A cell-based PBM for continuous open-circuit dry milling: Impact of axial mixing, nonlinear breakage, and screen size

This theoretical study examined the impact of the degree of mixing, nonlinear particle breakage, and screen opening size on the particle size distribution (PSD) and mass hold-up in continuous dry mills with internal classification. A cell-based population balance model (PBM) incorporating a non-ideal screen model was formulated, wherein the back-mixing ratio and number of cells modulated the extent of axial mixing. The set of differential–algebraic equations (DAEs) was solved for the spatio-temporal evolution of the PSD in the mill and the product stream. The simulation results suggest that a smaller screen opening delayed the attainment of the steady state, increased the hold-up, and yielded a finer product PSD. The cushioning action of fines resulted in a coarser product PSD; however, a screen with a smaller opening mitigated this effect. The cell-based PBM predicted various features of experimental milling observations while providing insights into the mixing–nonlinear breakage–classification interplay.