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Volume 114
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Effect of classifier on flow field characteristic and grinding media collision behaviour in horizontal stirred mill
Lingguo Meng a c *, Tianlin Liu a c, Jingzhong Kuang a c, Jingyu Wang a c, Tingsheng Qiu a c, Huashan Yan a c, Guoqiang Wang b, Shaobing Zhou d
a Jiangxi Provincial Key Laboratory of Low-Carbon Processing and Utilization of Strategic Metal Mineral Resources, Ganzhou, 341099, China
b State Key Laboratory of Mineral Processing, Beijing General Research Institute of Mining & Metallurgy, Beijing, 102628, China
c School of Mining Engineering, Jiangxi University of Science and Technology, Ganzhou, 341099, China
d Jiangxi Copper Company Limited, Nanchang, 330002, China
10.1016/j.partic.2026.04.009
Volume 114, July 2026, Pages: 293-306
Received 20 January 2026, Revised 7 April 2026, Accepted 13 April 2026, Available online 26 April 2026, Version of Record 12 May 2026.
E-mail: menglingguo1994@163.com
Highlights

• Classifier size increase boosts fluid tangential velocity and collision energy.

• Larger classifiers intensify reverse flow and disrupt vortex structures at d/D = 1.2.

• Total collision frequency drops at d/D = 1.2, but high-energy collision proportion rises.

• Peak energy utilization (74%) achieved at d/D = 1.1, efficiency declines beyond.


Abstract

As a critical component of horizontal stirred mills, the classifier plays a key role in precisely controlling the particle size distribution and energy efficiency. Adjusting its structural parameters is essential for addressing the challenge of efficient mineral resource liberation. In this study, numerical simulations were conducted to systematically elucidate the influence of classifier diameter on flow field characteristics and grinding media collision behaviour. Results show that increasing the diameter ratio of classifier to stirring disc (d/D) enhances tangential flow and collision energy, thereby creating a more intense stress environment conducive to particle breakage, but also intensifies axial backflow, which can impair classification and increase component wear. While collision frequency and energy generally rise with classifier diameter, an excessive ratio (d/D = 1.2) disrupts local flow, reducing collision frequency near the classifier and highlighting axial heterogeneity in media behavior. The collision energy spectrum is normally distributed, dominated by low-energy, high-frequency events. A d/D ratio of 1.1 yields the most concentrated energy distribution and highest density, which is hypothesized to optimize grind efficiency and product size control by providing a uniform and intense stress field. Although power and impact energy increase monotonically with diameter, energy utilization peaks (∼74%) at d/D = 1.1 before declining due to reduced flow stability. These findings provide a theoretical basis for parameter optimisation and performance regulation of horizontal stirred mills.

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