Minerals Engineering, Vol. 14, No. 10, pp.

1177-1186, 2001
Pergamon © 2001 Elsevier Science Ltd
All rights reserved
0892-6875(01)00135-2 0892-6875/01/$ - see front matter

MEDIA STRESS INTENSITY ANALYSIS FOR VERTICAL STIRRED MILLS*

A. J A N K O V I C

JKMRC, Isles Rd, Indooroopilly 4068, Qld, Australia. E-mail: a.jankovic @mailbox.uq.edu.au
(Received 23 March 2001; accepted 4 June 2001)

ABSTRACT

Experimental work has been carried out to investigate the effect of major operating variables on
milling efficiency of calcium carbonate in laboratory and pilot size Tower and Sala Agitated (SAM)
mills. The results suggest that the stirrer speed, media size and slurry density affect the specific
energy consumption required to achieve the given product size. Media stress intensity analysis
developed for high-speed horizontal mills was modified to include the effect of gravitational force in
the vertical stirred mills such as the Tower and SAM units. The results suggest that this approach
can be successfully applied for both mill types. For a given specific energy input, an optimum stress
intensiO, range existed, for which the finest product was achieved. Finer product and therefore
higher milling efficiency was obtained with SAM in the range of operating conditions tested. © 2001
Elsevier Science Ltd. All rights reserved.

Keywords
Fine particle processing; grinding

INTRODUCTION

Stress intensity is the most important parameter affecting milling efficiency in high-speed horizontal stirred
mills (HSH). There is an optimum stress intensity for particular HSH application when minimum energy is
consumed to obtain target product size (Kwade, 1996). Stress imposed on particles is result of the
centrifugal forces of grinding media being agitated at high speed. In this situation stress intensity is
proportional to the cub of media size, stirrer speed velocity squared and the difference between the media
and slurry density (Kwade, 1996).

In low speed vertical stirred mills (LSV) such as the Tower and Verti mill (see Figure 1), Sala Agitated
Mill (SAM), Metprotech mill etc, apart from centrifugal forces, there is the effect of gravitational forces on
stress intensity imposed on particles by the grinding media. This paper discusses the factors affecting stress
intensity in LSV and the stress intensity effect on milling efficiency.

Presented at Comminution '01, Brisbane, Australia, March 2001

1177
1178 A. Jankovic

EXPERIMENTAL

In order to investigate the effect of the stress intensity on milling efficiency, continuous grinding tests were
carried out in laboratory and pilot size Tower and SAM mills. Co]nmercially available calcium carbonate,
P80-65 gin, was ground using the experimental set-up shown in Figure 2, which allowed a continuous
stage-wise operation. A predetermined quantity of material was mixed with water in tile teed tank to give a
specific slurry % solids and total slurry volume of 80-100 litres (10 litrcs for the lab test). The slurry
density was checked by using a Marcy gauge and subsequently determined accurately by the drymg
method. The slurry was then pumped into the mill (pass 1) and discharged into the product tank. Samples
for the product particle size analysis (40 ml) from the mill discharge were taken towards the end of tile
pass. When the feed tank was emptied out, slurry from the product tank was returned to tile feed tank and
the test was continued (pass 2). The process was repeated several times depending on test c(mditions.

Grinding Meclla

Producl

Material

a. b,

Fig. 1 Stirred mills used in the study,: a - - T o w e r mill; b - - g a l a Agitated Mill (SAM).

Feed tank Motor Pr~xluct tank

Stirred mill

I
I
"~ Sampling point I

................................. £)

Fig.2 Experimental set-up.

 Media stress intensity analysis for vertical stirred mills 1179

The summary of the experimental conditions and test results is presented in Table 1. The test results are
discussed in following sections.

