Hammer premature wear in mineral crushing process

Kallel, M.; Zouch, F.; Antar, Zied; Bahri, Amir; Elleuch, Khaled

doi:10.1016/j.triboint.2017.06.025

Cited by 29 publications

(14 citation statements)

References 31 publications

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“…In general can be said, that the slit-specimen based geometry in the HT-mCIAT does provide good results close-to-reality. Here, the edge rounding, surface deformation as well as particle sticking in sieves [30] as well as crusher applications [36,37,38] can be simulated at the same order of magnitude.…”

Section: Impact-abrasion Wear Resultsmentioning

confidence: 99%

How the micro-mechanical stability of carbides in chromium-rich hardfacings influences the impact-abrasion resistance at elevated temperatures

Rojacz

Katsich

Varga

et al. 2023

Wear

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Section: Impact-abrasion Wear Resultsmentioning

confidence: 99%

How the micro-mechanical stability of carbides in chromium-rich hardfacings influences the impact-abrasion resistance at elevated temperatures

Rojacz

Katsich

Varga

et al. 2023

Wear

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“…Because of the continuous impact of barite particles on the hammer, numerous craters and a crack network are also observable on the damaged surface. As a result, it is possible to infer that the wear is a result of both abrasion and impact phenomena 9 .…”

Section: Introductionmentioning

confidence: 99%

Tribological performance of high chromium white cast iron and heat-treated steel used in barite crushing industry

Zouch¹,

Bahri²,

Antar³

et al. 2023

Sci Rep

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Barite sulfate (BaSO4) is considered a very important mineral material employed as a weighting agent for all types of drilling fluids. Meanwhile, crushers used for the grinding step during barite crushing are affected by catastrophic wear damage located in the hammer parts made from high chromium white cast iron (HCWCI). In the present study, a comparison of the tribological performance between HCWCI and heat-treated steel AISI P20 was conducted to investigate the possible substitution of HCWCI. The tribological test was performed under normal loads between 5 and 10 N for different durations (60, 120, 180, and 240 min). The wear response analysis for both materials showed that the friction coefficient increases as the applied load increases. Moreover, AISI P20 presented the lowest value compared to that attributed to HCWCI in all conditions. Furthermore, the analysis of the wear track obtained by means of scanning electron microscopy (SEM) revealed that the damage was an abrasive wear phenomenon for HCWCI with detection of a crack network throughout the carbide phase, which was more pronounced under the highest load. Regarding AISI P20, an abrasive wear mechanism was detected, characterized by several grooves and ploughing phenomena. Further, the analysis of the wear track using 2D profilometry revealed that for both loads, the maximum wear depth of the HCWCI wear track was significantly greater than that of AISI P20. As a result, when compared to HCWCI, AISI P20 exhibits the best wear resistance. Furthermore, as the load increases, the wear depth and the worn area increase as well. Also, the wear rate analysis supports the previous findings, which showed that under both loads, AISI P20 was more robust than HCWCI.

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“…The literature indicates that a mathematical model was developed in order to describe the efficiency of shaft impact crushers [11]. However, in the case of hammer crushers, the analysis so far has focused mainly on experiments, most often on a laboratory scale [12] and, in some cases, at an industrial scale, where hammers were analyzed for abrasion [13,14].…”

Section: Introductionmentioning

confidence: 99%

“…While other publications focus on individual stages [8][9][10][11][12][13][14][20][21][22] of preparing or using a numerical model, this article describes the entire process from its first stage (sample collection) to its last stage (application of the model). An additional difficulty addressed in this work and not present in other publications lies in the complexity of the lithology of the modeled ore [17], which required the parameterization and the calibration schemes of numerical models to be adapted to this specific case.…”

Section: Introductionmentioning

confidence: 99%

Industry Scale Optimization: Hammer Crusher and DEM Simulations

Doroszuk

Król

2022

Minerals

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The paper shows the preparation of the numerical models necessary for the simulation mapping of industrial-scale crushers of problematic material, such as copper ore with complex lithology. The crushers investigated in this work are located in the KGHM Polska Miedz S.A. copper ore processing plant. The complex ore consisting of sandstone, dolomite and shale is modeled using the Discrete Element Method (DEM) with Particle Replacement Model (PRM) that was chosen to simulate the crushing process. The article discusses the tests and calibration of material parameters and proceeds to test a breakage model in a laboratory-scale jaw crusher. The results are finally validated with the data from actual industrial-scale crushers and compared with the simulations. As an optimization option, the new shape of hammers is proposed and tested in a numerical environment. The performance of the newly designed hammers was examined using numerical methods. The numerical tests showed that the new design performed worse than the current solution. As a result, time and money were saved by avoiding industrial tests. In conclusion, the work shows how complex processes can be characterized in the numerical environment and used for further analysis.

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Hammer premature wear in mineral crushing process

Cited by 29 publications

References 31 publications

How the micro-mechanical stability of carbides in chromium-rich hardfacings influences the impact-abrasion resistance at elevated temperatures

How the micro-mechanical stability of carbides in chromium-rich hardfacings influences the impact-abrasion resistance at elevated temperatures

Tribological performance of high chromium white cast iron and heat-treated steel used in barite crushing industry

Industry Scale Optimization: Hammer Crusher and DEM Simulations

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