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Volume 117
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Effect of heterogeneous media in size and material on milling rate, efficiency, and particle size distribution in stirred media milling (Open Access)
Chiharu Tokoro a b *, Yuki Murata c, Shozo Tanaka c, Yutaro Takaya b a, Hidehiro Kamiya a, Kyoko Okuyama d, Yuma Hatakeyama d, Satoshi Shiina d, Osamu Ishikawa d
a Faculty of Science and Engineering, Waseda University, Tokyo, 169-8555, Japan
b Faculty of Engineering, The University of Tokyo, Tokyo, 113-8656, Japan
c Graduate School of Creative Science and Engineering, Waseda University, Tokyo, 169-8555, Japan
d Nippon Coke & Engineering Co., Ltd., Tochigi, 328-8503, Japan
10.1016/j.partic.2026.07.008
Volume 117, October 2026, Pages 249-261
Received 22 March 2026, Revised 5 July 2026, Accepted 16 July 2026, Available online 22 July 2026, Version of Record 6 August 2026.
E-mail: tokoro@waseda.jp
Highlights

• Heterogeneous media significantly impact early grinding and size distribution.

• Large steel media accelerate initial grinding via high collision energy.

• Silicon nitride media enhance grinding efficiency through high collision frequency.

• Product size distribution span correlates with the DEM-derived collision energy span.

• Lighter small media segregate outward, altering collision statistics in mixed systems.


Abstract

This study investigated the effect of heterogeneous grinding media in size and material on the milling rate, grinding efficiency, and particle size distribution in a horizontal stirred media mill. Dry grinding experiments were conducted for two silica sand feeds with different initial sizes using mixed media composed of large and small beads of steel, zirconia, and silicon nitride. Discrete element method simulations were conducted without powder particles to compare the media collision statistics across the conditions. The experiments showed that the media combination most strongly affected the early grinding response, and the effect was more pronounced for the coarse feed. Steel as a large medium accelerated the initial size reduction, whereas media involving silicon nitride improved the grinding efficiency. Steel-containing combinations tended to yield broader particle size distributions, whereas zirconia and silicon nitride combinations produced sharper distributions. The simulations demonstrated that the grinding trends cannot be explained solely by the collision energy magnitude and that the collision frequency and spread of collision energies are also important. The energy span derived from the collision energy distributions followed the same order as the span of the product particle size distribution. The simulations also indicated the outward segregation of lighter small media, providing a physical basis for changes in the collision statistics in mixed material systems.

Graphical abstract
Keywords
Discrete element method; Attrition; Collision energy; Media density; Grinding kinetics
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