In the heart of Iran, a groundbreaking study is set to revolutionize the way we think about energy efficiency in micronized powder production. Alireza Ghorbanifar, a mining engineering expert from the Tehran Science and Research branch of Islamic Azad University, has been delving into the comminution circuit of the Arak Company, a major player in bentonite micronized powder production. His findings, recently published in the esteemed journal ‘Rudarsko-geološko-naftni Zbornik’ (translated as ‘Mining-Geological-Oil Journal’), could have significant implications for the energy sector.
Ghorbanifar’s research focuses on optimizing the grinding systems and devices used in the production of bentonite, a crucial component in various industries, including drilling fluids, foundry, and civil engineering. The study reveals that the current grinding circuit, which consumes a staggering 48 kilowatt-hours of energy to produce one ton of bentonite, is operating at a mere 30% efficiency. “This is a significant energy drain,” Ghorbanifar explains, “and it’s clear that there’s a substantial opportunity for improvement.”
The innovative approach taken by Ghorbanifar involves not only the traditional Bond formula but also the Morrell and Austin relations to study various parameters such as rotation speed and mill filling percent. The results are promising. By increasing the percentage of charge in the tube mill from 21 to 70%, increasing the size of the mill feed by 7000 microns, using smaller balls with a diameter of less than 40 mm, and reducing the relative rotation speed to 60%, the efficiency of the grinding circuit can be boosted by a remarkable 50%.
The implications for the energy sector are profound. “If we can apply these findings to other plants, we could see a significant reduction in energy consumption and costs,” Ghorbanifar suggests. This could lead to more sustainable and cost-effective production processes, benefiting both the environment and the bottom line.
Moreover, the study highlights the issue of agglomerated particles in the tube mill’s product, which accounts for about 16% of the coarse particles. Addressing this phenomenon could further enhance grinding efficiency and reduce energy consumption.
As we look to the future, Ghorbanifar’s research offers a glimpse into the potential of innovative approaches to optimize comminution circuits. It’s a testament to the power of scientific inquiry and its ability to drive progress in the energy sector. With further research and development, we could see these findings shape the future of micronized powder production, making it more efficient, sustainable, and cost-effective.