Understanding the Energy-Saving mechanism of ceramic balls in tumbling mills

This study investigates why ceramic balls achieve superior grinding performance compared to steel balls at lower densities and lower energy consumption. Particle motion analysis shows that increasing the filling level significantly improves the velocity distribution of the grinding media. The energy input from the mill is mainly converted into the kinetic and potential energy of the media, with potential energy being dominant. As the filling level increases, the efficiency of kinetic energy conversion improves. Collisions between media and mineral particles dominate energy transfer, and lower media density enhances collision energy distribution uniformity. Reducing media density decreases grinding energy consumption while maintaining the same grinding effect.