A Comprehensive Review on Evolution Behavior of Particle Size Distribution During Fine Grinding Process for Optimized Separation Purposes

The grinding process is the primary process in mineral processing, which not only liberates target minerals from ore, but also provides the desired size interval for subsequent sorting processes. Since the feed of each sorting method and equipment has an optimal particle size range, particles outside this range are difficult to be separated effectively. While going through literatures, it has been found that very few works have been done in terms of comprehensive reviewing the evolution behavior and the optimization of particle size distribution during the grinding process. This comprehensive review delves into six crucial facets, offering a systematic appraisal: (1) the statistical framework and evaluation methodologies for characterizing particle size distribution, which includes the intricacy of model analysis and interpretation; (2) the property of grinding products, which emphasizes the physicochemical attribute that influences the sorting efficiency and the product quality; (3) grinding kinetics models, which emphasizes the integration of advanced algorithms and experimental validations; (4) the intricate relationship between characteristic particle size and energy consumption, which elucidates the mechanistic underpinning of particle size reduction and energy consumption; (5) stress intensity theory, which elucidates the role of mechanical forces in particle breakage and size reduction; and (6) optimization techniques tailored toward achieving the desired particle size interval, which highlights the grinding technical efficiency and the attainable region method inherent in optimizing the operation parameter of mills. Furthermore, this review critically assesses current applications in this domain and highlights their successes and limitations. It underscores the imperative for meticulous optimization of operational parameters, such as mill speed, grinding media size and so on, to maximize the yield of the desired size interval in the grinding product, thus enhancing energy efficiency and overall process performance. By aligning with the forefront of mineral processing technology, this review serves as a well-referenced source and fosters the development of innovative strategies for optimizing grinding processes.