TABLE 1 Experimental results

Mill Test Mill volume Media size Tip speed Slurry Ps. (~tm)
Type number (1) (ram) (m/s) (kg/ln 3) 20 kWh/t
SAM sam 3 50 2.5 1340 3..~
SAM sam 4 50 8 2.5 1530 29.0
SAM sam 5 50 8 2.5 1680 26.1
SAM sam 7 50 8 2.5 1530 30.3
SAM sam 12 50 6.8 2.5 1500 27.0
SAM sam 13 50 4.8 2.5 1510 22.1
SAM sam 14 50 2 2.5 1540 14.5
SAM ptm4 4.8 1.5 1550 16.0
Tower tm2 50 12 0.74 1543 24.9
Tower tm3 50 12 0.74 1661 23.1
Tower tm4 50 12 0.74 1555 25.6
Tower tm5 50 12 0.37 1550 24.2
Tower tm6 50 12 1.1 1570 26.2
Tower tml0 50 4.8 0.74 1572 21.5
Tower tml2 50 6.8 0.74 1563 I9.5
Tower tm 15 50 2 0.74 1580 30.7
Tower ltml 4.8 0.77 1550 20.5

STRESS INTESITY ANALYSIS

It is believed that the predominant mode of breakage in stirred mills is attrition, where particles are being
broken due to stress acting between the grinding media. The stress is proportional to the acting forces and
the size of the particles being stressed (Schonert, 1990). Centrifugal forces are predominant in high-speed
horizontal stirred mills (HSH) due to high stirrer tip speed and horizontal design that minimizes
gravitational forces. The stress intensity is defined differently for the two zones of high energy density:
near the disc the grinding beads are accelerated by centrifugal forces from the stirrer shaft towards the mill
wall; between the stirrer and mill wall grinding beads are supported by the chamber wall owing to the
centrifugal acceleration (Kwade eta/., 1996, 2). Near the disc where particles are accelerated the specific
energy Ev,b, is given by:

1 D~ ,2 1 SI m
Ev, b oc Dd * Vm * (Pm p) * a,. * - - ~c ,,, (Pm P) ~t * - - - (1)
Vp Vv Vp
9
Sire = D 3,,, (0m- P) V7 (2)

where:
Dd --stirrer (disc) diameter (m)
Dm --grinding media size (m)
Pill --grinding media density (kg/m 3)
P - - s l u r r y density (kg/m 3)
Vm --grinding media volume (m 3)
(J{ --grinding media centrifugal acceleration (n'l/S 2)
Vt --stirrer tip speed (m/s)
v,, --particle volume (m 3)
Sire --stress intensity of the grinding media (N)
1180 A, Jankovic

The specific energy Ev,b, is inversely proportional to the particle volume and proportional to stress intensity
of the grinding media Sire.
In the zone between the disc and vessel wall the particles are stressed by the pressure acting between the
grinding media. Taking the centrifugal acceleration of the grinding media at the outer stirrer radius as the
characteristic acceleration at, the average grinding pressure is given by:

oc V 3 . , ( p . , - o ) a * 1 - D 3.,(Om-O) v [ * * - - - 1 m_
SI (3)
Av Ae Ap Av

where:
Fc --centrifugal force (N)
A1, --particle cross-section (m 2)

Equation (1) and (3) are valid lbr a fixed stirrer diameter and under assumption that the grinding media
tangential velocity is proportional to the stirrer tip velocity.

It can be concluded that stress intensity Sire, is a measure of the pressure acting on the particles and it is
fixed during the comminution process as grinding media size and density, stirrer speed and slurry density
are normally constant. Therefore, for a fixed feed particle size and specific energy consumption, stress
intensity controls the size of the grinding product. It can be seen from the Figure 3 that there is optimum
stress intensity producing the finest product size.

50
I f {
Pb [ k g / r n 3 ] = 2894 7550

vd [ m / s ] = 6.4 v .

v d [m/s] = 9.6 o •
g
:z 10 % [m/s] = 12.8 ~ •

x
=.
A
J

Em = 1000 kJ/kg
!
FR b = 0.8

c m = 0.4
0.5 ....... i ........................ i ........
0.00002 0.0001 0.001 0.01 01 1 10 50
Stress intensity $1b [ 1 0 .3 N m ]

Fig.3 Influence of stress intensity on the ground limestone median size for a specific energy
consumption of 1000 kJ/kg (277.8 kWh/t) - After Kwade, 1996.

In the low speed vertical stirred mills (LSV) both centrifugal and gravitational forces are equally important.
Gravitational forces are dependent on the media height as well as mill design. It was found in the pin stirred
mill that the media pressure distribution due to gravitational forces can be described by a "hydrostatic law"
i.e. media pressure is directly proportional to the media height. On the other hand, the media pressure
distribution in Tower mills, using a screw type stirrer, does not follow this law due to the stirrer lifting
action. The pressure distribution in Tower mills can be described by a modified Janson's formula for slow
moving granular beds (Jankovic, 1999).

