Effect of the roll stud diameter on the capacity of a high-pressure grinding roll using the discrete element method

Nagata, Yu; Tsunazawa, Yuki; Tsukada, K.; Yaguchi, Yuichi; Ebisu, Yosuke; Mitsuhashi, Kohei; Tokoro, Chiharu

doi:10.1016/j.mineng.2020.106412

Cited by 40 publications

(10 citation statements)

References 48 publications

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“…The hopper level is an important aspect in DEM simulation of HPGRs, since particles located in this region only apply pressure to the particle bed sitting between the rolls (Cleary and Sinnott, 2021;Nagata et al, 2020). In the present study, the recommendation from Cleary and Sinnott (2021) was followed, where the minimum mass in the hopper (m hopper ) is given by:…”

Section: Equipment Setupmentioning

confidence: 99%

“…In particular, laboratory-and pilot-scale DEM simulations of HPGRs allowed to describe the effect of feed size distribution, roll dimensions and speed, applied specific force, besides features such as lateral confinement, roll wear profile and feed segregation. These have then been used to predict performance variables that include throughput, working gap, power consumption and compressive force profile along the rolls, besides skewing (Barrios and Tavares, 2016;Cleary and Sinnott, 2021;Nagata et al, 2020;Quist and Evertsson, 2012;Rodriguez et al, 2021;2022a;2022b).…”

Section: Introductionmentioning

confidence: 99%

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A Hybrid PBM-DEM Model of High-Pressure Grinding Rolls Applied to Iron Ore Pellet Feed Pressing

Rodriguez

Campos

Barrios

et al. 2023

KONA

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Mathematical models of high-pressure grinding rolls (HPGR) have attracted great attention, owing to their role in optimization of operating machines as well as in the design and selection of new ones. Although population balance models (PBM) and the discrete element method (DEM) have been used in this task, both suffer from important limitations. Whereas PBMs have challenges associated to the prediction of operating gap and to the validity of several of its assumptions in different formulations in the literature, application of DEM has its own challenges, in particular when fed with distributions containing large amounts of fines. This work proposes a hybrid approach in which the coupling of DEM to particle replacement models and multibody dynamics is used to predict operating gap, throughput and power, as well as providing information along the rolls length that is used in PBM to predict the product fineness. The hybrid approach is then compared to both DEM and a PBM (Modified Torres and Casali), demonstrating similar results to the later when applied to simulating a pilot-scale machine operating under different conditions, but improved prediction when applied in scale-up to an industrial-scale HPGR.

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Section: Equipment Setupmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Hybrid PBM-DEM Model of High-Pressure Grinding Rolls Applied to Iron Ore Pellet Feed Pressing

Rodriguez

Campos

Barrios

et al. 2023

KONA

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“…In some DEM applications such as ball mill [28], jaw crusher [24], high pressure roll grinding [29,30], agitated drum dryer [31], V-blender [32], and screw conveyor [33], the calculation of power draw is expressed by the sum of the scalar product of the force applied on the i-node and the velocity vector of the same node, v i , with the following expression:…”

Section: Gyratory Crushermentioning

confidence: 99%

Torque Analysis of a Gyratory Crusher with the Discrete Element Method

et al. 2021

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Comminution by gyratory crusher is the first stage in the size reduction operation in mineral processing. In the copper industry, these machines are widely utilized, and their reliability has become a relevant aspect. In order to optimize the design and to improve the availability of gyratory crushers, it is necessary to calculate their power and torque accurately. The discrete element method (DEM) has been commonly used in several mining applications and is a powerful tool to predict the necessary power required in the operation of mining machines. In this paper, a DEM model was applied to a copper mining gyratory crusher to perform a comprehensive analysis of the loads in the mantle, the crushing torque, and crushing power. A novel polar representation of the radial forces is proposed that may help designers, engineers, and operators to recognize the distribution of force loads on the mantle in an easier and intuitive way. Simulations with different operational conditions are presented and validated through a comparison with nominal data. A calculation procedure for the crushing power of crushers is presented, and recommendations for the selection of the minimum resolved particle size are given.

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“…2426) Since the DEM generally assumes that the particles are rigid spherical particles, the DEM cannot simulate particle breakage directly during grinding. However, our previous studies have reported the application of DEM to grinding/milling, either directly by simulating the milling process by introducing a particle breakage model 27) or indirectly by evaluating grinding/milling from the collision energy of particles or grinding media, or both. 2831) The objective of this study was to establish a design methodology to determine required operating conditions and the agitator design for scale-up of a media stirred mill.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Optimum Scale-Up of Media Stirred Mill Using the Discrete Element Method

Kosaku

Tsunazawa

Okuyama³

et al. 2022

Mater. Trans.

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Media stirred mills have been used in various fields to efficiently produce fine products. The scale-up of such mills is required to increase efficiencies and applications for industrial processes. Despite such circumstances, established scale-up laws remain unavailable, and scale-up has been conducted empirically. This study aims to propose essential requirements for the scale-up of a media stirred mill according to experiments and discrete element method (DEM) simulations. The experimental results were evaluated qualitatively by using particle size distributions of ground products and fitted using grinding kinetic theory as a quantitative evaluation. The grinding performance in the laboratory model was equivalent to the results using the scaled-up model (SU-model) with the modified Froude number, regardless of the rotation speed. DEM simulations identified the main factor that contributed to the agreement. The average collision energy of the media particles was almost identical. To set optimal conditions to fulfill this core requirement, the SU-model operation conditions need to follow the modified Froude number, and the intervals of each arm should be fixed to the same distance. These insights encourage the application of scaled-up media stirred mills.

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Effect of the roll stud diameter on the capacity of a high-pressure grinding roll using the discrete element method

Cited by 40 publications

References 48 publications

A Hybrid PBM-DEM Model of High-Pressure Grinding Rolls Applied to Iron Ore Pellet Feed Pressing

A Hybrid PBM-DEM Model of High-Pressure Grinding Rolls Applied to Iron Ore Pellet Feed Pressing

Torque Analysis of a Gyratory Crusher with the Discrete Element Method

Investigation of Optimum Scale-Up of Media Stirred Mill Using the Discrete Element Method

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