Canadian Metallurgical Quarterly

The Canadian Journal of Metallurgy and Materials Science

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Mineral Liberation and Particle Breakage in Stirred

Mills

R. Roufail & B. Klein

To cite this article: R. Roufail & B. Klein (2010) Mineral Liberation and Particle Breakage in Stirred
Mills, Canadian Metallurgical Quarterly, 49:4, 419-428, DOI: 10.1179/cmq.2010.49.4.419

To link to this article: https://doi.org/10.1179/cmq.2010.49.4.419

Published online: 29 Nov 2013.

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 419

Canadian Metallurgical Quarterly, Vol 49, No 4 pp 419-428, 2010

© Canadian Institute of Mining, Metallurgy and Petroleum
Published by Canadian Institute of Mining, Metallurgy and Petroleum
Printed in Canada. All rights reserved

Mineral Liberation and Particle Breakage in Stirred Mills

R. Roufail and B. Klein

Norman B. Keevil Institute of Mining Engineering

University of British Columbia
Vancouver, BC V6T 1Z4
rabaher@shaw.ca

(Received in revised form August, 2010)

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Abstract — In this paper, the study of particle breakage mode versus mill operating parameters is
addressed. Stirred mills grinding modes are mainly attrition but could be manipulated to include breakage
by compression or impact loading. Macro and micro analysis of particle breakage and grinding
mechanisms are correlated. Macro analyses convey information that relates grinding mechanism to
particle size and shape. Micro analysis on the other hand relates the particle breakage mode to the
fracture type whether transgranular or intergranular. Intergranular particle breakage leads to higher
mineral liberation compared to transgranular breakage. Similar minerals would have more homogeneous
properties that convey a stronger bond compared to dissimilar, heterogeneous mineral bonds. This paper
presents the results of an investigation that assesses how operating conditions can affect trans- versus
inter-granular breakage. It is deduced that with the standard stirred mill operation, the breakage mode is
primarily abrasion. Breakage mode is characterized using morphology analysis as a tool. Accordingly, if
mill operation is controlled such that compression and impact breakage modes are imposed, then there
will be a potential to impose inter-granular breakage rather than trans-granular.

Résumé — Dans cet article, on aborde l’étude du mode de fracture de particule en relation avec les
paramètres d’opération du broyeur. L’attrition est le principal mode de broyage des broyeurs agités, mais
on pourrait également inclure la fracture par compression ou par charge de chocs. L’analyse à l’échelle
macro et micro de la fracture de particule est corrélée aux mécanismes de broyage. Les analyses à
l’échelle macro donnent l’information qui relie le mécanisme de broyage à la taille et à la forme de la
particule. D’un autre côté, l’analyse à l’échelle micro relie le mode de fracture de la particule au type de
fracture, soit transgranulaire ou intergranulaire. La fracture intergranulaire de la particule mène à une
libération plus élevée du minéral par rapport à la fracture transgranulaire. Des minéraux similaires
auraient des propriétés plus homogènes donnant un lien plus fort par rapport aux liens de minéraux
dissimilaires, hétérogènes. Cet article présente les résultats d’une investigation qui évalue comment les
conditions d’opérations peuvent affecter la fracture trans- ou inter-granulaire. L’opération normale d’un
broyeur agité donne un mode de fracture principalement par abrasion. Le mode de fracture est caractérisé
par analyse de morphologie, comme outil. Donc, si l’opération du broyeur est contrôlée de telle manière
que l’on impose un mode de fracture par compression ou par impact, il sera alors possible d’imposer la
fracture inter-granulaire plutôt que trans-granulaire.

Keywords: Stirred mills, Grinding, Morphology, Breakage mode, Intergranular, Transgranular.

