Sensitivity Study of Operational Parameters in Ball Mills Using Usim Pac Software

Objectives: This study aimed to evaluate the sensitivity of three operational parameters—feed solids percentage, critical speed fraction, and ball load—to the product particle size distribution (D80) and the power required by a ball mill. Theoretical Framework: The grinding stage is recognized as one of the most critical and energy-intensive phases in mineral processing. In this context, the application of mathematical models and computational tools is an essential strategy for optimizing performance and energy efficiency. Method: A mathematical model implemented in the USIM PAC® software was employed, using data obtained from industrial samples. The simulations considered controlled variations in the selected parameters, allowing for the analysis of their effects on the process response. Results and Discussion: The results showed that critical speed fraction was the variable with the greatest impact on mill performance, followed by ball load. Conversely, feed solids percentage had no significant effect on D80, a fact attributed to the inherent limitations of the model used. The findings reinforce the importance of considering operating speed and grinding media load as key variables in controlling the grinding process. Furthermore, they indicate the need to improve mathematical models to better represent the influence of solids percentage. Research Implications: The study contributes to the understanding of the operational behavior of ball mills based on computer simulations, providing technical support for optimizing grinding circuits and reducing energy costs in mineral processing.