Qingfei Xiao , Chao Zheng , Yunxiao Li , Saizhen Jin , Boyuan Sun , Houyaun Tian , Xiaobo Liu
{"title":"Optimization study on apatite ball mill liner modification based on the Tavares UFRJ model","authors":"Qingfei Xiao , Chao Zheng , Yunxiao Li , Saizhen Jin , Boyuan Sun , Houyaun Tian , Xiaobo Liu","doi":"10.1016/j.mineng.2025.109722","DOIUrl":"10.1016/j.mineng.2025.109722","url":null,"abstract":"<div><div>The design of ball mill liners significantly affects the grinding process. However, due to the “black-box effect” within the mill, accurately understanding how liner structure influences ore breakage behavior remains a challenging issue. In this study, a particle breakage model was developed using the Discrete Element Method (DEM), with the Tavares UFRJ model parameters calibrated through uniaxial compression tests. Experimental results revealed that the specific fracture energy distribution of apatite particles follows a log-normal distribution, with Tavares model parameters: <em>σ</em><sup>2</sup> = 1.16, <em>E</em><sub>max</sub>/<em>E</em><sub>50</sub> = 4.72, <em>A</em> in the <em>A-b-t</em><sub>10</sub> breakage distribution function at 45.40 %, <em>b</em> = 0.012 %, and the damage accumulation coefficient at 1.88. DEM simulation results for liner modification, based on the Tavares UFRJ model, indicate that with double-wave liners of 70 mm height, particle motion inside the ball mill is most active, the breakage rate is highest, and mill energy consumption is significantly reduced. These findings offer theoretical support and engineering guidance for optimizing ball mill liner structure using DEM and analyzing its impact on ore particle breakage within grinding systems.</div></div>","PeriodicalId":18594,"journal":{"name":"Minerals Engineering","volume":"234 ","pages":"Article 109722"},"PeriodicalIF":5.0,"publicationDate":"2025-08-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144896019","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Dušan V. Milojkov , Miroslav D. Sokić , Vukosava M. Živković–Radovanović , Danijela D. Smiljanić , Jelena T. Petrović , Marija S. Simić , Ivana Jelić
{"title":"Biomimetic recovery of valuable metals from old flotation tailings in Majdanpek, Serbia, using Aspergillus niger for bioleaching and nanomaterial synthesis","authors":"Dušan V. Milojkov , Miroslav D. Sokić , Vukosava M. Živković–Radovanović , Danijela D. Smiljanić , Jelena T. Petrović , Marija S. Simić , Ivana Jelić","doi":"10.1016/j.mineng.2025.109738","DOIUrl":"10.1016/j.mineng.2025.109738","url":null,"abstract":"<div><div>The accumulation of old flotation tailings in Majdanpek, Serbia, presents significant environmental challenges and highlights the need for innovative, sustainable approaches to metal recovery. This study evaluates the bioleaching potential of the mould <em>Aspergillus niger</em> (<em>A. niger</em>) for extracting valuable metals from these tailings. Utilizing a batch system with <em>A. niger</em> cultivated in soybean broth we investigated its efficiency in leaching copper (Cu), zinc (Zn), manganese (Mn), aluminum (Al), and iron (Fe) under controlled conditions: initial pH 4, temperature 25 °C, and a solid-to-liquid (S/L) ratio of 1:20 (w/v). Over a 35-day period, approximately 45 % Cu, 40 % Zn, 35 % Mn, 5 % Fe, and 3 % Al were extracted from the tailings. Analytical techniques, including X-ray diffraction (XRD), optical microscopy (OM), Fourier-transform infrared spectroscopy (FTIR), and thermogravimetric analysis (TGA), confirmed transformations in the mineral phases, with secondary minerals such as oxalates and oxides forming. Field emission scanning electron microscopy (FESEM) coupled with energy-dispersive X-ray spectroscopy (EDS) revealed the degradation of sulfides and carbonates, leading to the formation of oxides and crystallized oxalates on the mineral surfaces. Additionally, FESEM-EDS analysis of the bioleaching liquor identified nano-sized metal-based particles of Cu, Zn, Mn, Al, and Fe. The proposed bioleaching mechanism involves acidolysis, complexolysis, alkaline lysis, and biosorption. This study demonstrates that <em>A. niger</em> offers a viable green technology for both sustainable metal recovery and nanomaterial synthesis from mining tailings, presenting a novel biomimetic approach to utilizing unconventional raw materials.</div></div>","PeriodicalId":18594,"journal":{"name":"Minerals Engineering","volume":"234 ","pages":"Article 109738"},"PeriodicalIF":5.0,"publicationDate":"2025-08-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144896018","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Jiahui Wu , Xiaole Wang , Meiqing Shi , Wenchao Zhang , Qingwei Wang , Yunyan Wang , Yong Ke , Xu Yan , Liyuan Chai
