Optimization and Experimental Study of Iron Ore Grinding Medium Parameters Using EDEM Discrete Element Software

Energy savings and consumption reduction of ball mills are crucial for industrial production. The grinding medium is an important component of a ball mill. In theory, using higher-density grinding media can yield better grinding results. However, for materials with varying grindability, employing grinding media of different densities can reduce energy consumption while maintaining the same grinding effect. This study simulates the motion of the grinding media in the mill using three different densities of balls and the same material (iron ore). The results reveal that balls with densities of 5.8 g/cm3 and 7.8 g/cm3 achieve faster grinding of materials into finer particles, but balls with a density of 5.8 g/cm3 consume less energy. Therefore, replacing a ball with a density of 5.8 g/cm3 in a ball mill can significantly reduce energy consumption. This study will assist in selecting the optimal grinding medium density for different materials, ultimately contributing to energy savings and reduced carbon emissions.