Simulation and optimization of crushing chamber of gyratory crusher based on the DEM and GA

Chen, Zeren; Wang, Guoqiang; Xue, Duomei; Cui, Da

doi:10.1016/j.powtec.2021.02.003

Cited by 27 publications

(22 citation statements)

References 21 publications

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“…Another way to show that the deformation during use is greater than that estimated using rolling is by analyzing X-ray diffraction peaks. The Williamson-Hall method [18] considers that peak broadening is attributed to deformation and crystallite size; for this reason, the effects of alloying elements, stacking failures, twins, or others have not been considered. Figure 9 shows (a) peak broadening by deformation for planes (111) and (b) the conventional Williamson-Hall plot.…”

Section: Crushing Surface (Zone 3)mentioning

confidence: 99%

“…Similarly, the effect of strain rate by impact through shot peeing [12,13], and explosive hardening [14,15] on the microstructure in austenitic steels with 12 mJ m −2 < SFE < 35 mJ m −2 has been studied. Most of the articles related to crusher liners have been approached from a simulation perspective [16][17][18]. After use, the crusher liners are recycled, so access to these samples is difficult; therefore, it is not possible to find information on these types of parts during or after use.…”

Section: Introductionmentioning

confidence: 99%

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Hardening by Transformation and Cold Working in a Hadfield Steel Cone Crusher Liner

Allende

Artigas

Bruna

et al. 2021

Metals

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This paper presents the characterization of a secondary cone crusher concave liner made of Hadfield steel used in Chilean mining after crushing copper minerals during all service life. During use, a cone crusher concave liner suffers indentation (cold working) and abrasion; this combination provides the concave with a layer that constantly renews itself, maintaining a surface highly resistant to abrasive wear. The results presented here were obtained using optical microscopy, microhardness test, measuring abrasion using the dry sand/rubber wheel apparatus, and x-ray diffraction peaks analysis through the classic Williamson–Hall method. After analysis of results, two hardened surfaces have been found—one a product of heat treatment and the other due to deformation during use. This work proposes ways to explain them; the first one uses a thermodynamic model to calculate stacking fault energy, and the second compares the liner with cold-rolled samples.

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Section: Crushing Surface (Zone 3)mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Hardening by Transformation and Cold Working in a Hadfield Steel Cone Crusher Liner

Allende

Artigas

Bruna

et al. 2021

Metals

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“…A complete force analysis of the loading force distribution acting on the crusher's mantle and the torque in the mantle geometry is performed with a moving frame of reference in polar coordinates. With this variable change, a planar force and torque distribution can be obtained, as can be observed in a previous work [21] and machines such as jaw crushers [24]. As a novelty, a calculation procedure for the crushing power of crushers is proposed where the torque is computed with radial forces because only these forces are transmitted to the eccentric.…”

Section: Introductionmentioning

confidence: 97%

“…Between the challenges that they proposed, an industrial-scale validation of DEM models of crushers is highlighted. A crushing chamber optimization with DEM (EDEM 2018) was performed by using a genetic algorithm [21]. The particle breakage was modeled by BPM, modeling the particles as a cube shape ore of 300 mm of edge formed by spherical particles of 30 mm of radius.…”

Section: Introductionmentioning

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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“…The feed parameters (grain size, mass, moisture, rock mechanical properties), the method of filling the crusher, the shape of the working parts, the speed of movement, grate gaps and other parameters all influence the output material. In the case of simple crushers, with jaw or cone, where the gap size and the working frequency can be changed, several mathematical models allow estimations of the efficiency and grain size of the crushed product [1][2][3].…”

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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Simulation and optimization of crushing chamber of gyratory crusher based on the DEM and GA

Cited by 27 publications

References 21 publications

Hardening by Transformation and Cold Working in a Hadfield Steel Cone Crusher Liner

Hardening by Transformation and Cold Working in a Hadfield Steel Cone Crusher Liner

Torque Analysis of a Gyratory Crusher with the Discrete Element Method

Industry Scale Optimization: Hammer Crusher and DEM Simulations

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