{"title":"Controlling magnetite heterogeneous nucleation for enhanced iron removal from zinc leachate via magnetic separation","authors":"Jiahui Wu , Xiaole Wang , Meiqing Shi , Wenchao Zhang , Qingwei Wang , Yunyan Wang , Yong Ke , Xu Yan , Liyuan Chai","doi":"10.1016/j.mineng.2025.109737","DOIUrl":"10.1016/j.mineng.2025.109737","url":null,"abstract":"<div><div>The separation of Fe from zinc leachate is a critical challenge in zinc hydrometallurgy. While current Fe removal methods (e.g., jarosite and goethite precipitation) generate hazardous low-iron wastes, this study presents a novel approach through magnetite precipitation, which offers high Fe content (∼72 %) and strong ferromagnetism for effective impurity separation. We systematically evaluated three magnetite precipitation methods, analyzing their iron-removal products, magnetic separation performance, and crystallization mechanisms. Our investigation revealed critical limitations of two conventional approaches: partial oxidation yields large, strongly magnetic magnetite particles but suffers from high nucleation barriers (∼15,000 k<sub>B</sub>T) that favor goethite impurities, while coprecipitation exhibits lower nucleation barriers (∼1000 k<sub>B</sub>T) but produces ultrafine, weakly magnetic particles that compromise separation efficiency. Building upon our previously established slow-dropping methodology, we demonstrated that this nucleation-controlled approach enables in situ formation of magnetite seeds, shifting the nucleation mechanism from homogeneous to heterogeneous. This innovative approach achieves dual benefits: reduced nucleation barriers and promoted growth of micrometer-sized magnetite mesocrystals. The resulting product demonstrates remarkable improvements, reaching 104.12 emu/g, substantially higher than that achieved by partial oxidation (77.75 emu/g) and coprecipitation (25.12 emu/g). The impurity removal efficiency reached 70 % for Pb and 81 % for Ca, significantly outperforming conventional methods. These findings extend the application of our slow-dropping protocol to investigate solid–solid separation between magnetite and impurities, thereby demonstrating its broader potential for sustainable resource recovery applications.</div></div>","PeriodicalId":18594,"journal":{"name":"Minerals Engineering","volume":"234 ","pages":"Article 109737"},"PeriodicalIF":5.0,"publicationDate":"2025-08-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144892805","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Zhenhui Xie , Runqing Liu , Wenchao Dong , Wei Sun
{"title":"Fe-content-induced sphalerite electronic structure transformation and interaction difference with DSBDTP: experimental and DFT studies","authors":"Zhenhui Xie , Runqing Liu , Wenchao Dong , Wei Sun","doi":"10.1016/j.mineng.2025.109729","DOIUrl":"10.1016/j.mineng.2025.109729","url":null,"abstract":"<div><div>This study systematically investigates Fe-content-induced electronic structures transformation and difference in flotation performance of sphalerite. DFT calculations demonstrate that rising Fe content narrows the bandgap and reduces the intensity of the Cu 3d orbital peak near the Fermi level and its hybridization with S atoms in the sphalerite, thereby reducing the reactivity of copper atoms and affecting the interaction between collector and copper-activated sphalerite surface. Flotation experiments further corroborate a decline in sphalerite recovery with increasing Fe concentrations. Adsorption analysis of the reagents on the surface confirmed that copper is the main adsorption site for sodium di-<em>sec</em>-butyl dithiophosphate (DSBDTP) on copper-activated sphalerite. However, as Fe content increases, the adsorption efficiency of CuSO<sub>4</sub> and DSBDTP weakens. The study also identifies that elevated Fe content lengthens the Cu-S bond, increases bond energy, and reducing the orbital hybridization strength between S<sub>37</sub> and Cu atoms. This weakened hybridization interaction diminishes the overall bonding strength between DSBDTP and copper-activated sphalerite. These findings provide critical insights into the detrimental effects of Fe impurities on sphalerite flotation.</div></div>","PeriodicalId":18594,"journal":{"name":"Minerals Engineering","volume":"234 ","pages":"Article 109729"},"PeriodicalIF":5.0,"publicationDate":"2025-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144892215","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Qing Ye , Liyun Zou , Manman Lu , Zijun Zhang , Yonghua An , Qingmiao Wang , Gongming Qian
