| While applications of stirred media mills for fine particle production have continued to grow, there is a lack of understanding of power requirements, optimum operating conditions and powder (product) characteristics underlying stirred media milling processes. To develop a physical understanding of stirred mill dynamics and scale-up principles, and to identify conditions and mechanisms for effective use of energy in fine grinding, the results of analysis of the literature and of tests in laboratory stirred media mills with media, limestone, and the effect of chemical additives as grinding aids are presented, and mill dynamics, performance and physico-chemical aspects are discussed. Four operational regions marked by sharp transitions are described: transition from static to dynamic friction; channeling; dispersion; and centrifugation. Equations, including power and modified Reynolds number, have been established for relating relevant operating and geometrical variables. Scale-up guidelines with respect to power consumption are also proposed. The best operating conditions for grinding limestone have been identified. The effect of additives on the grinding efficiency and the properties of ground product is discussed using the example of ultra fine grinding of limestone, in which more than a 100% increase in specific surface area and energy efficiency can be obtained. As solid concentration increases, media/pulp flow patterns pass through four regimes: vortex flow, rotating flow, layer formation above the impeller pins, and layer formation adjacent to the tank wall. Use of polyacrylic acid as an additive caused the media/pulp flow to move toward lower solid concentration situation, thus improving grinding conditions and resulting in better grinding. Fragmentation of the polymer molecules was found to occur during long term grinding and this was beneficial for ultrafine grinding. In summary, the research has led to the development of a physical understanding of mill dynamics, performance and physico-chemical effects in stirred media mills. The scale-up principles established, the optimum operating conditions identified and the mechanisms revealed in the use of grinding aids have pointed the way towards more efficient energy utilization during fine grinding in stirred media mills. |
