Application of TUSSIM with a variable Tromp curve for predicting optimal operation of multi-compartment mills with various ball size distributions

Nontawat Muanpaopong, Rajesh Davé, Ecevit Bilgili

Research output: Contribution to journalArticlepeer-review

1 Scopus citations

Abstract

A true unsteady-state simulator (TUSSIM) for ball milling was integrated with a variable Tromp curve for classification to simulate and optimize closed-circuit, multi-compartment cement ball milling. Using representative model–operational parameters from available literature, we first investigated the system dynamics for a two-compartment mill. Then, various simulations examined the impacts of closed-circuit vs. open-circuit operation, number of compartments, and various ball size distributions. Our results suggest that integrating an air classifier into an open-circuit ball mill can increase the production rate by 15% or increase the cement-specific surface area by 13%. A single-compartment mill entails a pre-milled feed for proper operation, whereas a two-compartment mill yields a finer cement product than a three-compartment mill. Uniform mass distribution of balls led to slightly finer product than uniform surface area or number distributions, while the impact of a classifying liner was negligibly small. Finally, we identified optimal ball mixtures in a two-compartment mill using a combined global optimizer–DAE solver, which suggests 14% capacity increase with desirable cement quality. Overall, TUSSIM's results are not only in line with limited, full-scale experimental studies and industry best practices, but also provide fundamental process insights, while enabling process optimization with tailored ball mixtures in different compartments.

Original languageEnglish (US)
Article number104171
JournalAdvanced Powder Technology
Volume34
Issue number10
DOIs
StatePublished - Oct 2023

All Science Journal Classification (ASJC) codes

  • General Chemical Engineering
  • Mechanics of Materials

Keywords

  • Ball size distribution
  • Closed-circuit cement milling
  • Multi-compartment mill
  • Population balance model
  • Process optimization

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