{"title":"Pyrometallurgical extraction of titanium from titanium-bearing blast furnace slag: Recently development and prospect","authors":"Qing Ye , Liyun Zou , Manman Lu , Zijun Zhang , Yonghua An , Qingmiao Wang , Gongming Qian","doi":"10.1016/j.mineng.2025.109734","DOIUrl":"10.1016/j.mineng.2025.109734","url":null,"abstract":"<div><div>Titanium-bearing blast furnace slag (TBFS) is an important titanium-bearing resource because it contains TiO<sub>2</sub> over 20%. Efficient resource utilization is difficult to achieve because of the common occurrence and complex embedding relationship between Ti-bearing components and gangue minerals. Pyrometallurgical routes are considered the primary method for TBFS because of their high potential recovery and important pathway for industrial production. This article reviews various pyrometallurgical processes and slag recovery based on the properties and thermodynamic characteristics of TBFS, including alkali melt calcination, alloying and metal thermal reduction, carbonization and chlorination, selective enrichment precipitation, and unconventional pyrometallurgical technology. Particular attention is devoted to specific technical challenges emerging in the pyrometallurgical processing of TBFS and potential measures for improving slag utilization by developing new routes and promoting process efficiency. Strengthening the directional transformation and migration enrichment of valuable components during roasting is a prerequisite for achieving effective resource utilization. Current pyrometallurgical methods still suffer from high energy consumption and low extraction rates. Future research should focus on multi-technology coupling and intelligent control systems to achieve precise control and dynamic optimization of extraction process parameters, expanding traditional engineering boundaries and interdisciplinary integration for efficient resource utilization.</div></div>","PeriodicalId":18594,"journal":{"name":"Minerals Engineering","volume":"234 ","pages":"Article 109734"},"PeriodicalIF":5.0,"publicationDate":"2025-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144890797","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Green flotation of ilmenite with bio-based sophorolipid: New insights into the effects of temperature on interfacial adsorption","authors":"Jihua Zhai , Pan Chen , Hongbin Wang","doi":"10.1016/j.mineng.2025.109742","DOIUrl":"10.1016/j.mineng.2025.109742","url":null,"abstract":"<div><div>Temperature is an important factor influencing minerals flotation, particularly when temperature variation over the year is severe. This study investigated the impacts of temperature on adsorption behaviour of sodium oleate (NaOL) and sophorolipid (SL) on ilmenite surface and the resultant ilmenite floatability. XPS and TOF-SIMS results indicated that higher temperatures could strengthen NaOL and SL adsorption on ilmenite surface, thereby improving ilmenite floatability. It was further demonstrated that SL, with a much lower critical micelle concentration (CMC) than NaOL, provided better ilmenite surface coverage and induced significant Raman spectral changes. All these findings were supported by flotation results that SL could achieve higher ilmenite recoveries than NaOL under the same conditions. Particularly when the temperature was low, SL still exhibited superior performance in floating ilmenite than NaOL. Therefore, as the eco-friendly and bio-based surfactant, SL was a promising alternative in ilmenite flotation to make its processing more sustainable.</div></div>","PeriodicalId":18594,"journal":{"name":"Minerals Engineering","volume":"234 ","pages":"Article 109742"},"PeriodicalIF":5.0,"publicationDate":"2025-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144892214","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Unveiling the role of anionic polyacrylamide flocculants in nanobubble generation and stabilization","authors":"Liming Liu, Liang Cao, Yongjun Peng","doi":"10.1016/j.mineng.2025.109739","DOIUrl":"10.1016/j.mineng.2025.109739","url":null,"abstract":"<div><div>Nanobubbles (NBs) are gaining prominence in mineral processing due to their ability to enhance mineral separation, reduce reagent consumption and improve overall process efficiency. Although the role of surfactants in NB generation and stabilization is well documented, the impact of flocculants, despite their structural similarities and extensive use in mineral systems, has received little attention. This study investigated the potential of two anionic