ELSEVIER PowderTechnology86 t Iq9'6)59--68

Motion add stress intensity of grinding beads in a stirred media mill.

Part 1: Energy density distribution and motion of single grinding beads
Lutz Blecher, Ainu Kwade, JiSrg Schwedes
hLvriuae of Mechanicql Prt~t'es,v Enginee¢ing. TechnicM University r)f Braunschweig, Votkmareate: Stras.r¢ 4Pd. D-38104 Braunschweig. Germany
Received26 September1994;revised12.lane 1995;accepted20 July 1995

Abstract

Numerical calculations concerning the flow field, the distribution of the specificenergy and the motion of single grinding beads in the
grinding chamber of a stirred media mill have been carried out. The calculationsare based on steady-stalelaminar stirring of a Newt~nian
fluid without grinding media. The flow field of the stirred fluid generates a characteristicdistribution of the specific energy. Two 2,.ones
characterizedby a high energy density exist, In these zones the heal specificenergy is larger than the mean specificencrD" which is obtained
by dividing the total amount of energy dissipated in the grinding chamber by the net volume of the grinding chamber. One zone extends
around the stirrer disc whereas the other is located at the grindingchamber wall,The volume of these two zones is only about 10% of the net
grinding chamber volume. Approximately90% of the entire energy input is dissipated there. Single grinding beads that are exposed to, a
previouslydetermined flow pattern tend to follow an almost stationary individual trajectory in the grinding chamber. The position of the
trajectorydepends on the mfioof bead-to-fluiddensity,the ralio of head-to-discradiusand the Reynoldsnumberwhichdescribesthe operating
conditions of the stirred media mill. The influenceof these parameterscan he describedby the so-calledmotion index. Up to a critical value
of the motion index, the single bead follows basically the fluidflow and passes throughthe two zones of high energy density.

Keywords: Commination;Grinding;Fluiddynamics;Computermodelling

L Introduction comminution result for a wide range. Thus, the respective

Stirred media mills are used successfully for fine and ultra-
fine grinding of several products. Basically the stirred media
mill consists era stin'er placed in the centre era fixed grinding
cylinder. The so-formed grinding chamber is filled with
grinding media (normally spherical glass, steel or ceramic
beads ) and a suspension containing the prodact particles. The
filling rate of the grinding media (bulk volume related to the
net volume of the grinding chamber) normally varies
between 0.7 and 0.85. By stirring the product-fluid-grinding
media mixture a characteristic [low patt_ern and a grinding
effect is generated in the grinding chamber. The respective
kind of flow determines the spatial distribution of zones with
high eommioution intensity as well as the predominant types
of eomminution mechanisms and their composition.
As the investigations of Schwudes, Welt and Stehr [ I-5 ]
have shown, the specific energy input (net energy input into
the grinding chamber related to the mass or the volume of the
product) is the main parameter which determines the com-
miaution result. The specific energy describes the influence
of mill size, circumferential speed of the stirrer, solids con-
centration of the suspension and density of the beads on the
value of the specific energy characterizes the efficiency of
comminution without knowing the predominant commina-
tion mechanisms which are mainly dependent on the motion
of grinding beads and suspension. Further investigationspub-
lished more recently [6--10] show that, besides the specific
energy, the size of the grinding heads strongly affccLs the
comminution result. Thus, the combination of specificenergy
input and bead size is very important for the prediction of the
comminution result+ Because the flow field in the grinding
chamber determines the motion of the grinding heads as well
as the specific energy consumption, the physical connection
between bead size, specific energy and commination result
can be deduced by more detailed information about the phys-
ical events in the grinding chamber.
Taking these considerations into account, theoretical
investigationson the [low field in the grinding chamber and
experimental investigationscencerning the inttuence of the
specific energy input, the circumferentiatspeedof the agitator
disc and density and size of the grinding heads on the com-
minution result have been carried out. The theoretical inter-
pretations are presented in this paper and the experimental
investigationsin the accompanying paper, Part 2 [ 16]. Here,

0032-591fll96t$15.00© 1996EIsevier,Scica~S.A. Allrightsreserved

$SDi0032-5910(95 )03038-B
fi0 L. Blecller et al. /P~ wder Tech ¢d ~,~,,y86 (1996) 59-68

re~ults of numerical calculations concerning flow patterns, 7able I

energy distributions and the motion of single grinding beads Milldimen~ior.s
in the grinding chamber t,fa stirred media mill are presented. Symbol Dimensions Dimensionxrelatedin R,l
tram) I-)

