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Volume 113
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Ultrafine grinding of waste marble: A synergistic optimization of mechanical stressing and pulp rheology
Eyup Sabah a *, Selçuk Koltka b, Mustafa Ercan c
a Afyon Kocatepe University, Department of Mining Engineering, 03204, Afyonkarahisar, Türkiye
b Kimtas-Carmeuse, Bergama-İzmir, Türkiye
c Ermaş Madencilik A.Ş., Ula-Muğla, Türkiye
10.1016/j.partic.2026.03.030
Volume 113, June 2026, Pages 249-263
Received 20 December 2025, Revised 10 February 2026, Accepted 18 March 2026, Available online 2 April 2026, Version of Record 8 April 2026.
E-mail: esabah@aku.edu.tr
Highlights

• Slurry rheology is the primary factor limiting stirred media milling performance.

• The polymeric dispersant synergistically unlocks a high-solids grinding regime.

• Holistic optimization yields ultra-fine marble powder with high energy efficiency.


Abstract

The valorization of waste marble into high-value ultra-fine calcium carbonate powders presents significant challenges related to energy consumption and process control. This study provides a comprehensive optimization of the wet grinding of waste marble in a vertical stirred media mill, integrating physical parameters with chemical rheology control. A systematic investigation of grinding time, stirrer speed, media filling ratio, solids content, and media size revealed that process performance is fundamentally constrained by pulp rheology. High viscosity at solids concentrations above 70 wt% limited grinding efficiency, establishing a performance ceiling for purely physical optimization. To overcome this, the efficacy of inorganic and polymeric dispersants was evaluated. The addition of 0.4 wt% of a polymeric dispersant proved to be a critical enabling technology, transforming the rheological state of the pulp. This chemical intervention synergistically unlocked the potential of a high-solids (70 wt%), high-collision-frequency (2 mm media) grinding regime that was previously inefficient. The globally optimized process yielded a final product with an ultra-fine median particle size (d50) of 1.63 μm, exceptional whiteness (99.05%), and a high specific surface area (11.06 m2/g), all achieved at a competitive specific energy consumption of 318 kWh/t. This work demonstrates that a holistic optimization approach, where pulp chemistry is treated as a primary design parameter alongside mill mechanics, is essential for the energy-efficient production of high-quality mineral powders from industrial waste.

Graphical abstract
Keywords
Waste marble; Vertical stirred media milling; Ultra-fine grinding; Rheology; Process optimization
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