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Volume 105
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Evaluation of fine-grinding products in horizontal stirred mill: Particle size distribution prediction, parameter optimization, industrial comparison, and fluid motion simulation
Hongquan Wei a b c, Xiaolong Zhang a b c *, Ruizhe Liu a b c, Ruichen Wang a b c, Yuexin Han a b c
a School of Resources and Civil Engineering, Northeastern University, Shenyang, 110819, China
b State Key Laboratory of Digital Steel, Northeastern University, Shenyang, 110819, China
c National-local Joint Engineering Research Center of High-efficient Exploitation Technology for Refractory Iron Ore Resources, Shenyang, 110819, China
10.1016/j.partic.2025.07.015
Volume 105, October 2025, Pages 64-73
Received 24 June 2025, Revised 7 July 2025, Accepted 16 July 2025, Available online 25 July 2025, Version of Record 11 August 2025.
E-mail: zhangxiaolong@mail.neu.edu.cn
Highlights

• Prediction equations of particle size distribution for grinding products in HSM were established.

• Process parameters of HSM grinding process were optimized.

• Grinding and leaching effects significantly improved.

• Visualization of fluid motion in the HSM grinding process was achieved.


Abstract

Fine grinding was an essential process in the development and utilization of mineral resources, and a horizontal stirred mill, as a representative equipment for fine grinding, was widely used in the fields of mining and metallurgy. In this study, the prediction and optimization of the particle size distribution for the grinding product in a horizontal stirred mill was carried out. A prediction equation of particle size distribution for grinding products in a horizontal stirred mill was established based on grinding kinetics principles, with a relative error of 5 %. The effect of grinding process parameters on the grinding efficiency was investigated. The results indicated that the grinding parameters had a significant effect on the particle size distribution of the grinding product. Under the optimum conditions (mill speed 1700 rpm, grinding concentration 36 %, pulp handling capacity 20 L/h, and media filling ratio 54 %), the content of −45 + 15 μm was 40.01 %, and the uniformity index n was 0.99, with a uniform particle size distribution. The fluid motion simulation results indicated that the high-velocity gradient and high turbulence intensity occurred near the stirring disk with a better grinding effect, relatively, the grinding effect near the barrel wall was poor.


Graphical abstract
Keywords
Horizontal stirred mill; Grinding kinetic; Particle size distribution; Fluid motion simulation
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