DEM modelling of non-spherical particle breakage and flow in an industrial scale cone crusher

Predictions of particle flow and compression breakage of non-round rock passing through an industrial scale cone crusher are presented. The DEM (Discrete Element Method) particle breakage model is generalised to allow non-round particles to be broken into non-round progeny. Particles are broken in this DEM model when the elastic energy of a contact is sufficiently high to initiate fracture. Progeny size distribution data from JKMRC Drop Weight Test (JKDWT) or JKMRC rotary breakage test (JKRBT) is used to generate the specific daughter fragments from each breakage event. This DEM model is able to predict the production of both coarser progeny which are resolved in the DEM model and finer progeny which are not. This allows the prediction of product down to very small sizes, limited only by the fineness of the fragments measured in the breakage characterisation. The predicted flow of material through the crusher, product size distribution and liner wear are discussed. The generalised breakage model demonstrated here is suitable for modelling all forms of crushers.

[1]  Erik Hulthén,et al.  Control systems for improvement of cone crusher yield and operation , 2014 .

[2]  Hans J. Herrmann,et al.  Fragmentation of grains in a two-dimensional packing , 1998 .

[3]  Paul W. Cleary,et al.  Simulation of particle flows and breakage in crushers using DEM: Part 2 – Impact crushers , 2015 .

[4]  Paul W. Cleary,et al.  Using DEM to compare the energy efficiency of pilot scale ball and tower mills , 2009 .

[5]  Paul W. Cleary,et al.  Large scale industrial DEM modelling , 2004 .

[6]  Validation of a model for impact breakage incorporating particle size effect , 2007 .

[7]  Paul W. Cleary,et al.  DEM prediction of particle flows in grinding processes , 2008 .

[8]  Ian Lowndes,et al.  A laboratory investigation and discrete element modeling of rock flow in a chute , 2012 .

[9]  Runyu Yang,et al.  Effect of slurry properties on particle motion in IsaMills , 2009 .

[10]  Paul W. Cleary,et al.  Simulation of particle flows and breakage in crushers using DEM: Part 1 – Compression crushers , 2015 .

[11]  Paul W. Cleary,et al.  An investigation of the comparative behaviour of alternative contact force models during elastic collisions , 2011 .

[12]  Paul W. Cleary,et al.  Using DEM to model ore breakage within a pilot scale SAG mill , 2004 .

[13]  Paul W. Cleary,et al.  Industrial particle flow modelling using discrete element method , 2009 .

[14]  Fengnian Shi,et al.  Modelling of incremental rock breakage by impact: For use in DEM models , 2007 .

[15]  Paul W. Cleary,et al.  Testing the validity of the spherical DEM model in simulating real granular screening processes , 2012 .

[16]  Paul W. Cleary,et al.  Charge behaviour and power consumption in ball mills: sensitivity to mill operating conditions, liner geometry and charge composition , 2001 .

[17]  S. Morrell,et al.  Mineral comminution circuits: their operation and optimisation , 1996 .

[18]  Runyu Yang,et al.  Discrete particle simulation of particle flow in IsaMill-Effect of grinding medium properties , 2008 .

[19]  Sylvester Ejikeme Amalum Awachie.  Development of crusher models using laboratory particle breakage data , 1983 .

[20]  Paul W. Cleary,et al.  Analysis of stirred mill performance using DEM simulation: Part 2 – Coherent flow structures, liner stress and wear, mixing and transport , 2006 .

[21]  Paul W. Cleary,et al.  Analysis of stirred mill performance using DEM simulation: Part 1 -Media motion, energy consumption and collisional environment , 2006 .

[22]  N. Djordjevic.  Influence of charge size distribution on net-power draw of tumbling mill based on DEM modelling , 2005 .

[23]  Alexander V. Potapov,et al.  a Three-Dimensional Simulation of Brittle Solid Fracture , 1996 .

[24]  Thomas Gustafsson,et al.  Control oriented modeling of flow and size distribution in cone crushers , 2014 .

[25]  Paul W. Cleary,et al.  The packing properties of superellipsoids , 2010 .

[26]  Runyu Yang,et al.  Discrete Particle Simulation of Particle Flow in the IsaMill Process , 2006 .

[27]  Paul W. Cleary,et al.  Towards a virtual comminution machine , 2008 .

[28]  Malcolm Powell,et al.  Modeling breakage environment in tumbling mills using DEM and analyzing the outputs , 2010 .

[29]  Paul W. Cleary,et al.  Prediction of industrial, biophysical and extreme geophysical flows using particle methods , 2013 .

[30]  Timothy J. Napier-Munn,et al.  The influence of liner condition on cone crusher performance , 1990 .

[31]  Erik Hulthén,et al.  Real-time algorithm for cone crusher control with two variables , 2011 .

[32]  Paul W. Cleary,et al.  Modelling comminution devices using DEM , 2001 .

[33]  Malcolm Powell,et al.  Applying DEM outputs to the unified comminution model , 2008 .

[34]  I. Einav,et al.  Force attractor in confined comminution of granular materials. , 2010, Physical review letters.

[35]  Paul W. Cleary,et al.  Predicting charge motion, power draw, segregation and wear in ball mills using discrete element methods , 1998 .

[36]  Paul W. Cleary,et al.  Recent advances in dem modelling of tumbling mills , 2001 .

[37]  Paul W. Cleary,et al.  DEM modelling of industrial granular flows: 3D case studies and the effect of particle shape on hopper discharge , 2002 .

[38]  Paul W. Cleary,et al.  Novel application of DEM to modelling comminution processes , 2010 .

[39]  Jens Lichter,et al.  New developments in cone crusher performance optimization , 2009 .

[40]  Malcolm Powell,et al.  DEM modelling of liner evolution and its influence on grinding rate in ball mills , 2011 .

[41]  Magnus Evertsson,et al.  The contribution of DEM to the science of comminution , 2013 .

[42]  P. Cundall,et al.  A bonded-particle model for rock , 2004 .

[43]  N. Djordjevic.  Discrete element modelling of the influence of lifters on power draw of tumbling mills , 2003 .

[44]  Ian Lowndes,et al.  Discrete element modelling of a rock cone crusher , 2014 .

[45]  Michael H. Moys,et al.  Discrete element method (DEM) modelling of evolving mill liner profiles due to wear. Part II. Industrial case study , 2005 .

[46]  Michael H. Moys,et al.  Discrete element method (DEM) modelling of evolving mill liner profiles due to wear. Part I: DEM validation , 2005 .

[47]  Brahmeshwar Mishra,et al.  Simulation of charge motion in ball mills. Part 1: experimental verifications , 1994 .

[48]  Paul W. Cleary,et al.  The selection and design of mill liners , 2006 .

[49]  Jochen Franke,et al.  Integrating liner profile evolution and mill performance with 3D DEM modelling , 2011 .

[50]  Brahmeshwar Mishra,et al.  The discrete element method for the simulation of ball mills , 1992 .