2. Calculation procedure R,I 60 I

& 21 O.35
R~ 75 125
The mechanisms of motion of the stirred product-bead- Da 43 0.717
fluid mixture in the grinding chamber arc very complex. W,~ q 0.15
According to MOlls and H~rille [ t 11 they are affected by L., 380 6.33
forty-four parameters and can only he calculated by means
plan appropriate - - from the mathematical point of view - - Table2
realizable limitation of the problem. Th,~icfo;,;, the calcula- Expressionsfor the generalqnanlilit:.stit:,and Sly)
tion results presented in this paper are based on a laminar
stiffed, homogeneous Ncwtonian fluid (in the absence nf
Conservationlaw ~b S,t~
beads), Experimental investigations concerning the entire ~,,~omenium radial(r) u - r ~ + Iz
power consumption of a stirred media mill [ 31 indicate that
[ I) i Oil 2R÷ tl rf)ll '
there should be a similar ilow pattern in the grinding chamber
bath with and without beads. The flow pattern of the stirred
Newtonian fluid is calculated using a simulation program 2 I~t I<r)
langenlial (l) i'~
(finil¢ volume procedure). Furthermore, the distribution of Re Dr
ap
the specific energy in the grinding chamber is calculated axiali:~ w -r~
directly from the flow pallera previously determined. Finally,
Ma~s I a
the motion of individual spherical beads exposed to the flow
pattern of the stined tluid is investigated. Steady-stale stirring
of the Newtonian fluid and discontinuous processing is pro- i ~ calculated can be restricted to tbc calculation domain
vided in all investigations. ,shown in Fig. I.

3.2. Calcularion of the fltdd flow

3. Geometry and fundamentals
3.1. Geometry of the stirred media mill
A commercially available stirred media mill (see Fig, l )
was used as the subject ['or all nf these calculations, Its
geometric dimensions and the standardized ones (related to
the outer disc radius) used in this paper are summarized in
Table 1.
The slirrer located in the centre of the grinding ,~'ylinderis
equipped with six agitator discs. Discontinuous processing is
carried out. Since the geometry is symmetrical in a circum-
ferential direction, and due to the assmnption that th~ end fa-
ces of the mill have no effect on the flow pattern, the area to
C~leul~tion
i~~'*'-~ . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . .
In order to determine the flow field, conservation laws are
solved for the calculation domain. In the ease of steady state.
laminar stirring of a Ncwtonian fluid, the theorem of momeo-
lure in a radial, tangential and axial direction, as well as the
mass conservation law, have to be applied. For numerical
reasons, both are formulated in an identical lbrm based on a
cylindrical co-ordinate system:
a [ . ro<l,~ o i ra,p~
--Iru~P-----t+--lrw~-----l= S@ ( I)
0r~ Re ;Jr) ,'~Z~ Re itz,I
Re - PRava (2 )
In Eq. (!) the general quantities qJ and $ . have to
replaced respectively by expressions summarized in Table 2.
Dom~ir~ .... !
The entire equation system represented by Eq. (1) and
' i Table 2 is formulated in a standardized form. The local radial
and axial co-ordinates r and z are related to the outer disc
radius Ra, the radial, tangential and axial velocities u, re and
w are related to the circumferential speed of the disc ~Jaand
the pressure p is related to the product pl:~. The Reynolds
:i, "7' number Re ( see Eq. (2)) results li'mn the standardization in
the theorem of momentum. It depends on the density p and
dynamic viscosity "4,of the fluid as well as on va and Ra. All
.....

paramelers influencing the fluid flow appear in the Reynolds

liig, 1, Gem~eiry of the stirred media mill, number. Thus, it becomes the only parameter describing the
 L Blecherelal,/Powder Technology 86 f1996) 59~8

operating conditions of the mill, The conservation laws are
solved by using a simulation program developed by Blecfier
[ 12] which is based on a finite volume procedure.
3.3. Calculation of the energy density distribution
Based on the prediction of the flow field for a certain
Reynolds number, the distribution of the non-dimensional
local specific power Nev:,,~, representing the energy dissi-
pation (local power dP per local volume dV), is directly
calculated by means of the following equation:
where v= (u,v,w) T and vt, = (Uh,t,b,Wr,)"r denote veclors of
the non-dimensional (relative to vd) fluid and bead velocities
in a radial, tangential and axial direction, Ph the bead density,
Rr, the bead radios, t the non-dimensional time (relative to
RJea) and v,~ the non-dimensional relative velocity between
fluid and bead. F,q (7) describes the balance of forces acting
on the bead as it moves along its trajectory. The term on the
left-hand side results from the inertia force acting on the bead
due to its acceleration. The terms on the right-hand side rep-
resent forces due to drag, fluid pressure gradient and inertia
of virtual mass respectively.