Figure 4 illustrates the effect of media height on media pressure due to gravitational forces. It can be seen
that after a certain depth media pressure in Tower mills becomes constant, while it increases proportionally
with depth in pin stirred mills.
 Media stress intensity analysis for vertical stirred mills 1181

Me d i a ~ ,~.-..-.----Shaft

Media pressure (N/cm2) :~

t # [

i :11 ', I P,.m,,

I ~ ]] ', Towerlmill

Stirrer Media heght (cm)

Fig.4 Media pressure distribution due to gravitational forces in the Tower and pin stirred mill.

In the pin stirred mills the media grinding pressure due to gravitational forces is given by:

Fg p*A 2 ~ I SIgm
Ap oc A----~- Dm -4- (19m- 19)*g* h * --OC (4)
Ae Ap
- -

P = ( P m - 19)*g*h (5)

Slgm = D2m (19m - [3) *g * h (6)

where:
Fg --gravitational force (N)
A I, --particle cross-section (m 2)
P - - m e d i a pressure due to gravitational forces (N/m 2)
h - - m e d i a height (m)
g --gravitational constant (m/s 2)
Slgm --gravitational stress intensity of the grinding media (N)

In the Tower mill the maximum media grinding pressure due to gravitational forces can be described as
follows:

Fg Pgm~x *A ,,, * D2 Jr * l g____~

SI
(7)
Ap ~: Ae - p~. . . . . . ~ A--7 oc AP

(D-Ds)(p,,,-p)
Pg.... = K * , (8)
4* zz

(O3~/4.3) -f2
kl- 13 ' kf=l forl>5 (9)
1-exp(-f 1. )

Slgm = K * D~, * ( D - D s )(p., - p )

(10)
4"/~
where:
1 - - n u m b e r of media between the screw tip and mill wall
D, D~ --mill and screw diameter respectively (m)
1182 A Jankovic

fl, ~[2 - - m o d e l constants

COs - - s c r e w angular velocity (rad/s)
K --ratio between vertical and horizontal media pressure, (Jankovic, 1999)
Pglnax - - m a x i m u m media pressure due to gravitational forces (N/m 2)
/t --coefficient of friction

Stress intensity due to centrifugal forces in LSV can be described using equation (2).

The total stress intensity in LSV is the sum of the Slgmand Slm• It can be seen from Table 2, showing the
stress intensity at different conditions, that in general, the centrifugal component of stress intensity is more
pronounced at higher stirrer speeds (pin mill). At low stirrer speed (0.37 m/s) the gravitational component
dominates. It can be also noticed that media size has a major effect on both components of stress intensity,
the SIm being a function of the media size to the power 3, and Slem to the power 2.

TABLE 2 Stress intensity in the Tower and pin mills (SAM) used in the testwork

Mill Type Tower mill Pin mill

Mill diameter (m) 0. I 0.24 0.24 0.24 (1.1 0.28 0.28 0.28
Stirrer diameter (m) 0.07 0.14 0.14 0.14 0.07 0.2 0.2 0.2
Tip speed (m/s) 0.77 0.74 0.74 0.37 1.5 2.5 2.5 2.5
Slurry density (kg/m3) 1550 1572 1555 1550 1550 1530 1510 1540
Media height (m) 0.32 0.42 0.68 0.68 0.313 0.48 0.35 0.34
Media Size (ram) 4.8 4.8 12 12 4.8 8 4.8 2.0
Stress intensity (Nm*10 4)
SIm 0.41 0.38 5.9 1.5 1.55 20.7 4.35 0.32
SI~,,, 0.21 0.17 6.1 7.1 0.45 1.9 0.5 0.08
Sire+Siam 0.62 (/.55 12 8.6 2.0 22.6 4.84 0.4
SIJSI~m 1.95 2.23 0.96 0.2 I 3.44 10.9 8.7 4.0

Figure 5 illustrates that at low stirrer tip speed (0.75 m/s) and small media height (0.5 m), Slem > Sire for
media sizes bellow 8 mm. In the industrial units where tip speed is around 3.0 m/s (or higher) and media
heights up to 2 m, centrifugal component Sire dominates the total stress intensity. Total stress intensity is
one or two orders of magnitude higher in industrial size mills comparing to pilo! and laboratory size units.
It may be therefore expected that different breakage paterns are taking place.

