Mechanistic modeling and simulation of grinding iron ore pellet feed in pilot and industrial-scale ball mills

Various approaches have been used over the years to describe quantitatively ball milling, with different levels of success. The present work presents the application and validation of a mechanistic model to describe ball milling of iron ore pellet feed. The approach started by estimating selected parameters describing the ore characteristics by back-calculation from batch grinding tests, followed by validation of the model in batch grinding as well as continuous open-circuit ball milling at a pilot-scale operating at a variety of solids concentrations, both with overflow and grate discharge. An industrial ball mill was then laser scanned and surveyed, including measurements of residence time distribution. Simulations using the discrete element method were then conducted and the model was applied to simulate closed-circuit operation, resulting in good agreement between measured and predicted size distributions and circulating load ratio. [Display omitted] •Mechanistic ball mill model applied to grinding iron ore pellet feed.•Particle breakage parameters back-calculated from bench-scale ball mill tests.•Model predictions validated for other batch milling conditions.•Open-circuit pilot-scale tests predicted with good accuracy.•Application to simulation to full-scale milling circuit provided valid results.