1 f2[/ou~:+/0wl:+hfi"l Two time derivatives have to be distinguished:

t clU aff~ s nL' ~"

Fau ,~w-I:+ r r - - - fi, l" + [ovl-~l

+ ---F-- --
--= b i b - - -~- W h - - -}- --
o, I Or O:l I" I (g)
dP l d r * dV I ~"+~n':l / 0 /
me ..... = ~rd~dV~ with =R~ (4)
The standardized mean specific power Nev is obtained by
averaging Nev.l,,, over the non-dimensional grinding chamber dr -7
volume Vc:
!
dt /d'/ I / (9)
Nev=,7. IJ~ Nev,,,~dV* with V~
, c c - _Voc
3 (5)
V~c vd,: R~t
During stationary operation, the ratio of the non-d/men- In the case elf steady-stale fluid motion, Eq. (8) describes
siena| local specific power to the non-dimensional mean spe- the total time derivative of Ibe fluid velocity for a reference
cific power reflects the proportion of the corresponding frame moving with the bead. Eq. (8) is split into two terms
dimensional specific energies (EV.lo~and Ev). This ratio will of which the second results from using a cylindrical co-ordi-
be called energy density: nate system. Eq. (9) gives the derivative in a reference frame
fixed to the flow configuration. For the same reasonsas before
energy density ~Nev'i<'~=Ev'l'¢ (steady state) (6) the fight-hand side of Eq. (9) is composed of two terms. The
Nev Ev
second term contains the Cur/oils acceleration in a radial
The mean specific energy Ev corresponds to the specific direction and the centrifugal acceleration in a tangent/aid/nee-
energy input of a cumin/nut/on process which is an important lion.
parameter for predicting the cumin/notion result. An increase The drag c(•flicient CDappearing in the first term on the
in the mean specific energy leads to an increase in the product right-hand side of Eq. (7) is approximated by the following
fineness. Therefore, grinding chamber zones where the function [14]:
energy density is > I represent areas where cumin/nut/on is
most successful. In the following these areas are called zones 24 4
co(reo= ~ + ~ + 0 . 4 (tO)
of high energy density or zones of high cumin/nut/on inten-
sity.
The drag coefficient is a function of the Reynolds number,
3,4. Calculation of the bead motion
Rub,of the bead, which represents the ratio of inertia-to-drag
forces acting on the bead:
After calculating the energy density distribution and the
Reh 2R~(v~ivd) ( l 1)
fluid flow, individual spherical beads are exposed to the flow
pattern and tbeir trajectories are determined numerically. The
equation of bead motion which has to be solved has the The head Reynolds numberdepends on tbe Reynolds num-
following form [ 13] ber, Re, the ratio of head radius and disc radius, Rt,lRd, and
the non-dimensional relative velocity r~z which is a function
dvh 3 p Rd of fluid and bead velocities.

