Enhancing the Grinding Efficiency of a Magnetite Second-Stage Mill through Ceramic Ball Optimization: From Laboratory to Industrial Applications

Abstract

Ceramic ball milling has demonstrated remarkable energy-saving efficiency in industrial applications. However, there is a pressing need to enhance the grinding efficiency for coarse particles. This paper introduces a novel method of combining media primarily using ceramic balls supplemented with an appropriate proportion of steel balls. Three grinding media approaches, including the utilization of steel balls, ceramic balls, and a hybrid combination, were investigated. Through an analysis of the grinding kinetics and the R–R particle size characteristic formulas, the study compares the breakage rate and particle size distribution changes for the three setups. The results indicate that employing binary media effectively improves the grinding efficiency for +0.3 mm coarse particles while maintaining the energy-saving advantages of ceramic ball milling. Simultaneously, the uniformity of the ground product is ensured. This proposed approach has been successfully validated in industrial applications, providing robust theoretical support for the expansion of ceramic ball milling applications.