INTRODUCTION energy (input energy, specific energy, volume / mass specific

Ultra-fine grinding and stirred mills are widely considered in
mining operations since the mineralogical complexity of the
available mines is increasing and the demand for mineral
liberation often requires grinding to below 10 microns. Over
the past decade several research studies, such as those by
Kwade et al. [1], were performed to relate different forms of
energies), stress intensity and the final product fineness.
Other studies focussed on mill design and/or stress intensity
distribution in the grinding mill [2-5]. Further studies
considered the mechanical properties of the grinding media
and ground material on the comminution process [1,6]
Comminution process knowledge in stirred mill is still
limited. Although empirical and experimental results are

Canadian MetallurgiCal Quarterly, Vol 49, no 4

 420 R. Roufail and B. Klein
consistent, still optimizing the mill operation and achieving
the highest performance of the mill needs further research.
It is known that particle breakage mode affects particle
surface texture and morphology which is reflected on
subsequent mineral processing operations such as flotation.
Hiçyilmaz et al. [7] found that the highest hydrophobicity of
talc and quartz particles are the ones with the highest flatness
and elongation ratio.
Breakage in a grinding process is an intentional fracture
of the particles. Hence parameters such as particle shape and
means of loading directly affect the grinding performance.
Stress raisers in particles are sharp corners, pre-existing
flaws, cracks and internal inclusions. At such high stress
zones where the stress raisers are, the stress intensity factor
(KI) can reach its critical value which would ultimately
propagate the fracture. The smaller the particle thickness
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facing the propagation direction of the crack, the higher the
critical stress factor value (Kc). In other words less energy is
required for the fracture to propagate.
Tromans and Meech [8] mathematically modelled
fracture toughness of 48 minerals (oxides, sulphides and
silicates) based on their ionic crystal bonding. The relative
order of magnitude of the fracture toughness values of the
minerals researched was correct relative to each other.
Transgranular fracture toughness for the pure single phase
mineral is about 10-14% higher than the intergranular
fracture.
The grinding mechanism is directly related to particle
size and shape. Yue and Klein [9] suggested that the primary
breakage mechanism in the horizontal stirred mills is massive
fracture which changes to attrition (abrasion) when the
grinding limit (i.e. size reduction ration) approaches 1.
Tromans and Meech [10] stated that ultra-fine grinding
has a minimum limiting size that can be generated. The
limiting size is associated with critical stress intensity factor
of the particle. Since critical stress intensity factor is
controlled by pre-existing flaw (crack) size and orientation,
the smaller the particles size the fewer flaws. A smaller flaw
size relative to the particle diameter would require a higher
stress to propagate the crack. In summary, if the particle size
reaches its grinding size limit, the breakage mode changes
from fracture to deformation. Yue and Klein [9] agreed with
Tromans and Meech [10] about the existence of grinding
limit. It was proposed that the limit depends on the effective
Table I – Critical fracture toughness and surface energy computed values for transgranular and intergranular
sulphide mineral [9]
Transgranular
Mineral
type KIC
(MPa √m)
Galena 0.547
Sphalerite 0.588
Pyrite 1.349
Canadian MetallurgiCal Quarterly, Vol 49, no 4
stresses created in the mill which are factors of bead size,
agitator speed and pulp density in the mill.
PARTICLE FRACTURE HYPOTHESIS
The particle fracture creates new surface area via propagating
crack flaws or initiating a crack at stress raiser zones. Stress
raisers in a particle are where sharp corners or dislocations or
inclusions exist. Critical fracture toughness KIC (MPa √m) is
the energy needed to propagate a pre-existing crack.
K IC = Y s  a (1)
where Y is a constant related to crack geometry (-), a is crack
length (for a surface crack), half crack length (0.5 a) for an
internal crack (m) and s is the stress applied to the material
(MPa).
Equation 1 could be re-written as a function of Poisson’s
ratio u (-), modulus of elasticity E (Pa) and critical energy
release rate per unit area of crack plane J (J/m-2) as per
Equation 2 [8].
  =  EJ 
1/ 2 1/2
K IC 1- u 2 (2)
IC
Comminution of minerals is a brittle fracture process;
therefore neglecting plastic deformation at the crack tip is a
valid approach. According to Tromans and Meech [9] the
surface energy per unit area g (J/m2) is half the critical crack
energy release rate per unit area J (J/m2). Using ionic bond
theory [9] the intergranular and transgranular energy between
minerals of single phase are calculated. Critical fracture
toughness and surface energies of galena, sphalerite and
pyrite both transgranular and intergranular are listed in Table
I. Intergranular energies are less than transgranular, which is
the same trend for the critical fracture toughness values.