p Ov , 1 p [l~, dv,~ Reb= Re × 2-:- v~a

Rb
(12)
 L Blecher et el,/Pmvder Tech.afogy 86 ~1996) 59-6g
Therefore, in Eq. (7), Re, R,/Rn and p~/p remain as the
indepcndcm paramcte~ delermining the motion of a single
bead.
The numerical solution of the equation system describing
the bead motion is carried out by using a time step controlled
Runge-Kutta-Nystroem procedure (see Ref. [ 12] ).
4. Results of the calculation
The calculations concerning the prediction of the fluid flow
have been carried out for w~rious Rcynolds numbers
( I0 < Re _<g000). The results have shown that two operating
ranges of the stirred media mill exist. In each range, a char-
acteristic flow pattern of the stirred fluid occurs and hence a
typical energy density distribution is generated, Operating
range I stands for low Reynolds numbers ( Re _<100). In this
range the radial and axial fluid velocities are very small (per
oil range) compared to the speed of the agitator disc whereas
the tangential fluid velocities and the speed of the agitator
disc are of the same order of magnitude. Therefore, the tan-
gential velocity field is predominant and mainly responsible
for the generated energy density distribution which is quite
homosenenus, However, the entire power consumption at
low Reynolds numbers is very ,,;mall and a comminutioa
process can hardly be performed, Therefore, this range will
not be investigated further (for more information see Refs.
[ 12,151 ), This paper focuses on operating range il in which
successful comminution takes place and all components of
the fluid velocities are of identical order of magnitude.
4.1, Flow panern and energy density distribation
According to section 3.1, the flow pattern in the grinding
chamber can fully be described by the vetocity field which is
generated on the so-called calculation domain (see Fig. I).
For reasons of symmetry in a circumferential direction, the
calculation domain is a plane extending in radial and axial
directions. In Figs_ 2 to 4 some calculated results concerning
the non.dimensional velocity field and the energy density
distribution are displayed graphically on this plane which is
rotated through 90° in a clockwise direction compared to the
m.15
.....
r ->
Fig. 2. Axial profiles of the tangential velocity for Re =
presentation in Fig. 1, Thus, the left a×is of each figure (i.e.
r~ 0.35) is restricted by the agitator shaft and the right axis
( r = 1.25) is limited by the grinding chamber wall. Hence,
the bottom and the top limitations arc given by lines of sym-
metry in the middle of one agitator disc (z = -0.075) and
between two discs (z = 0.3585) respectively. According to
section 3.2 the radial (r) and axial (z) co-ordinates are
related to the outer disc radius R,j.
As a typical result of operating range II, Fig. 2 shows
profiles of the non-dimensional tangential velocity (calcu-
lated for Re - 2000) which occur parallel to the agitator shaft
(i.e. in the z-direction at r~constanl), The profiles are dis-
played in the non-dimensional r-z plane of the calculation
domain whercas the real direction of the tangential velocity
is normal to the plane of representation,
In the vicinity of the shaft (where r=0.4) the fluid is
rotating as a solid body. Thus for a constant radius, the veloc-
ity of the fluid corr'~:;pondsto the velocity of the rotating disc.
With increasing radial distance to the shaft, a velocity profile
develops with decreasing values in a positive z-direction, A
steep velocity decrease in the vicinity of the disc surface is
foltowed by velocities which are nearly constant. A similar
velocity i,rolile can be found above the disc (here r = 1.05).
Due to the no-slip condition at the disc surface, maximum
velocity values of o = I (see the scale at the upper limit of
Fig. 2) occur at the outer disc radius (r = I ). If the areas in
the vicinity of the agitator disc and the grinding chamber wal!
arc not taken into account all tangential velocities have nearly
the same magnitude,
Fig. 3 (Re = 2000) shows a characteristic result concern-
ing the flow pattern of the radial and axial fluid velocities,
Streamlines representing the local Ilow rate of the fluid (in
the r-z direction) are displayed in the non-dimensional r-z
plane. Between each of the adjacent streamlines the same
local flow rate exists, Therefore, if the local distance between
two streamlines becomes smaller (high slreamline density)
the local velocities of the fluid composed of radial and axial
components are increasing. This figure proves that a rota-
tional flowexists in the r-z plane. The rotational flow is caused
by the fluid being driven outwards owing to the rotation of
the disc (centritugal effect). The centrifuged fluid coming
from the vicinity of the disc touche s the region near the grind-
Re - 2000
~,]5 I
^0,15,
O,vm
.oi o.~ o.~ e,~ e.T ¢.P O,g '.0 '.~ ~.Z
r ->
,O. Fig. 3. Strgamlines of the slin~d fluid in the r-z plane for Re ~ 2000,
 L Bl¢chtr et al./Po~'der Technology g6 ~19°~6) 59-68
Fig. 4, Isolines of the energy den:~.ily dislribution for Re ~ 201~..
ing chamber wall where it is diverted to the direction of the
top symmetry line. For reasons of continuity, the fluid then
flows back towards the region of Ihe chamber where it slatted.
The local streamline density shows that higher velocities
composed of radial and axial components occur particularly
in the periphery of the rotational flow (vicinity of the disc
surface, symmetry field between two discs, vicinity tff the
grinding chamber wall, gap between disc and grinding cham-
ber wall). Maximum values of the composed non-dimen-
sional radial and axiat velocities of ahnut 0.2 are found in the
vicinity of the top of the disc. High velocity gradients causing
high energy densities (see Eq, (3) ) appear very close to the
disc surface, in the gap between disc and grinding chamber
wall and at the grinding chamber wall near to the disc.
The characteristic flow pattern in the grinding chamber
causes a charaeterstic energy density distribution which is
mainly determined by the velocity gradients of the fluid (see
Eq. (3)). Fig. 4 shows isolines of the energy density calcu-
lated for a P,.eynoldsnumber of Re = 2000. The isolines with
the value I are of great importance. They separate the grind-
ing chamber into different characteristic zones. In these zones
the local specific energy is larger (high energy density) or
smaller (low energy density) than the mean spc,'ilic energy
which represents the entire energy cunsumption o~ Ihe stirred
media mill related to the net volume of the grinding chamber.
As a typical result, standing ror high Reynolds numbers two
zones characterized by higlq energy densities exist. The tirst
zone extends around the disc and runs very close to it. It arises
from the high gradients of the tangential velocity and from
the very high gradients of the radial velocity which are caused
by the centrifuged fluid. The second zone is Iocan,-dnear Ihe
grinding chamber wall. It results from gradients caused by
the axial return transport of the centrifuged fluid which ig
directed to the top symmetry line. Since high energy densities
are necessary for a successful eomminution process, these
two zones denote the areas where eomminution is most sue-
cessful. Both zones together cover only a small part of the
entire grinding chamber volume.
Fig. 5 quantifies the lasl statement. It shows the part of the
grinding chamber volume where high energy densities exist
as a function of the Reynolds number. The second curve
indicates the portion of the entire energy consumption dissi-
pated within this volume part. Starting with 20%, at a Reyn-
fi3
, part of energy
t
o
UO
port of volume
20
• 1
2000 4000 60on 8000
Re = p R ~ v J r l
Fig. 5. Part of the grinding chamber volumr: with high energy density and
part ufthe entire enezgy input dissipated the:re a~ a function of Re.
olds number of 200. the volume part decrea~-:c:.:'::.tinuously
for increasing Reynolds numbers, whereas lhe part of the
entire energy dissipated in these subvolumes increases. For
Re ~ g000, the zones of high energy density cover only about
10% of the grinding chamber volume, However, within this
small subvolume, about 90% of the entire energy input is
dissipated. This example in,.ilcntes chat effective comminu-
lion takes place only in the two very small zones of high
energy density located at the disc surface and at the grinding
chamber wall.
4.2. Motion of single grbtdiug beads
The main part of the entire energy is converted in the two
small zones of high e nergy density. There fore, optimum com-
mination results can be expected if grinding beads pass
permanently through these zones. The calculated results con-
cerning the motion of a single bead will show which kind of
grinding beads lead to optimum eomminution.
All calculated results have shown that a single bead which
is exposed to the flow field in the grinding chamber tends to
follow a stationary trajectory. The moment when the head
reaches this trajectory depends on the starting conditions
(position and bead velocity). The course of the stationary
trajectory is determined by the radius and density ratio as well
as the Reynolds num~r.
In Fig. 6, four different stationary trajectories representing
four different radius ratios Rb/Rd are depicted. The density
ratio of I~lp = 2.5 is kept constant. The trajectories are pro-
jected into the non-dimensional r-z plane. Therefore, the bead
motion in a circumferential direction cannot be seen. A ~aph-
ical indicator for the tangential motion is given by the ~uares
which are plnt'.cd at the graphical slatting position as well as
every time the bead passes a complete cycle of 360° in the
grinding chamber, The distance between two adjacent spher-
ical symbols on a trajectory which are calculated for regular
non-dimensional time intervals of ~t = 1.5 (see Eq. (7)) is
 L. Bluchererat I Prm'derTechu~dogy~6 (I996) 59~g

