Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations
It has been known that the performance of high-pressure grinding rolls (HPGR) varies as a function of the method used to laterally confine the rolls, their diameter/length (aspect) ratio as well as their condition, if new or worn. However, quantifying these effects through direct experimentation in...
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-07-01
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| Series: | Minerals |
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| Online Access: | https://www.mdpi.com/2075-163X/11/8/801 |
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| author | Victor Alfonso Rodriguez Gabriel K. P. Barrios Gilvandro Bueno Luís Marcelo Tavares |
| author_facet | Victor Alfonso Rodriguez Gabriel K. P. Barrios Gilvandro Bueno Luís Marcelo Tavares |
| author_sort | Victor Alfonso Rodriguez |
| collection | DOAJ |
| description | It has been known that the performance of high-pressure grinding rolls (HPGR) varies as a function of the method used to laterally confine the rolls, their diameter/length (aspect) ratio as well as their condition, if new or worn. However, quantifying these effects through direct experimentation in machines with reasonably large dimensions is not straightforward, given the challenge, among others, of guaranteeing that the feed material remains unchanged. The present work couples the discrete element method (DEM) to multibody dynamics (MBD) and a novel particle replacement model (PRM) to simulate the performance of a pilot-scale HPGR grinding pellet feed. It shows that rotating side plates, in particular when fitted with studs, will result in more uniform forces along the bed, which also translates in a more constant product size along the rolls as well as higher throughput. It also shows that the edge effect is not affected by roll length, leading to substantially larger proportional edge regions for high-aspect ratio rolls. On the other hand, the product from the center region of such rolls was found to be finer when pressed at identical specific forces. Finally, rolls were found to have higher throughput, but generate a coarser product when worn following the commonly observed trapezoidal profile. The approach often used in industry to compensate for roller wear is to increase the specific force and roll speed. It has been demonstrated to be effective in maintaining product fineness and throughput, as long as the minimum safety gap is not reached. |
| first_indexed | 2024-03-10T08:34:39Z |
| format | Article |
| id | doaj.art-e4d8294f4d20498baf1b4150e00ae767 |
| institution | Directory Open Access Journal |
| issn | 2075-163X |
| language | English |
| last_indexed | 2024-03-10T08:34:39Z |
| publishDate | 2021-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Minerals |
| spelling | doaj.art-e4d8294f4d20498baf1b4150e00ae7672023-11-22T08:49:08ZengMDPI AGMinerals2075-163X2021-07-0111880110.3390/min11080801Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM SimulationsVictor Alfonso Rodriguez0Gabriel K. P. Barrios1Gilvandro Bueno2Luís Marcelo Tavares3Department of Metallurgical and Materials Engineering, Universidade Federal do Rio de Janeiro-COPPE/UFRJ, Cx. Postal 68505, Rio de Janeiro CEP 21941-972, BrazilDepartment of Metallurgical and Materials Engineering, Universidade Federal do Rio de Janeiro-COPPE/UFRJ, Cx. Postal 68505, Rio de Janeiro CEP 21941-972, BrazilVale S.A., Complexo de Tubarão, Vitória CEP 29090-911, BrazilDepartment of Metallurgical and Materials Engineering, Universidade Federal do Rio de Janeiro-COPPE/UFRJ, Cx. Postal 68505, Rio de Janeiro CEP 21941-972, BrazilIt has been known that the performance of high-pressure grinding rolls (HPGR) varies as a function of the method used to laterally confine the rolls, their diameter/length (aspect) ratio as well as their condition, if new or worn. However, quantifying these effects through direct experimentation in machines with reasonably large dimensions is not straightforward, given the challenge, among others, of guaranteeing that the feed material remains unchanged. The present work couples the discrete element method (DEM) to multibody dynamics (MBD) and a novel particle replacement model (PRM) to simulate the performance of a pilot-scale HPGR grinding pellet feed. It shows that rotating side plates, in particular when fitted with studs, will result in more uniform forces along the bed, which also translates in a more constant product size along the rolls as well as higher throughput. It also shows that the edge effect is not affected by roll length, leading to substantially larger proportional edge regions for high-aspect ratio rolls. On the other hand, the product from the center region of such rolls was found to be finer when pressed at identical specific forces. Finally, rolls were found to have higher throughput, but generate a coarser product when worn following the commonly observed trapezoidal profile. The approach often used in industry to compensate for roller wear is to increase the specific force and roll speed. It has been demonstrated to be effective in maintaining product fineness and throughput, as long as the minimum safety gap is not reached.https://www.mdpi.com/2075-163X/11/8/801discrete element methodsimulationmultibody dynamicsparticle replacementhigh-pressure grinding rolls |
| spellingShingle | Victor Alfonso Rodriguez Gabriel K. P. Barrios Gilvandro Bueno Luís Marcelo Tavares Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations Minerals discrete element method simulation multibody dynamics particle replacement high-pressure grinding rolls |
| title | Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations |
| title_full | Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations |
| title_fullStr | Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations |
| title_full_unstemmed | Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations |
| title_short | Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations |
| title_sort | investigation of lateral confinement roller aspect ratio and wear condition on hpgr performance using dem mbd prm simulations |
| topic | discrete element method simulation multibody dynamics particle replacement high-pressure grinding rolls |
| url | https://www.mdpi.com/2075-163X/11/8/801 |
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