Pyrite consumes higher energy to fracture compared to galena
and it would fracture easier along its grain boundaries
(intergranular) than across the grains (transgranular).
Grinding and comminution operations have multiple
operating parameters that contribute to particle fracture and
Intergranular
g KIC g
(J/m2) (MPa √m) (J/m2)
1.868 0.512 0.458
2.090 0.554 0.468
3.072 1.245 0.910
 Mineral Liberation and Particle Breakage in Stirred Mills
their quality. Soft mineral breakage rate is higher than harder
minerals at low impeller speed in a horizontal stirred mill
[12]. The softer mineral will require less specific energy input
to overcome its surface energies and exceed its critical
fracture toughness value to propagate the cracks. Particle
fracture is a function of loading forces of grinding media on
target particles as well as the size and orientation of flaws and
internal defects relative to the loading axis and critical
fracture toughness values. If mill operation is controlled such
that the major mode of fracture in the mill is via impact or
compression rather than abrasion (attrition), then imposing
intergranular fracture could be achievable. There are several
advantages of intergranular fracture over transgranular
fracture. Intergranular fracture will consume less specific
energy and will produce better mineral liberation for
downstream operations.
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EXPERIMENTAL WORK
Experimental work is adopted from Parry’s work [12]. The
samples evaluated were from the lead regrind circuit and the
zinc first retreat regrind circuit at the Red Dog Mine. The zinc
concentrate and lead concentrate were ground in a SMD mill
as well as a Netzsch (ISA) mill. Both mills are high speed
stirred mills, however, their lifting and the material flow
mechanisms are not similar due to their orientation.
Comparing them was essential to validate the fact that their
breakage mechanism is similar.
The Netzsch mill, testing was conducted using a media
charge volume of 80% of the effective mill volume and the
solids content was 40% solids by weight. As for the SMD
mill, the slurry was 40% solids by weight and the media
added was equal in volume to the slurry volume occupying
the mill. Colorado River Sand with a P80 of 2.7mm was used
as the grinding media in both mills. In order to test the effect
of slurry concentration on particle breakage mechanism, a test
was conducted on the lead sample at 30% solids in the
Netzsch mill.
Samples are cyclosized to obtain sized particle fractions
and their morphology features were analyzed using an MLA
(Mineral Liberation Analyzer). Particle circularity, convexity
Table II – Samples data [12]
Feed Products MLA modal mineralogy (%)
Sample
size size
type
(m) (m) Galena Sphalerite
14
Zinc 29.4 2.7 65.2
16
13
Lead 25.8 14 27.4 34.4
15
421
and elongation values are statistically compared, as well as
individual particles are further analyzed. Due to the large
amount of data to be compiled, only a few samples were
chosen for analysis in this paper. The 80% pass (P80) for both
the feed and product size were chosen to be close in value for
both materials (zinc and lead) as well as the mills under
investigation. Since it is not feasible to analyze all the size
fractions produced, one size fraction is chosen for analysis
which is C3. The samples chosen and their sizes are
summarized in Table II and the mineral modal distributions
are presented in Figure 1.
The hard minerals in the samples are quartz and pyrite
with Moh’s values 7 and 6.5, respectively and the soft
minerals are galena and sphalerite with 2.5 and 3.5-4 Moh’s
values, respectively. The ratio of hard minerals to soft is 3:7
and 3.7:6.3 for the zinc and lead samples, respectively. The
zinc sample has about 96% more sphalerite than galena
compared to the lead sample that has about equal ratio of
sphalerite to galena. The sphalerite is the dominant mineral in
the zinc sample which is slightly higher in hardness value
than lead as opposed to the lead sample that has an equal ratio
of hard versus soft minerals. Accordingly, those samples were
chosen to study the effect of the existence of hard and soft
minerals on each other in both the grinding process and their
breakage mechanism.
Statistical Analysis
Statistical analyses were performed on an average of 10,000
particles per sample. Samples chosen for presentation in this
paper are the C3 fraction (mean particle size about 20
microns). The surfaces analyzed are the particle surfaces that
are fractured via the mill operation. The analysis compared
basic morphological particle features such as convexity,
circularity and elongation. Convexity is an indirect measure
of particle roughness. It is the measure of the hull perimeter
divided by the actual particle perimeter. The hull perimeter is
the perimeter of an analogous elastic band stretched around
particle. A smooth particle surface will return a value of one
and the lower the value of convexity, the rougher the surface.
Circularity determines the particle roundness and is
Size
Solid
fraction Mill
(%)
Pyrite Quartz (P80, m)
C3/22.66 Netzsch 40
16.7 12.5
C3/23.62 SMD 40
C3/24.72 Netzsch 40
30.9 4.7 C3/28.67 SMD 40
C3/28.41 Netzsch 30
Canadian MetallurgiCal Quarterly, Vol 49, no 4
 422 R. Roufail and B. Klein