polyacrylamide (APAM) flocculants, AN 934 and its higher molecular weight variant AN 934 VHM, to promote NB formation and stability. Remarkably, both flocculants produced NB concentrations comparable to those generated by the conventional anionic surfactant sodium oleate (NaOL), despite exhibiting negligible surface activity and minimal surface tension reduction. Instead, their stabilizing effect was driven by two key mechanisms: enhanced electrostatic repulsion indicated by significantly more negative zeta potentials, and increased solution viscosity which inhibited gas diffusion and bubble coalescence. AN 934 VHM demonstrated superior performance due to its higher molecular weight, yielding greater charge stabilization and viscosity enhancement, and thus more persistent NB populations. These findings reveal an unrecognized capability of APAM flocculants in NB stabilization, opening new avenues for their strategic use in flotation, tailings dewatering and other particle–bubble interaction-driven processes in mineral processing.</div></div>","PeriodicalId":18594,"journal":{"name":"Minerals Engineering","volume":"234 ","pages":"Article 109739"},"PeriodicalIF":5.0,"publicationDate":"2025-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144892213","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Gradient elution method for treating the residual ammonium from the weathered crust elution-deposited rare earth tailings","authors":"Kejia Wu, Ruipu Wang, Jia Wang, Xiaodi Li, Yuchi Chen, Li Guo, Qingbiao Zhao, Zhenyue Zhang, Chunqiao Xiao, Ruan Chi, Junxia Yu","doi":"10.1016/j.mineng.2025.109736","DOIUrl":"10.1016/j.mineng.2025.109736","url":null,"abstract":"<div><div>In-situ leaching of weathered crust elution-deposited rare earth ores generates substantial ammonium salt residues, which might cause environmental contamination. To address this issue, this study developed a novel gradient elution method combining sequential deionized water and 0.02 mol/L MgCl<sub>2</sub> elution, targeting differently bound ammonium fractions for efficient removal. Experimental results demonstrated that gradient elution method achieved a remarkable NH<sub>4</sub><sup>+</sup> removal efficiency of 1290.0 mg/kg, significantly outperforming single deionized water elution (163.3 mg/kg) or 0.02 MgCl<sub>2</sub> elution (1146.8 mg/kg). Compared with single Mg<sup>2+</sup> elution, the gradient elution method also reduced MgCl<sub>2</sub> consumption by 244.0 g per kg of tailings at equilibrium. Furthermore, it simultaneously removed 253.9 mg/kg of calcium ions, 135.8 mg/kg of nitrate, and 125.5 mg/kg of sulfate, mitigating secondary pollution risks. Mechanistic analysis revealed that deionized water preferentially extracts weakly bound water-soluble ammonium from the diffuse layer, while Mg<sup>2+</sup> subsequently displaces ion-exchangeable ammonium in the Helmholtz plane via ion exchange reaction. This dual-stage strategy overcomes the inefficiency of single-step elution, optimizing reagent use while maximizing contaminant removal. The proposed method offers an economically viable and environmentally sustainable solution for rare earth tailings remediation, with significant implications for industrial-scale applications in minimizing post-leaching pollution.</div></div>","PeriodicalId":18594,"journal":{"name":"Minerals Engineering","volume":"234 ","pages":"Article 109736"},"PeriodicalIF":5.0,"publicationDate":"2025-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144890800","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Xin He , Guo-zhi Lv , Bing-shen Liu , Qing-dong Li , Xiao-lei Zhang , Zhuang-zhuang Yun , Ting-an Zhang
{"title":"Straw-induced hematite-to-magnetite conversion in alkaline media: Experimental study and potential in Bayer process","authors":"Xin He , Guo-zhi Lv , Bing-shen Liu , Qing-dong Li , Xiao-lei Zhang , Zhuang-zhuang Yun , Ting-an Zhang","doi":"10.1016/j.mineng.2025.109723","DOIUrl":"10.1016/j.mineng.2025.109723","url":null,"abstract":"<div><div>High-iron bauxite is a vital iron-aluminum symbiotic mineral, primarily processed through the Bayer method for alumina extraction. This method generates a substantial quantity of highly alkaline red mud, which possesses significant application potential due to its elevated iron content. However, the iron-bearing minerals in red mud predominantly exist as weakly magnetic hematite, making it challenging to achieve an optimal recovery rate through straightforward physical separation techniques. Consequently, additional treatment is required for effective iron recovery. This paper presents an