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    Analysis of grinding aid performance effects on dry fine milling of calcite
    (Elsevier, 2022) Cayirli, Serkan
    The control mechanism in the production of fine particles is important in dry grinding processes, which are popular in the grinding of some minerals. The behavior of the fine particles with each other and with the mill environment is complex and needs to be investigated in detail (on a micro-scale) in every appli-cation. One of the parameters controlling the fine particles in a mill is the use of the correct amount and type of grinding aid. Mechanisms of action must be understood well to develop grinding aids and fully utilize their positive effects. As a general explanation, with the use of grinding aids, the production ton-nage can be increased at the desired product fineness, as well as achieving a finer product at the same production tonnage. However, it is necessary to know other mechanisms and effects to increase efficiency and correct use. The influence of grinding aids on the dry fine grinding of calcite using several analysis methods was revealed in the present study. Within the context, the results were assessed considering grinding performance (particle size distribution and size reduction ratio), product quality (color proper-ties), flowability, adsorption properties (FTIR), and agglomeration behavior (SEM). Moreover, the tested effect of each grinding aid was discussed for each analysis, and the collected results were combined around a summary core diagram.(c) 2022 The Society of Powder Technology Japan. Published by Elsevier B.V. and The Society of Powder Technology Japan. All rights reserved.
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    Comparison of Particle Shape, Surface Area, and Color Properties of the Calcite Particles Ground by Stirred and Ball Mill
    (Mdpi, 2023) Ulusoy, Ugur; Cayirli, Serkan; Bayar, Guler; Gokcen, Hasan Serkan
    Since the particle size, shape, specific surface area, and purity of the ground calcium carbonate (GCC) decide its usability in the paper, paint, and plastic industries, the effect of grinding is important. However, the effect of stirred and ball mill grinding on the particle shape of GCC by dynamic image analysis (DIA) is still lacking in the literature. Therefore, the aim of this study is to compare the aspect ratio at the same fineness (d97 = 50 mu m) and evaluate other properties such as color, and surface area of GCC particles by stirred and ball mill grindings. DIA results showed that particles produced by the ball mill had higher aspect ratio values than those by the stirred mill. This was attributed to the impact, and attrition breakage modes produced by the ball and stirred mill, respectively. This conclusion is supported by XRD and SEM. Finally, the results related to physical properties such as aspect ratio, surface area, and whiteness are discussed depending on the usage area of GCC.
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    Dry grinding of talc in a stirred ball mill
    (E D P SCIENCES, 2016) Cayirli, Serkan; Kowalczuk, PB; Drzymala, J
    The aim of this work was to investigate micro fine size dry grindability of talc in a stirred ball mill. The effects of various parameters such as grinding time, stirrer speed, powder filling ratio and ball filling ratio were investigated. Alumina balls were used as grinding media. Experiments were carried out using the 2(4) full factorial design. The main and interaction effects were evaluated using the Yates method. Test results were evaluated on the basis of product size and surface area.
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    Investigation of the usage of waste materials and By-Products as grinding aids in calcite grinding
    (Pergamon-Elsevier Science Ltd, 2023) Cayirli, Serkan; Gokcen, Hasan Serkan; Yuce, Nuri; Elchi, Obaidullah
    Along with the increasing importance of water worldwide, it is thought that developments in fine grinding processes performed by dry grinding and using grinding aids are too essential to be ignored. Indeed, grinding chemicals in the form of pure or commercial mixtures are intensively used in mineral processing plants in dry grinding systems to micronized sizes, e.g., dry grinding of calcite to micronized sizes. This study investigated the usage of olive pomace oil (OPO) and olive waste water (OWW), waste/by-products of the olive oil industry, as grinding aids in the dry grinding of calcite to micronized sizes using a laboratory-scale stirred ball mill and compared them with pure and commercial grinding aids. The test results were evaluated in terms of product fineness, powder flowability, color factor, surface adsorption characteristics, and agglomeration behavior. The study revealed that using any of the grinding aids tested improved the grinding process in comparison with the no aid condition. It was understood from the experiments and analyses that using OPO and OWW as grinding aids positively affected grinding performance. Particularly, the particle size analyses showed that the product fineness obtained in dry grinding tests was close to that obtained with commercial and pure grinding aids. Considering all the investigated grinding aids (except for OWW), powder flowability increased with the increasing concentration of the grinding aid. Remarkably, the OWW results demonstrated that the increase in dosage was not beneficial in terms of the ffp index. However, the enhancement of particle size was obvious. When evaluated in terms of product quality, four types of grinding aids increased total color differences with respect to feeding material and no aid test. Furthermore, the Fourier transform infrared spectroscopy (FTIR) conducted to determine the interaction between particle surfaces and grinding aids indicated that the grinding aids used in this study were adsorbed on the calcite surfaces by their non-polar, polar functional group and hydroxyl group. The analysis, in which the agglomeration phenomenon was examined with SEM (scanning electron microscopy) images, revealed that using grinding aids reduced the formation of agglomerates in comparison with the no grinding aid condition.
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    The effect of liquid grinding aids on the dry fine grinding of muscovite
    (Oficyna Wydawnicza Politechniki Wroclawskiej, 2023) Cayirli, Serkan; Gokcen, Hasan Serkan; Bozkurt, Volkan; Ucbas, Yasar
    This paper investigates the production of a micronized muscovite to a target product size of d(50)similar to 15 mu m with a minimum energy consumption to suit the product requirements of the paint industry by a dry grinding process in a laboratory-scale vertical stirred ball mill. A series of batch dry grinding tests were conducted without and with two commonly used industrial liquid grinding aids, ethylene glycol (EG, C2H6O2) and triethanolamine (TEA, C6H15NO3). The results were evaluated based on particle size distribution (PSD), specific energy consumption, span value, and aspect ratio. The results showed that using liquid grinding aids resulted in a finer PSD, lower specific energy consumption, a narrower size distribution, lower span values, and a higher aspect ratio, which meant better delamination and improved grinding efficiency to that of no grinding aid. The interaction between grinding aids and ground muscovite surfaces was investigated by Fourier Transform Infrared Spectroscopy (FTIR). FTIR measurements revealed that EG and TEA were physically adsorbed on muscovite surfaces. Scanning Electron Microscopy (SEM) was also employed to determine differences between ground muscovite surfaces with and without grinding aids. SEM images indicated that grinding aids could prevent the agglomeration of ground muscovite particles while improving delamination. Adding grinding aids led to a decrease in muscovite agglomeration and an improvement in lamination owing to the adsorption of grinding aids on the particle surfaces.
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    The Influence of Stirred Mill Orientation on Calcite Grinding
    (Springer Heidelberg, 2021) Cayirli, Serkan; Gokcen, Hasan Serkan
    The purpose of this study was to investigate the dry grindability of calcite powders in a vertically and horizontally orientable laboratory batch type stirred mill. The experimental results were evaluated using stress intensity analysis. The performance was also compared in terms of mill orientation. The results showed that the d(50) values decreased with increasing stress energy down to a certain point and then increased for both milling orientations. Even though the optimum stress energies for both vertical and horizontal orientations were in the range of 1*10(-3) to 5*10(-3) Nm at 750 and 1500 kJ/kg energy consumption, the product size was finer for the horizontal orientation at the same stress energy value. Additionally, to the best of the authors' knowledge, this is the first study to compare mill orientation (vertical vs. horizontal) for the same mill and under the same test conditions.