Zinc sample Lead sample

Galena Quartz
Quartz 3% 5%
13% Galena
28%
Pyrite
Pyrite 32%
17%

Sphalerite
67% Sphalerite
35%
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Fig. 1. MLA modal mineralogy

calculated by dividing the circumference of an equivalent
circular area by the measured particle perimeter. Similar to
convexity, the perfect circle will return a value of one and the
less circular particle will return a value of between zero and
one. The elongation is the measure of length to width
relationship and is equal to 1.0 minus the aspect ratio. An
elongated particle will return a value close to one and an
equiaxed particle will return a value close to zero. Elongation
is inversely proportional to circularity and is not sensitive to
convexity changes.
Zinc Samples: Zinc samples showed that there is no clear
difference in product size or morphological features between
the Netzsch mill and SMD. Both mills produced similar
product size (P80) with the majority of the particles exhibited
high smoothness as well as high circularity and less elongated
features (Table III). Convexity and circularity data are
negatively skewed, which suggests that the majority of the
data are inclined towards the high values. Such features
represent a fracture mode of abrasion and attrition. In other
words, particle breakage is transgranular rather than
intergranular. For convexity and circularity, the absolute
values of skewness for the SMD mill are higher than for the
Netzsch mill, which indicates that abrasion intensity is higher
in the SMD mill than in the Netzsch mill.
Lead Samples: The lead sample analysis demonstrated a
trend similar to the zinc samples. Smooth surfaces reflected
high convexity and high circularity and low elongation values
(Table IV). The effect of solid concentration on operation is
also tested. It proved that change in concentration from 40 to
30% does not change grinding mode. The prominent mode of
fracture is attrition and abrasion.
Convexity and circularity data are skewed toward the
high values, which reflect the fact that the majority of the
particles analyzed are smooth and round whereas the
elongation values are skewed towards the low values
which means that the particles are equiaxed. The highest

Table III – Zinc sample statistical data

Statistical
Sample Convexity Circularity Elongation
criteria

Mean 0.93 0.78 0.47

Mode 1.00 0.85 0.41
Zinc - Netzsch mill Standard 0.04 0.07 0.13
40% solids deviation -1.67 -0.97 0.15
Skewness -1.67 -0.97 0.15
Range 0.43 0.49 0.80