innovative approach that employs agricultural waste straw as a reductant, facilitating the directional transformation of hematite into magnetite via a one-step dissolution process integrated within the Bayer method framework. This addresses the issue of low recovery rates associated with the weak magnetism of iron-bearing phases in red mud. The transformation process from hematite to magnetite induced by alkali thermal dissolution of straw was examined using X-ray fluorescence spectroscopy (XRF), X-ray diffraction (XRD), and scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS). During the simulation of the Bayer process for the alkali thermal reduction of hematite, it was noted that increases in temperature and straw quantity significantly enhanced the reduction and conversion of hematite. Specifically, when the caustic concentration of the sodium aluminate solution reached 240 g/L, with a molecular ratio of 3.1, a reaction temperature of 280 °C, a liquid-to-solid ratio of 4:1, and a mass ratio of straw to hematite of 1:4, the reduction rate of iron oxide achieved an impressive 94.21 % after 60 min of dissolution. Analysis using a vibrating sample magnetometer (VSM) and laser particle size analysis (LPSA) demonstrated that the magnetic saturation intensity and average particle size of the transformed magnetite increased by over 80 times and 10 times, respectively, reaching 86.84 emu/g and 20.73 µm, thus enhancing its susceptibility to separation by magnetic force in subsequent roughing processes. Scanning surface zeta potential analysis (SSZPA) revealed that the absolute values of the zeta potential of the desilication product (DSP), hematite, and transformed magnetite under strong alkaline conditions followed the order: magnetite > DSP > hematite, with magnetite exhibiting stronger repulsive forces. Further scanning tunneling microscopy (STM) analysis indicated that the solvation tendency of magnetite particles was magnetite < DSP < hematite, making them more prone to aggregation and growth during the alkaline thermal dissolution process. By further incorporating straw into the Bayer process dissolution of high-iron bauxite, the recovery rates of alumina and the reduction rates of hematite reached 90.81 % and 85.31 %, respectively. XRD and SEM-EDS analyses confirmed the conversion of hematite to magnetite induced by s","PeriodicalId":18594,"journal":{"name":"Minerals Engineering","volume":"234 ","pages":"Article 109723"},"PeriodicalIF":5.0,"publicationDate":"2025-08-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144886421","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Jianbo Guo , Guoqiang Wang , Zhengbin Liu , Shuai Wang , Wei Guan , Shuwei Wu , Shibo Liu , Chaoyang Ma
{"title":"Optimization and study of roll stud parameters of high-pressure grinding rolls based on DEM-PRM","authors":"Jianbo Guo , Guoqiang Wang , Zhengbin Liu , Shuai Wang , Wei Guan , Shuwei Wu , Shibo Liu , Chaoyang Ma","doi":"10.1016/j.mineng.2025.109733","DOIUrl":"10.1016/j.mineng.2025.109733","url":null,"abstract":"<div><div>This paper mainly investigates the influence of the size and arrangement of studs on the surface of high-pressure grinding rolls (HPGR) on performance. Firstly, the structural principles of HPGR are introduced, and the discrete element method (DEM) simulation model simulating the operation of HPGR is established based on the contact model and particle replacement model (PRM). Then, calibration and verification of contact parameters and breakage parameters in the DEM simulation are conducted through the tumbling test and piston-and-die test. The DEM model of HPGR is validated in combination with experiments. A simulation scheme for optimizing stud parameters is established based on the Box-Behnken design (BBD). The effects of stud diameter, surface spacing, and angular interval on HPGR performance are analyzed through analysis of variance (ANOVA) and response surface methodology (RSM). Based on this, a performance prediction model based on multivariate nonlinear regression is established. Additionally, throughput, specific energy consumption and discharge fineness are taken as the optimization objectives. The results after optimization show that the specific energy consumption is reduced while throughput and discharge fineness are improved to varying degrees.</div></div>","PeriodicalId":18594,"journal":{"name":"Minerals Engineering","volume":"234 ","pages":"Article 109733"},"PeriodicalIF":5.0,"publicationDate":"2025-08-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144886420","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}