Re= 2000 [Z~ high energy density

o.1~o.i3s 1 :=
~=--"-.-~
......
1 -.,.1,..-...........] .... /~'1
NO'f0 ~ "~"~.- Q.

O. OS -'~ -~--'-"-_ "-'~.- lit I • RJP~ = I t 30

0.00

-fl, 05

0.4 0'.5 0.6 0,7 0`.S 0.9 1.0 L1 1.~

p ->

Fig. 6. Influence af the radius ratio belween bead and disc on |ht, l acanon of the slationary head Irajeclary Ior p j p - - 2,5 alld Re = 2000,

Re: 2000 ~ higln energy density

o.ssF- ~ .... = ...... :~-............ -t--.-:~.-
0.30 it ~ 'l Rb/[~ = 11120

A r, x ,

0.'~ O,S 0.~ 0,7 O.B 0,9 ~,0 I.I 1,2

r ->

Fig, 7 Influence of'the dcn:~ily f,~tio between bead and fit.lid nn Ihe lOralion of the stationar; bead trajectory for Rh./~l = I ,/120 and Re = 2000,

an indicator of Ihe bead vcloeily in the r-z plane. Besides the
motion in a circumferential direction, all beads move in a
coun;er-clockwise direction along their individual trajectory
located in the r-z plane. The smalles~ beads (Rh/Rd= 1/240
and Rh/Rd= 1/120) fi)llow almost the same stalionary tra-
jectory whicb leads them from the graphical starting position
through both zones of high energy density, down to the shaft
along the vicinity of the top syrametry line and back to the
starting position. On their way along lhese trajectories, both
beads almost follow the streamlines of the stirred fluid (See
Fig. 3). For increasing radius ratios the stationary trajectories
are constricted and shifted towards the top symmetry line.
The largest bead (Rh,'Ra= I/30) does not reach the zones of
high energy density when following its trajectory. As
described before, the bead moves along the top symmetry
line down to the shaft. A bead exchange between the two
adjacent mill domains now takes place. A bead leaving the
calculation domain is replaced graphically by anolber one
entering at a corresponding angle. The course hack to the
grinding chamber wall runs closer to the top symmetry line.
In so-doing the bead moves partially against the direction of
the fluid flow. The complete trajectory is located in regions
where low energy densities are predominant.
Fig. 7 indicates the influence of the density ratio on the
location of stationary trajectories. The radius ratio of RJRd
= I / 120 is kept constant, The stationary trajectory calculated
for ~/p = 2,5 corresponds to the one already described in
Fig. 6. An incr,:ase of the density ratio from 2.5 to 7.6 leads
to a displacement of the stationary trajectory to the top sym-
metry line. The bead moving along this trajectory only passes
the zone of high energy density located at the grinding cham-
ber wall. The course of the trajectory does not always corre-
spond to the streamlines of the stirred fluid.
Finally, Fig. 8 shows the influence of the Reynolds number
on the stationary trajectory. The results have been obtained
using a constant radius ratio ofRblRj = I / 120 and a constant
density ratio of&J#= 2.5 The zones of high energy d~nsity
are not plotted in Fig. 8 because their extension (but not their
Incation) varies slightly for the different Reynolds numbers.
For Reynolds numbers of 800 and 2000 both trajectories run
through the regions next to the disc surface and close to the
grinding chamber wall where high energy densities exist.
Beads moving along these trajectories basically follow the
fluid flow. For increasing Reynolds numbers ( see Re = 8000)
the trajectory is constricted and shifted towards the top sym-
 L Bl*cheret al, / Po v.'der Technology86 ¢199~)59~8 65