Mean 0.94 0.79 0.47

Mode 1.00 0.82 0.22
Zinc - SMD mill Standard 0.03 0.07 0.13
40% solids deviation
Skewness -2.18 -1.13 0.13
Range 0.37 0.47 0.99

Canadian MetallurgiCal Quarterly, Vol 49, no 4

 Mineral Liberation and Particle Breakage in Stirred Mills 423

Table IV – Lead sample statistical data

Statistical
Sample Convexity Circularity Elongation
criteria

Mean 0.92 0.78 0.46

Mode 1.00 0.87 0.29
Lead - Netzsch mill Standard 0.05 0.08 0.13
30% solids deviation
Skewness -151 -0.87 0.05
Range 0.38 0.47 0.79

Mean 0.92 0.78 0.46

Mode 1.00 0.80 0.39
Lead - Netzsch mill Standard 0.04 0.07 0.13
40% solids deviation
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Skewness -1.35 -0.77 0.06

Range 0.33 0.47 0.76

Mean 0.93 0.79 0.44

Mode 1.00 0.86 0.19
Lead – SMD mill Standard 0.06 0.08 0.13
40% solids deviation
Skewness -1.48 -0.94 0.05
Range 0.33 0.47 0.76

skewness is in the zinc sample that was ground in the SMD
mill at 40% solids by weight. In this case, the number of
particles that showed high smoothness and circularity as
well as low elongation is greater than in the other tested
samples. The zinc sample exhibited a high ratio of zinc to
galena. The effect of small amounts of soft mineral in the
mix on the overall performance of different mills needs
further investigation.
Morphology Analysis
It is speculated that the mode of fracture is directly related to
operating parameters which in turn dictates the type of forces
and loading directions on the particles in the mill.
Zinc Samples: Particles a) and b) shown in Figure 2 and
described in Table V are characterized by an overall particle
convexity/circularity/elongation values as 0.88/0.73/0.59
consecutively for sample a) and 0.85/0.77/0.29 for sample b).
The MLA analyzer calculated the convexity/circularity/
elongation for each mineral (grain) per particle. Data shows
that the largest grain area has rough locked contours. If
intergranular breakage mode is imposed on such a particle,
fractures will open along the grain boundaries and it is very
likely that the particles will be well liberated and will exhibit
rough surfaces i.e. convexity values will be low.
Particles c) and d) shown in Figure 3 and described in
Table VI are zinc samples that are ground in an SMD mill.
They exhibited similar features as the ones ground in a
Netzsch mill. Sample c) exhibits the roughest surface (0.72
/0.6/0.46 for convexity/circularity/elongation, respec-
tively). Visual evaluation suggests an intergranular
fracture surface rather than transgranular. On the other
hand, sample d) has a smooth surface (convexity value is
0.91), but the locked quartz/sphalerite planes are rough
(convexity value is 0.63).

Zn_sulphides Zn_sulphides

Pyrite Pyrite
a c
b d
Quartz Quartz

0.44 µm/pixel 60 µm
0.44 µm/pixel
60 µm

Fig. 2. Zinc sample ground in Netzsch mill. Fig. 3. Zinc sample ground in SMD mill.

