Optimization study on apatite ball mill liner modification based on the Tavares UFRJ model

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: σ² = 1.16, E_max/E₅₀ = 4.72, A in the A-b-t₁₀ breakage distribution function at 45.40 %, b = 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.