A true unsteady-state simulator (TUSSIM) for ball milling was integrated with a variable Tromp curve for classification to simulate and optimize closed-circuit, multi-compartment cement ball milling. Using representative model–operational parameters from available literature, we first investigated the system dynamics for a two-compartment mill. Then, various simulations examined the impacts of closed-circuit vs. open-circuit operation, number of compartments, and various ball size distributions. Our results suggest that integrating an air classifier into an open-circuit ball mill can increase the production rate by 15% or increase the cement-specific surface area by 13%. A single-compartment mill entails a pre-milled feed for proper operation, whereas a two-compartment mill yields a finer cement product than a three-compartment mill. Uniform mass distribution of balls led to slightly finer product than uniform surface area or number distributions, while the impact of a classifying liner was negligibly small. Finally, we identified optimal ball mixtures in a two-compartment mill using a combined global optimizer–DAE solver, which suggests 14% capacity increase with desirable cement quality. Overall, TUSSIM’s results are not only in line with limited, full-scale experimental studies and industry best practices, but also provide fundamental process insights, while enabling process optimization with tailored ball mixtures in different compartments.

中文翻译：

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应用具有可变 Tromp 曲线的 TUSSIM 来预测具有各种球尺寸分布的多室研磨机的最佳运行

用于球磨的真正非稳态模拟器 (TUSSIM) 与用于分类的可变 Tromp 曲线集成，以模拟和优化闭路、多室水泥球磨。使用现有文献中的代表性模型操作参数，我们首先研究了两室研磨机的系统动力学。然后，各种模拟检查了闭路与开路操作、隔室数量和各种球尺寸分布的影响。我们的结果表明，将空气分级机集成到开路球磨机中可以将生产率提高 15% 或将水泥比表面积提高 13%。单仓磨机需要预磨饲料才能正常运行，而两仓磨机可比三仓磨机生产出更细的水泥产品。球的均匀质量分布比均匀表面积或数量分布产生的产品稍细，而分级衬里的影响小到可以忽略不计。最后，我们使用组合的全局优化器 - DAE 求解器确定了两室磨机中的最佳球混合物，这表明产能增加了 14%，水泥质量达到理想水平。总体而言，TUSSIM 的结果不仅符合有限的全面实验研究和行业最佳实践，而且还提供了基本的工艺见解，同时通过不同隔室中的定制球混合物实现工艺优化。