Canadian MetallurgiCal Quarterly, Vol 49, no 4

 424 R. Roufail and B. Klein

Lead Samples: Particles e) and f) shown in Figure 4 are from the
sample that is ground at 30% solids in the Netzsch mill.
Particles showed similar characteristics as in the zinc samples.
Particle e) showed a rougher surface that indicated Intergranular
fracture (convexity 0.77 and circularity 0.66). On the other
hand, particle f) showed a smoother surface (convexity 0.88 and
circularity 0.73), but the grains are more complex and locked.
Particles g) and h) also shown in Figure 4 are from
samples ground at 40% solids in the Netzsch mill. Particle (g)
has complex locked grains of different minerals. The locked
quartz grain has a high convexity value as shown in Table
VIII. The other grains in the same particle show less
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roughness because most of its perimeters are exposed to the
outer line of the particle which is already abraded. Statistical
analyses are consistent with the MLA images obtained for
both samples performed at 40% and 30% solids.
Particles i) and j) in Figure 5 and described in Table IX
are lead particles from the sample that was ground in the SMD
mill. Similar results confirmed that overall particle roughness
and circularity were due to mode of breakage and loading in the
mill. For particle i), the convexity/circularity/elongation were
0.84/0.8/0.17 respectively and for particle j) they were
0.94/0.8/0.55 respectively. Locked planes have more rough
surfaces reflected in their convexity values shown in Table IX.

Quartz

Pyrite

f Pb_sulphides

e Zn_sulphides

Other
20 µm 0.44 µm/pixel

g
60 µm h
0.44 µm/pixel

Fig. 4. Lead sample ground in Netzsch mill, (Particles e) and f) ground at 30% solids; g) and h) ground at 40% solids)

Quartz

Pyrite

Pb_sulphides

i Zn_sulphides

Other

0.44 µm/pixel

Fig. 5. Lead sample ground in SMD mill.

Canadian MetallurgiCal Quarterly, Vol 49, no 4

 Mineral Liberation and Particle Breakage in Stirred Mills 425

Table V – Grain morphology zinc sample ground in Netzsch mill

Sample a)

Mineral Area% Convexity Circularity Elongation

name

Zn_sulphides 36.78 0.62 0.47 0.52

Pyrite 41.18 0.66 0.50 0.49
Zn_sulphides 16.03 0.93 0.74 0.57
Zn_sulphides 0.91 0.94 0.67 0.53
Quartz 5.1 0.86 0.58 0.75

Sample b)

Zn_sulphides 55.07 0.59 0.44 0.51

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Pyrite 43.81 0.73 0.56 0.62

Zn_sulphides 0.41 0.94 0.66 0.4
Zn_sulphides 0.71 0.99 0.78 0.39

Table VI – Grain morphology zinc sample ground in SMD mill

Sample c)*

Mineral Area% Convexity Circularity Elongation

name

Quartz 58.65 0.59 0.44 0.54

Zn_sulphides 13.25 0.89 0.75 0.33
Zn_sulphides 4.21 0.89 0.72 0.33
Pyrite 4.03 0.91 0.68 0.43
Zn_sulphides 10.23 0.94 0.73 0.58
Zn_sulphides 6.1 0.96 0.81 0.33
Pyrite 2.63 0.98 0.77 0.39

Sample d)

Quartz 47.44 0.63 0.46 0.59

Zn_sulphides 19.57 0.84 0.56 0.71
Zn_sulphides 32.99 0.92 0.77 0.5

*Area less than 1% are not presented.

Canadian MetallurgiCal Quarterly, Vol 49, no 4

 426 R. Roufail and B. Klein

Table VII – Grain morphology - lead sample ground in Netzsch mill at 30% solids

Sample e)*

Mineral Area% Convexity Circularity Elongation

name

Pyrite 31.46 0.7 0.59 0.36

Zn_sulphides 42.13 0.76 0.57 0.63
Quartz 6.63 0.85 0.66 0.58
Zn_sulphides 1.73 0.93 0.77 0.46
Pb_sulphides 1.61 0.93 0.74 0.52
Pb_sulphides 14.99 0.94 0.88 0.2

Sample f)*
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Zn_sulphides 29.8 0.6 0.69 0.42

Pyrite 18.49 0.75 0.68 0.53
Other 11.64 0.78 0.53 0.62
Pb_sulphides 16.4 0.81 0.73 0.48
Pyrite 5.86 0.9 0.48 0.71
Pyrite 4.48 0.92 0.42 0.71
Zn_sulphides 2.91 0.93 0.48 0.66
Other 8.01 0.94 0.65 0.67
Pyrite 1.8 1.0 0.55 0.7

* Area less than 1% are not presented.

