Particle Breakage Research Articles

Exploring the Regimes of Particle Behavior upon Impact via the Discrete Element Method.

Discrete element method simulations are conducted to probe the various regimes of post-impact behavior of particles with solid surfaces. The impacting particles are described as spherical agglomerates consisting of smaller constituent (or primary) particles held together via surface adhesion. Under the influence of a wide range of impact velocities and particle surface energies, five distinct behavioral regimes-rebounding, vibration, fragmentation, pancaking, and shattering-are identified, and force transmission patterns are linked to post-impact behavior. In the rebounding regime, the coefficient of restitution decreases linearly as impact velocity increases and the particle agglomerate experiences compaction. In the fragmentation regime, rebound velocity generally decreases with increasing fragment size. The rebound velocity of fragments decreases with time except for the smallest fragments, which can increase in velocity due to collisions with other fragments of high velocity. Particle breakage in the pancaking regime does not follow common mechanistic models of breakage.

Effect of axial stress-induced coal particle breakage on the evolution laws of coal spontaneous combustion characteristics and limit parameters of loose broken coal

Coal particles are broken to varying degrees under the axial stress, thereby affecting the particle size distribution, which has an essential impact on coal spontaneous combustion (CSC). This work investigated the evolution behavior of the characteristic parameters and limit parameters of the coal oxidation process under different breakage degrees. Results showed that as the axial stress increased, the breakage degrees of coal gradually increased, while the permeability gradually declined. The increase in the breakage degree of particle induced by axial stress would promote the CSC process and increase the risk of CSC. The promotion effect reached the most prominent at 12 MPa and began to decrease at 15 MPa. Particle breakage and increasing specific surface area caused by stress were responsible for the change in CSC characteristic parameters. The reduction in permeability caused by stress dominated the changes in CSC limit parameters.

A comprehensive evaluation on particles breakage characteristics of waste argillaceous gangue as subgrade filler

Reutilising waste argillaceous gangue (AG) in road engineering is crucial to reducing its environmental pollution. To effectively control settlement and long-term performance of subgrade filled with AG, the effects of humidification and loading on the particle crushing evolution of AG were investigated. The effects of dry-wet cycles, compaction work, and initial coarse grain content (CGC) on the breakage characteristics were evaluated. The relationship among fractal dimension D and compaction work, initial CGC, and breakage index Bg was established. The results show that the initial CGC and compactness are essential factors affecting the breakage characteristics of AG. It is recommended that the CGC be controlled at 50% when AG is used as subgrade filler. The fractal dimension increases logarithmically with the increase of compaction work and decreases linearly with the rise of CGC. Fractal dimensions D and Bg can effectively evaluate the breaking process of AG and the gradation after compaction.

Enhancing geomechanical characteristics of calcium sulfoaluminate (CSA) cement-treated soil under low confining pressures

This study examines the efficacy of employing calcium sulfoaluminate (CSA) cement, an environmentally friendly binder, for enhancing the geomechanical characteristics of sand, particularly under low confining pressure conditions. A series of triaxial consolidated drained tests were performed on sand samples treated with varying content (5, 7, and 10%) of CSA cement and 10% ordinary Portland cement (OPC) under various low confining pressures (50, 100, 200, and 400 kPa). The test findings demonstrated the importance of cement content and confining pressure on the mode of failure, stress–strain and volumetric behavior, failure characteristics, and shear strength parameters of the treated quartz sand. After a curing period of 14 days, samples treated with 10% CSA cement exhibited a remarkable 212% increase in peak deviator stress and an 89% reduction in axial strain at failure, indicating higher initial stiffness compared to untreated samples under a 400 kPa confining pressure. Furthermore, the samples treated with 10% CSA exhibited higher peak deviator stress, initial stiffness, and strength development compared to those treated with 10% OPC. The scanning electron microscopy analysis provides insights into particle breakage and bond degradation processes, which increase with confining pressure in CSA-treated samples. Also, the mode of failure analysis reveals a transition from ductile to slightly brittle behavior with increasing cement content. Notably, the geomechanical properties of the treated material emphasized the significant impact of CSA cement on soil improvement. Thus offering a sustainable alternative for soil improvement in construction projects.

