Investigation of Liner Wear on Different Ball Mill Profiles Using Discrete Element Method

Abstract

In low-income nations with mineral-rich deposits, mainstream mining faces challenges due to high capital demands, leading to the prevalence of small-scale mining. Limited funds result in the use of locally crafted machinery, impacting efficiency. Improving the reliability and efficiency of these machines is essential. The ball mill, a crucial tool in mineral processing, comprises of various components, including the power source, support structure, drum, and liners, essential for reducing abrasive ore-induced wear. Excessive liner wear necessitates costly replacements, affecting efficiency. The choice between cylindrical and polygonal drum profiles is thought to influence small-scale mining productivity, prompting an investigation into their impact on liner wear. Using the discrete element method and laboratory-scale experiments, this study created particle and wear models to assess wear severity on the two drum profiles, favoring the hexagon as a polygon representative. Findings indicate that material slip significantly affects wear in cylindrical profiles, whereas the wear on polygonal profiles results from both material slip and concentrated compressive force at the vertices. Despite lifters reducing wear in all profiles, the impact of compressive force on the polygonal profile remains unresolved. On average, the polygon profile exhibits 17.9% less wear than the cylindrical profile. However, the cylindrical profile with lifters experiences a 32.2% reduction in wear compared to the polygon profile with lifters at all rotation speeds. This research underscores the importance of tailored solutions to enhance machine durability and operational efficiency in small-scale mining contexts.