'~f ..: ..... ~ . . . . . . . ~C " = - F,=/R,

0,30 ~..0"~ p.lp = 2.5
11,20

i~ ~).10 I Re = 2000

D.05 ~'rn-._ ~ . Ao - 9000

- O. 05

0.4 0.5 0.6 0.7 O.S 0.9 1.0 1.1 1.2

f" - >
Fig, 8. lnflocn~ of the Reynolds number or= the location of tile Satlionar~ head ttajoct0~ for RJg, = t / 120 and f~lp- 2.5,

merry line, i,e. to those regions in which low energy densities
are predominant.
The results presented in Figs. 6 to 8 have shown that for
certain combinations of RhlRd,Pt~/P and Re the trajectories
are similar to the streamlines of the stirred fluid and the beads
move through both zones of high energy density. This behav-
iour is positively influenced if the values of the three para-
meters are decreased. Beyond a certain limit of the parameter
combination, i.e. for high values ofR~/Rd,Ph/P and Re, the
trajectories begin to constrict and move towards the top sym-
metry line where low energy densities exist. Different bead
motions are caused by the ratio between drag and incxlia
forces acting on the bead. The ratio of these forces mainly
depends on the individual mass of the bead. For decreasing
density or radius ratios, the individual inertia (mass) of the
head is also decreasing. If the mass of the bead is small
enough, drag forces become predominant compared to the
inertia forces (e.g. centrifugal forces) and cause the bead to
follow the streamlines. Hence, the relative velocity between
fluid and bead is very small. In contrast, an increase in the
mass of the bead leads to a predominance of the inertia forces.
The most important inertia force is the centrifugal force which
is caused by the rotating system and acts in positive r direc-
tion: if the bead moves down along the top symmetry line,
the centrifugal forces cause a reduction of the bead velocity,
Finally, the bead stops an d turns around tit the opposite direc-
tion. The bead is now accelerated strongly in a positive r
direction and moves towards the grinding chamber wall.
Before the forces acting in direction of the disc surface
(mainly drag forces) have a chance to move the bead to the
disc, the be.,ad reaches the vicinity of the grinding chamber
wall. There it is exposed to the axial back flow of the fluid
and is transported to the top symmetry line,
Fur be'ads with a constant radius and a constant density,
the 'variation in Reynolds number changes as well as the ratio
between drag and inertia forces: for increasing Re the cen-
trifugal field in the grinding chamber increases and therefore
the inertia forces acting on the bead become more predomi-
nant.
The interpretation given above is confirmed by results pre-
sentad in Figs. 9 and 10. The figures show the bead Reynolds
number, Reb. as a function of the Reynolds number Re with
the radius ratio (Fig. 9) and the density ratio (Fig. tO) as
parameters, The bead Reynolds number presented in the fig-
ares is obtained by averaging the local ones defined by Fxls.
( 11) and (12) over the complete stalionavj trajectory which
is fixed by a combination ofRJRd, ~ t p and Re. F~ra con-
stunt Reynolds number, an increase in Rb/R=(see Fig. 9) as
well as an increase in A l p (see Fig. tO) leads to an increase
of the [mad Reynolds number, i.e. the ratio of inertia to drag
forces increases. For fixed density and radius ratios an
increase ia the Reynolds namlmr, Re, leads m an increase in
Re~,.The two figures indicate the existence of a definite cor-
relation between Reb and the parameters,Rb/Rd,Pb/P and
Re.
With respecttocomminution, the grinding beads to be used
are those able to pass permanently through the zones of high
energy density. In these zones they can contribute most effnc-
IO =
10"
ill/
,o-ii/i
10 tO z 10 ~ TO ~
Re - ,
Fig. 9. Influence of Re and R~/I~c~ the averaged bead Reynolds number.
66 L B/ether ar al. 1 P,~'der l~" "hmdogy 86 (1996159-68

(9)) is valid. Furthermore, both accelerations should be pro-

IO=~
P portional to the centrifugal acceleration at the top of the disc
I (t:~/Rd). These assumptions lead to constant non-dimen-
sional accelerations:
1 - -
Du du
--
Dt ~ c o n s t a n t ; ~
dr
= con.';ta~ll ( 15 )

