Industry Scale Optimization: Hammer Crusher and DEM Simulations

Robert Król,Błażej Doroszuk

doi:10.3390/min12020244

Abstract

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.

Highlights

The optimization of various crusher types is very demanding because many factors influence the final product of the crushing process
Research on copper ore crushers shows that their components are exposed to damage [4], which can be detected by vibration analysis [5,6]
The jaw was set to move in the range of approx. 32.5 to 46.5 mm

Summary

Introduction

The optimization of various crusher types is very demanding because many factors influence the final product of the crushing process. 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]. The most important criterion to be considered when designing a crusher is its failurefree operation. Research on copper ore crushers shows that their components are exposed to damage [4], which can be detected by vibration analysis [5,6]. A breaker failure may cause the processing line to stop working or reduce its efficiency [7]

Objectives

Methods

Results