The role of slurry rheology in stirred media milling of quartzite has been investigated by varying important grinding parameters such as media bead density and size, addition of chemicals, solids concentration, Stirrer rotational speed as well as the combined effect of these factors. Media bead density has an evident but complex effect on stirred milling performance, depending on stirrer rotational speed and solids concentration. The effect of media bead size on the ultra-fine grinding of quartzite is relevant to the feed size. Optimal ratio of media bead size to the median size of a feed is between 150 and 200. The combined effect of grinding bead size and stirrer speed or solids concentration is insignificant. The addition of Dispersant S40 or a lower solids concentration results in better grinding performance (i.e., a higher energy efficiency and a smaller median size) due to the maintenance of lower viscosities at shear rates investigated during grinding. Stirrer rotational speed interacts with solids concentration. For a given solids concentration, an optimal stirrer speed exists. The observed phenomena can be explained by the interaction of slurry rheology and the stress intensity of individual grinding bead. In addition, an empirical particle size-energy model provides a good fit (R(2) >0.904) to the grinding results under the experimental conditions investigated. Furthermore, the wear of grinding media beads is involved. ZrO(2) beads have a lowest wear rate whereas the wear Of SiO(2) beads is most serious. The wear rate of Al(2)O(3) beads is related to bead size. (c) 2006 Elsevier B.V. All rights reserved.