to its toxic components. In addition, it contains many more base metals (copper, aluminum, nickel, lead, tin, etc.) and precious metals (silver, gold, palladium, platinum, etc.) compared with a run of mine ore. Recycling these values with an economic and environmental understanding will ensure sustainability and prevent the rapid depletion of natural resources. Specific gravity, magnetic, electrostatic, optical, surface, thermal, and other property differences between particles as well as the shape, size, and distribution of individual particles directly determine the success of the recycling process. By determining the behavior of the particles during enrichment and producing grains suitable for enrichment with better performance in the size reduction stage, the quality of the concentrate to be subjected to the final chemical/metallurgical treatment will be enhanced. The main aim of this study is to reveal the effect of particle size and shape properties on the recovery of valuable metals from two different waste electrical and electronic equipment (WEEE) sources, end-of-life printed circuit boards and waste electric wires, using environmentally friendly, easier-to-use, and cost-effective mechanical, physical, and physiochemical processes. Deciding on the most suitable enrichment process after detailed characterization of the products obtained from different comminution equipment and their particle size and shape directly affected the amount, content, and recovery of the final concentrate. Full article

The present research aims to analyze the comminution behavior of ferrochrome slag using high-pressure grinding rolls. The laboratory bench scale high-pressure grinding rolls were used to study the three significant variables on the grinding efficiency of ferrochrome slag. The Central Composite Design was used to study the process variables, such as roll gap, applied load, and roller speed. The grinding efficiency was evaluated based on the product size and the energy consumption. The results showed that the increased gap between the rolls and roller speed decreases the product size with increased energy consumption. The results also found that an increase in applied load decreases the product fineness with increased energy consumption. The models were developed for the responses of P₈₀ (size of 80% mass finer) and Ecs (specific energy consumption). Both the responses show high regression coefficients, thus ensuring adequate models with the experimental data. The minimum values of the P₈₀ size and specific energy were determined using quadratic programming. The optimum values of the roll gap applied load and roll speed were found to be 1.43 mm, 16 kN, and 800 Rpm, respectively. The minimum values of P₈₀ and the specific energy consumption were found to be 1264 µm and 0.56 kWh/t, respectively. Full article

This study presents an approach for targeted comminution of component mixtures within a wet-operated stirred media mill. In the first step, a general understanding of the interactions between individual components on the grinding result with mixtures could be gained with basic experiments and following our former research work. In particular, a protective effect of the coarser particles on the fines could be elucidated. These findings were used to develop a process for the production of a battery slurry containing fine ground silicon particles as well as dispersed carbon black and graphite particles. By a tailored sample preparation applying a combination of particle dissolution and separation, the particle size distributions of carbon black and graphite particles were analyzed separately within the produced battery slurries. Based on the selective particle size analysis, the slurry preparation could be transferred from a complex multistage batch process using a dissolver to a stirred media mill, which was finally operated in a continuous one-passage mode. The prepared slurries were subsequently further processed to silicon-rich anodes using a pilot scale coating and drying plant. Afterward, the produced anodes were electrochemically characterized in full cells. The cell results prove a comparable electrochemical behavior of anode coatings derived from a dissolver- or mill-based slurry production process. Therefore, we could demonstrate that it is possible to integrate the mixing process for the production of multicomponent slurries into the comminution process for the preparation of individual materials upstream. Even with nearly identical starting sizes of their feed materials, the targeted particle size distributions of the single components can be reached, taking into account the different material-dependent particle strengths and sequential addition of single components to the multicomponent comminution process. Full article

Controlling the size of powder particles is pivotal in the design of many pharmaceutical forms and the related manufacturing processes and plants. One of the most common techniques for particle size reduction in the process industry is powder milling, whose efficiency relates to the mechanical properties of the powder particles themselves. In this work, we first characterize the elastic and plastic responses of different pharmaceutical powders by measuring their Young modulus, the hardness, and the brittleness index via nano-indentation. Subsequently, we analyze the behavior of those powder samples during comminution via jet mill in different process conditions. Finally, the correlation between the single particle mechanical properties and the milling process results is illustrated; the possibility to build a predictive model for powder grindability, based on nano-indentation data, is critically discussed. Full article

Deflector wheel classifiers are widespread in industry for the separation of powders into fine and coarse powders. Even though this separation process has been known for quite some time, it is not yet fully understood, and existing models fail to precisely predict the separation characteristics. Due to the high throughput of deflector wheel classifiers, it is greatly beneficial to estimate the separation characteristics before the experiment. Here, the developed model critically examines the usual assumptions, such as ideal airflow, neglection of particle–wall and particle–particle interactions, or spherically-shaped particles. First, the investigation of the air flow using a Particle Image Velocimetry (PIV) system showed significant differences to the assumed ideal flow field, then particle sphericity and its influence on the interaction between the particles and the paddles of the deflector wheel was investigated and compared with particle rebound behavior on a static wall. Surprisingly, comminuted glass behaves similarly to comminuted limestone in multiple aspects and not like glass beads. To determine the number of particle–particle collisions, Discrete Element Method (DEM) simulations were performed. The aforementioned aspects found application in the model and the separation behavior was well-estimated. Full article

The comminution of spent lithium-ion batteries (LIBs) produces a powder containing the active cell components, commonly referred to as “black mass.” Recently, froth flotation has been proposed to treat the fine fraction of black mass (<100 µm) as a method to separate anodic graphite particles from cathodic lithium metal oxides (LMOs). So far, pyrolysis has been considered as an effective treatment to remove organic binders in the black mass in preparation for flotation separation. In this work, the flotation performance of a pyrolyzed black mass obtained from an industrial recycling plant was improved by adding a pre-treatment step consisting of mechanical attrition with and without kerosene addition. The LMO recovery in the underflow product increased from 70% to 85% and the graphite recovery remained similar, around 86% recovery in the overflow product. To understand the flotation behavior, the spent black mass from pyrolyzed LIBs was compared to a model black mass, comprising fully liberated LMOs and graphite particles. In addition, ultrafine hydrophilic particles were added to the flotation feed as an entrainment tracer, showing that the LMO recovery in overflow products is a combination of entrainment and true flotation mechanisms. This study highlights that adding kerosene during attrition enhances the emulsification of kerosene, simultaneously increasing its (partial) spread on the LMOs, graphite, and residual binder, with a subsequent reduction in selectivity. Full article