100

§ ~o
E

- - ~ . ~ z s ......
/A ~ -41-- cenlrilugalSire,1.5hiS I
01 f J --,e-- cenb-itugalSire,0.75r~s I
/ - - grav~a~nalSlgr¢0.5 rn |
grav~onal Slgm,2 rn I

0.01
2 4 6 8 10 12 14
media size (ram)

Fig.5 Grinding media stress intensily at different stirrer speeds and media sizes.

TEST RESULTS

The most common way of presenting grinding results is to plot the characteristic grinding product size as a
function of specific net energy input. In mineral processing industry, P80 size (80 ~7,. passing size) is the
 Media stress intensity analysis fi~r vertical stirred mills 1183

most frequently used and the energy consumption is given in kWh/t. Therefore, Figures 6 and 7 depict
some test results in terms of P80 size as a function of kWh/t.

5O 5O

4O ~m 6,smm J
Io 1660kglm31

3O~, O& i•
• •

a.
20

f
0 5 10 15

specific net energy (kWh/t)

""
20
•

25
•

30 35

b.
20

10
10
specific net energy (kWh/t)
20
z~

30

Fig.6 Effect of slurry density (a) and media size (b) on Tower mill grinding product.

It can be seen that slurry density affected the grinding efficiency in Towel mill, higher densities being more
efficient. Media size was also very important. It appears that 6.8 mm size media was the most efficient in
the Tower mill tests.

The effect of stirrer tip speed for the pin mill is presented in Figure 7 a. It appears that lower stirrer speed
(2,5 m/s) would provide a finer product size at the same energy input in the tested range. A very strong
effect of grinding media size can be observed with grinding efficiency increasing considerably as the
grinding media size reduces.

40 r 4O
n 3.9 rrYs
&O o
30 A 2.5 m/s j 3O B
0
0 0
20 • o [] o
A An
• ,0.
0
10 10 B 6.8 mm i •
0 4.Smm l
• 2.0 mm
b. 0
0 10 20 3O 40 50 60 70 80 0 10 20 30 40 50
a° specific net energy (kWh/t) s pecific net energy (kW h/t)

Fig.7 Effect of stirrer tip speed (a) and media size (b) on pin mill grinding product.

The stress intensity of grinding media combines the influence of stirrer tip speed, media size and density as
well as slurry density. Figure 8 shows that for 20 kWh/t specific energy input stress intensity determines
the product fineness for both Tower and pin mills. The optimum stress intensity for the Tower mill can be
identified to be around t* 10 -3 Nm. For the pin mill an optimum value can not be clearly identified due to
lack of data. Trend shown in the Figure 8 for pin mill is anticipated one and it suggest somewhat lower
optimal stress intensity, although experimental confirmation is required.
1184 A. Jankovic

35
O .,"**
30

25

"g 2o
0
%,..,,~. H....- o°"
o SALA pilot, 8 mm media
..~ SAM pilot, media < 8rnrn
lo
o SAM lab, 4.8 rrrn media

5
20 kWhtl • TOWE~ p~ot, 12 mm media
• TOWIER pilot, media < 12ram
.. TOWE~ lab, 4.8 mm media
o i i 1 - •

o.o 0.1 1.0 10.0 100.0

Stress Intesity (Nm*0.001)

Fig.8 Grinding product size at 20 kWh/t energy input as a function of stress intensity.

It is important to note that the minimum P80 size at 20 kWh/t energy consumption was lower in the pin
mill than it the Tower mill. It may indicate higher power utilisation for grinding in the pin mill. Due to
higher stirrer velocity (2.5 m/s vs. 0.74 m/s) proportion of media collisions with sufficient stress intensity
to break particles may be higher in the pin mill and therel~re less energy is wasted for "low stress
collisions". Majority of breakage occurs in the area close to the stirrer (active volume) were media
acceleration is high (Blecher et al., 1996, 1). Size of this "active volume" is proportional to the stirrer speed
and the media size and directly affects the grinding power utilisation.

DISCUSSION

Presented results indicate that the media stress intensity is an important grinding parameter in low speed
vertical stirred mills (LSV). For a particular mill design there is an optimum stress intensity that would
produce the finest product for a given energy consumption (kWh/0. Below that optimum, particle breakage
becomes less efficient as more stress events are required to break a particle. If the stress intensity is higher
than optimum, energy utilisation in the breakage event decreases due to increased energy losses.