Combining the balance of forces in radial direction given

in Eq. (7) with Eqs. (13) to (15), replacing the relative
velocily by Eq. (12), neglecting the force due to the inertia
IQ 1~_..~// of virtual mass and re-arranging the terms yields:

R%ct(RhI~(P~- I)Re"-=M~ (16)

~ 2 . 5
I0 I0 ~ 1(~ j IO"
Fig. I0. tr,fluence of Re lind/,*l,/p lib Ihe avcrag,zd bead Reynolds number
tively to the eomminntion process. The calculated rcsuhs
presented here indicate that a combination el'parameters,
R~,/~lp and Re, causing a transport dominated by a drag
force is favourablc. In this case, the single bead basically
follows the fluid flow and passes the zones of high energy
density, If the grinding chamber is filled with alarge quantity
of beads, it can he assumed that the bead distribution over the
entire grinding chamber volume is quite homogeneous. Thus,
a sufficient quantity of beads moves lhrough linezones of high
energy density. However, if the calculations indicate a bead
motion dominated by the inertia forces, an inhomogcnenus
distribution of the bulk is expected at which the majority of
the beads is located in the low energy density regions between
the discs. Only a few beads would be found in the zones of
high energy density.
In the case of bead motion dominated by the drag force, a
correlation between the parameters of influence can be
deduced. The decision for a bead to follow the fluid flow or
not depends mainly on the ratio olccntrifugal-to-drag forces.
Since the centrifugal forces act in a radial direction the bal-
ance of fcJreesin this direction is most important fur the basic
behaviour of bead motion and thus will be investigated. If
drag forces are dominant the relative velocity is very small:
i,,<.l~l -'* u=u~, and lu-ubl =t',,l
Furthermore, the bead Reynolds number is small. Eq. (10)
\RJ \,o
The term on the right-hand side is called motion index M,h.
It is valid for single bead motion and describes the mean ratio
between inertia and drag forces acting on the bead. It depends
on the product of a reduced density ratio, the square of the
Reynolds number and the third power of the radius ratio.
Thus, the radius ratio has the strongest influence on the
motion of the bead and on the shape of the stationary trajec-
R=,/ tory r~spectivety,
Furthermore, a proportionality between the standardized
relative velocity and the three parameters of influence can be
deduced by combining Eqs. (12) and ( 16):
t%l <Z(Rh'~z(a - l~Re (17)
t,~d t p J
The validity of the correlation given in Eq. (16) is shown
in Fig. I 1. For a wide range of different parameters, calculated
bead Reynolds numbers Rel,arc plotted against the respective
motion index. The head Reynolds numbers have been
obtained by averaging the local ones over their stationary
Irajeciory. Up to a bead Reynolds number of Re=,= 1 (see
validity of Eq. (14)), corresponding to a motion index of
M,h ~ 13.5, all data points lie on one curve. In this region
drag forces are predominant. The heads basically follow the
10 ~¸
(13)
IO -~ i Re = lO,.aeeo

then gives the following proportionality: P

I
,o-, / , 7i"
lO "+ = , I/ 60 2.5
c~¢X-- valid tbr: Re,,~< l (technical case) (14)
Rel,
10 -I ! ~ "- i I t ,
! ', ' • I ~ SO 7.'ll
~m (14) corresponds to Stokes" law of resistance which :, ',i I= 1,1 30 7.6
in technical applieation~ is used ~p to a bead Reynolds num- ~o ~o.7?t; :.,,;~ :,,,;,~:'i~-' ~ " 7 ~ ' % r';~ i;'~ ='T~'
ber of Rel,= 1. u,, = IRJnD' OoJp-i) i~d ->
For sir=allrelative velocities, the assumption of nearly iden- Fig I I. The averaged bead Reynolds nambl)r as a flmetlon of Ihe luotion
tical local fluid and bead accelerations (see Eqs. (8) and indux,
 L Btecber et nL / Powder Technology 86 (1996) 5 9 q ~ fi7