Table VIII – Grain morphology - lead sample ground in Netzsch mill at 40% solids

Sample g)*

Mineral Area% Convexity Circularity Elongation

name

Quartz 30.05 0.46 0.31 0.58

Pb_sulphides 20.19 0.87 0.73 0.42
Pyrite 16.3 0.79 0.64 0.46
Pyrite 10.81 0.79 0.54 0.73
Zn_sulphides 8.91 0.82 0.64 0.53
Other 2.9 0.87 0.66 0.51
Other 2.17 0.91 0.73 0.43
Pyrite 2.15 0.90 0.66 0.55
Zn_sulphides 1.8 0.86 0.67 0.37
Pb_sulphides 1.07 0.97 0.74 0.55

Sample h)*

Quartz 30.95 0.75 0.55 0.58

Zn_sulphides 8.86 0.88 0.66 0.61
Pyrite 57.55 0.89 0.78 0.42
Pb_sulphides 2.2 0.95 0.65 0.74

* Area less than 1% are not presented.

Canadian MetallurgiCal Quarterly, Vol 49, no 4

 Mineral Liberation and Particle Breakage in Stirred Mills 427

Table IX – Grain morphology - lead sample ground in SMD mill

Sample i)*

Mineral Area% Convexity Circularity Elongation

name

Pb_sulphides 60.35 0.46 0.34 0.46

Zn_sulphides 9.27 0.74 0.55 0.55
Zn_sulphides 12.77 0.77 0.6 0.49
Other 4.3 0.79 0.53 0.73
Pb_sulphides 1.24 0.85 0.57 0.61
Zn_sulphides 1.76 0.87 0.59 0.7
Other 1.65 0.89 0.69 0.48
Zn_sulphides 1.03 0.93 0.73 0.5
Pyrite 1.88 0.96 0.79 0.51
Other 1.76 0.97 0.78 0.38
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Sample j)*

Pb_sulphides 61.58 0.55 0.38 0.67

Zn_sulphides 6.73 0.8 0.59 0.64
Other 22.45 0.87 0.73 0.4
Other 8.24 0.92 0.73 0.55

*Area less than 1% are not presented.

CONCLUSIONS comminution transgranular was the major breakage

The goal is to achieve the highest valuable mineral liberation
while avoiding over grinding that can complicate flotation
due to associated issues such as high entrainment. Ideally if
comminution produces inter-granular breakage should
enhance liberation compared to trans-granular breakage.
This study showed that breakage modes could be
related to particle morphology within a stirred mill through
studying the morphological features of the particles. The
three major morphological parameters addressed in this
paper are convexity, circularity and elongation. The
convexity is an indirect evaluation of the particle surface
roughness. Whereas circularity and elongation emphasize
the types of erosion and/or impact loading the particle has
been exposed to.
This study also showed that the Isa Mill and the SMD
mill are behaving similarly. In spite of theSe differences in the
lifting and agitation mechanism of the two mills, they both
produced similar breakage mechanisms.
The typical stirred mill operation produces an overall
smooth particle surfaces with convexity values of 0.9 or
higher. However, locked intergranular minerals of the same
particles showed rougher surfaces; their convexity values are
as low as 0.46. This observation indicates that during
mechanism. Additionally the sphalerite and galena hardness
values were not wide enough to have a noticeable impact on
each other.
Based on the quantitative assessment performed in this
study, the primary breakage mode in stirred mills is attrition
(abrasion) which will not entirely enhance particle liberation
for complex ore. However, there is a potential to enhance
liberation if particle breakages are initiated and propagated
along the grain boundaries via controlled operating
parameters.
There is work in progress in the field of breakage
mechanism and operating conditions of Stirred Mills using
the morphology analysis as a tool.
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