Mill design clearly affects the product size at the optimum stress intensity, the pin mill having a finer
product than the Tower mill. It could be explained by the lact it utilizes a higher proportion of the total
media lk)r grinding. This leads to better power utilisation and therel~re finer product size. The majority of
breakage occurs in the active grinding area situated around the stirrer and the size of that area is directly
proportional to the stirrer speed and media size. Because the pin stirrer speed was higher than the Tower
mill stirrer (2.5 m/s vs. 0.74 m/s), power utilisation with small media was higher in the pin mill.

The optimum stress intensity concept is important for mill selection as well as optimisation. It can reduce
the amount of experimental work required to find the best grinding media for a particular operation. The
optimum stress intensity can be determined using experiments with one media type and than used to
calculate the optimum media size fi)r other media types.

In the plant design stage the optimum stress intensity concept can be used to select the most appropriate
grinding mill. The optimum and most advantageous stress intensity depends always on the demanded
product fineness. In Figure 9 curves for six different specific energy inputs are presented (Kwade et at.,
1996, 2). With increasing the specific energy input and therefore increasing the product fineness, the
optimum stress intensity decreases. For tl~e fine grinding products below 10 microns, mills that can utilize
the small grinding media and still produce the required stress intensity, should be used. These mills would
have high stirrer speed that would enable the sufficient stress intensity to be reached•
 M e d i a slrcss intensity a n a l \ s i s for xerlical slirrcd mills 1185

'001 I FP~ = 0.8

lO°=o, I
4

10--
I
Six~_,iticenerg~
40 kJ/kg
/ ....... 100 kJ,lkg
~ i 2oo~
g

0.3, [ °:37 ....... ! ....... ................ i

0.0001 0.001 0.01 0.1 10 100200
Suess intensity SI b [10 ~ Nm]

Fig.9 Product fineness as a function of stress intensity and the specific energy input - After Kwade,
1996.

If a higher stress intensity is required (coarse feed and grind, hard materials) then the low speed mill with
coarser grinding media is advantageous. The wcar of mill components at high stress intensities and mill
speeds is rapid and the maintenance cost and avaih/bility would restrict the use of high speed mills.

It could he expected that the optimum media stress intensity for a particular energy input should be
independent of mill design, however due to limited cxperimenial data this can not be confirnaed.

CONCLUSION

The grinding media slrcss intensity in vertical stirred mills has an gravitational component. In the industrial
size units the gravitational component is significantly lower titan the centrifugal for media sizes larger than
8 mm. In the pilot and laboratory size units two components are in the similar range and should be added
up to obtain the total grinding media stress intensity.

The stress intensity is one or two orders of magnitude higher in industrial size mills comparing to pilot and
laboratory size units and therefore different breakagc paterns at+e expected.

There is an optin/um stress intensity range lbr a particular material and feed and product size where
maximum grinding efficiency is achieved. Oplimunl stress intensity should be used for the selection of
appropriate mill type and scale-up.

Pilol vertical pin stirred mill was more energy efficienl for grinding an calcium carbonate sample than the
pilot Tower mill.

REFERENCES

Blecher, L., Kwade, A., Schwedes, J., 1996. Motion and stress intensity of grinding beads in a stirred
media mill. Part l: Energy density distribution and motion of single grinding beads. Powder Technology
vol. 86
Kwade, A., Blecher, L., Schwedes, J., 1996. Motion and stress intensity of grinding beads in a stirred
media mill. Part2: Stress intensity and its effect on comminution. Powder Technology vol. 86
Jankovic, A., 1999. Mathematical Modeling of Stirred Mills. Ph.D. Thesis, The Universio'of Queensland,
Australia.
1186 A. Jankovic

Sch6nert, K., 1990. Aspects of very fine grinding, in: Sastry, K.V.S., and Fucrstenau, M.C., (cditors)
Challenges in Mineral Processing, Soc. Min. Engrs., Bookcrafi, Chelsea, pp 155-172.
Sch6nert, K., 1991. Advances in comminution fundamental, and impacts on technology. XVII Inter. Nat.
Miner. Process. Cong., Dresden, Vol 1, Sept., pp 1-2I.

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