Table 3 of head-to-disc, the density ratio of bead-to-fluid and the

Motion index for the pesutts presented in Figs. 5-7
Reynolds number on the head motion can he described by
RblRo t~l p Re M,n the so-called motion index. At small values of the motion
index, the bead motion is dominated by the drag force so that
1130 2.5 2000 222,22 the bead basically follows the fluid flow and passes the zones
1160 2.5 2000 27.78 of high energy density. Above a transition region, high values
2.5 800 0.55 of the motion index describe a bead motion that is dominated
2.5 2000 347 by inertia forces. Then the bead basically does not follow the
25 8000 55.55 fluid flow and tends to move in the vicinity of the top sym-
7.6 2000 15.28
metry line where low energy densities exist.
1/240 2.5 2000 0.43
Using a bulk of beads, a small motion index which ensures
bead transport dominated by the drag force indicates a favour-
fluid flow and pass permanently the zones of high cocrgy aOie operating condition of the mill because all beads basi-
density (see Figs. 6-8 and Table 3). cally follow the streamlines of the stirred fluid. Therefore, for
The critical value ofM, b= 13.5 marks the transition region small motion indices, a homogeneous head distribution over
between bead motions which are dominated by the drag force the entire ginding chamber can be expected and thus enough
or by inertia forces. Above the limit of M.,b= 13.5 the pro- beads come into the zones of high energy density. Here they
portionality between the bead Reynolds number and the contribute most effectively to comminution. For a fixed oper-
motion index becomes worse as it can be seen from the ating point of a stirred media mill this situation can mainly
scattering of the data points. In this range of the motion index, be adapted by the choice of sufficiently small heads. In con-
inertia (centrifugal) forces have become predominant and trust, a high motion index, which describes a bead motion
shifting ofthestationary trajectory towards the top symmetry dominated by inertia forces, indicates an inhomogeneous
line occurs (see Figs. 6-8 and Table 3). The sharp decrease head distribution over the grinding chamber, whereas the
in some of the data at high values ofM, brepresents situations highest bead concentration will he found in the zone extend-
in which the bead is completely cm,trifttged ,rote the grinding ing around the top symmetry line~Only a few beads are found
chamber wail. in the zones of high energy density and consequently the
Eq. (16) can also be formulated as follows: eomminution result becomes worse.

Ms~= [ R ~ ( ~ - p)v~][I IRd] [P/n:] (18)

energy ~ nr,,,~b~y nmlerial 6. List of symbols
In this formula M~t,depends again on three terms, namely
or, drag coefficient (-)
those shown in square brackets, energy, geometry and mate-
Ev.,,,~ local specific energy ( J / m b
rial respectively. The first one characterizesthe kinetic energy
Ev mean specific energy (Jim 3)
of an individual bead whereas the second and the third terms
M~h motion index (-)
represent the geometry of the stirred media mill and the stirred
Nev.1~ standardized local specific power (-)
material (fluid) respectively. With regard to commination
Nov standardized mean specific power (-)
the magnitude of the energy of a single bead becomes an
P power (W)
important parameter as shown in Past 2 [ 16].
p pressure (relative to pv~) (-)
Rb outer bead radius (m)
Ra outer disc radius (m)
$, Conclusions Rob bead Reynolds number (-)
Re Reynolds number of the stirred media mill (-)
The numerical calculations concerning the fluid flow and r radial eo-urdinate (relative to Ra) (-)
the energy density distribution in the grinding chamber of a S,i, common source term (-)
stirred media mill have shown that a characteristic flow pat- t time (relative to Ralvu) (-)
tern of the stirred fluid develops which generates a typical radial velocity (relative m Vd) (-)
energy density distribution. Two zones of high energy density V volume (m 3)
occur which are located in the vicinity of the disc surface and Vc net grinding chamber volume (relative to Ra3)
at the grinding chamber wall. Although these two zones cover (-)
only abot/t 10% of the entire grinding chamber volume about v tangential velocity (relative to vd) (-)
90% of the entire energy input is dissipated there. In order to Vd velocity vector (relative to va) (-)
achieve optimum comminution action, it has to be ensured v circumferential speed of the agitator disc at R..
that the grinding heads permanently pass these zones. (m/s)
Calculations concerning the prediction of trajectories of v,cL relative velocity between fluid and bead
single heads have shown that the influence of the radius ratio (relative to v,j (1)
68 L. Blecher et .l. / Pmvder Tecltmllogy
~6 (1996~59 "6~

axial velocity (relative to tJd) ( - ) References

axial co.ordinalc (relative to ~a) ( - )
[ I ] N. Stehr, Disserlarion, TU Braanschweig, Gerlnany, 1982,
[2 ] N. S~eltrand J. Sch'a,ede~, Int. Syrup, l~ece~tAdvances in Partk~date
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[ 3] H. Weir, Dissertation, TU Braanschweig, Germany, 198?,
"0 dynamic viscosity (Pa s) 14] H. ',,Veiland J. Schwedes. Chem, Eng, Techn~t. 10 (1997) 3Q8,
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Tecknalagy. Nfirnberg, Ger~rany. 19i~7,Pall 2, p. 709.
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velocities) [ 10] J.P. Thi¢,l.Dis,venation. TU Braunsch',,vcig,Germany, | 992,
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[131 J.A. B~tevich,FI, idDynamies, t (19661 119,
Acknowledgements 114] H, $¢hlichting, Grenzschichr-Theorie, "9"ol. 5. Braun Vetlag,
Karlsruh~ 1984.
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