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<p>Vertical stirred mills are increasingly used for fine and ultrafine grinding in the mineral processing industry due to their high energy efficiency. Accurate prediction of energy consumption and its distribution within the mill is therefore critical for equipment design, optimization and aftermarket services, as demonstrated by existing analytical models. In this study, torque distribution along the mill shaft is quantified for various rotor configurations using DEM, with systematic variation of rotor diameter, spacing and alignment. Furthermore, a coupled DEM–CFD approach is employed to model torque and power draw under different operating conditions, including shaft speed, flow rate and filling level. The results quantify the influence of these operating parameters and are validated against measurements from a sensor-equipped water-fluidized test mill, demonstrating that a one-way coupled DEM–CFD model reproduces system behavior with high fidelity (NRMSE &lt; 3% for power draw). Additionally, comparison between DEM and DEM–CFD results highlight the importance of hydrodynamic effects in stirred milling.</p>

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Validated DEM-CFD Modeling of Torque Draw and Distribution in a HIGmill

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月31日

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  • Michael Denzel,
  • Fisher Wang,
  • Alan Boylston,
  • Ruari Soutar-Dawson,
  • Michael Lehner

摘要

Vertical stirred mills are increasingly used for fine and ultrafine grinding in the mineral processing industry due to their high energy efficiency. Accurate prediction of energy consumption and its distribution within the mill is therefore critical for equipment design, optimization and aftermarket services, as demonstrated by existing analytical models. In this study, torque distribution along the mill shaft is quantified for various rotor configurations using DEM, with systematic variation of rotor diameter, spacing and alignment. Furthermore, a coupled DEM–CFD approach is employed to model torque and power draw under different operating conditions, including shaft speed, flow rate and filling level. The results quantify the influence of these operating parameters and are validated against measurements from a sensor-equipped water-fluidized test mill, demonstrating that a one-way coupled DEM–CFD model reproduces system behavior with high fidelity (NRMSE < 3% for power draw). Additionally, comparison between DEM and DEM–CFD results highlight the importance of hydrodynamic effects in stirred milling.