Spatial reconstruction, microstructure-based modeling of compressive deformation behavior, and prediction of mechanical properties in lightweight Al-based entropy alloys

Lightweight Al-based entropy alloys are newly emerged materials with promising potential for structural applications; however, their modeling and strengthening prediction require further exploration. In this study, the spatial distributions of various phases in three Al-based entropy alloys were investigated. A closely interconnected intermetallic compound (IC) network comprising Al2Cu and Al45Cr7 phases was identified. Finite element (FE) modeling was conducted based on the reconstructed three-dimensional microstructure to simulate compressive deformation behavior. The IC network served as the main stress bearer during deformation. Thin sections in the Al2Cu network were the weak sites where stress concentration and damage first occurred. However, the breakage of this limited region contributes to relatively coordinated deformation and extended plasticity. The breakage of large particles accounts for the final alloy failure. The results of the FE model were compared with the experimentally measured stress–strain behavior and mechanical properties, showing very good agreement. Given the non-uniform distribution of strain and stress during deformation, a strengthening model, merging the Voigt and Reuss models, was also developed to predict the mechanical properties of Al-based entropy alloys with the aim of facilitating Al-based entropy alloy development.

Study on size effect and crushing characteristics of gangue-filling material under the confined compression

ABSTRACT The diameter, particle size distribution, and diameter-height ratio of coal gangue backfill material directly affect its mechanical behavior. This study investigated the influence of different particle sizes on the bearing characteristics and particle breakage of coal gangue backfill material under constrained compression through orthogonal experiments. A numerical model of randomly geometrically filled stones under compression was developed to reveal the micro-damage mechanism of coal gangue backfill material under different particle size effects. The results indicate that the diameter Rd of coal gangue backfill material has the greatest impact on its mechanical behavior, followed by the particle size distribution Rg, with the diameter-height ratio Rd-h having the least impact. The diameter significantly affects the compressive strength of the samples, with larger diameters leading to poorer initial force chain stability and lower compressive strength. The particle size distribution has a significant impact on sample breakage, with the breakage rate and fractal dimension increment being negatively correlated with the initial particle size distribution. Particle breakage in the samples gradually progresses from the periphery towards the center, with tensile failure being the primary mode of damage.

Effect of compression and shear on particle breakage of silica and calcareous sands

Effect of compression and shear on particle breakage of silica and calcareous sands

An Image-based method for evaluating changes in particle size and morphology distributions of aggregate materials after vibratory compaction test

Particle breakage and abrasion of aggregate materials can be induced by field compaction during construction, which adversely affects their mechanical properties. However, current compaction quality control testing does not evaluate changes in particle size distribution and particle morphology of aggregate materials due to the lack of fast and inexpensive testing methods. In this study, a modified watershed-based segmentation image analysis method and computational geometry algorithms were used to quickly quantify changes in particle size and morphology distributions of a large amount of contacting aggregate particles. The accuracy and required minimum sample size of the image analysis method were statistically evaluated. Compared to the conventional ASTM C136 aggregate sieve analysis test, the image analysis method conducted on a 40% sample size of the conventional method yielded less than 6% difference between the results, which can meet the ASTM C136 test repeatability criteria. In addition, demonstration tests were conducted to incorporate the image analysis method into a laboratory vibratory compaction test for evaluating the overall particle size and morphology changes of an aggregate material after compaction. Results indicate that the initial gradation and water content of the aggregate material can influence the particle breakage and abrasion characteristics of aggregate materials under compaction.

Triaxial behavior of unreinforced and geogrid-reinforced calcareous gravelly sand: Experiment and discrete element modelling

Geogrid reinforcement is a feasible technique for improving the mechanical and deformation behaviors of calcareous gravelly sand that is predominantly distributed in reclaimed foundations as construction materials. However, the shear behavior of geogrid-reinforced calcareous gravelly sand still remains unclear. In this paper, a series of large-scale drained consolidated triaxial compression tests (the specimen 300 mm in diameter by 600 mm in height) were conducted to investigate the effects of confining pressure, moisture content and geogrid inclusion on the mechanical and deformation behaviors of calcareous gravelly sand. The dilation effect, strain-softening behavior, reinforcing effect and particle breakage characteristics of unreinforced and geogrid-reinforced calcareous gravelly sand were comprehensively analyzed and discussed. Additional analysis was also performed from a microscopic perspective using the three-dimensional discrete numerical modelling. The experimental results indicate that calcareous gravelly sand exhibited a greater resistance to strain-softening tendency, and produced a higher susceptibility to crushing under the same input energy than calcareous coarse sand. Geogrid inclusion can effectively mitigate the susceptibility of calcareous gravelly sand to volumetric dilation through constraining the lateral expansion within the reinforced zone, and thus substantially increased the peak shear strength. Moreover, particle breakage appeared to be insensitive to geogrid reinforcement and water content, but increased significantly with increasing confining pressures. The numerical results further indicate that the mechanical response of geogrids was regulated by axial strain and confining pressure. As axial strain was greater than 10%, increased confining pressure resulted in a wider area of stress concentration within the geogrid meshes, and the upper geogrid sustained a greater contact force and tensile strain. The findings in this study are of practical significance for the design and construction of structures in calcareous gravelly sand reinforced with geogrids.

The ordered lattice host framework induced guest Li+ disordering in high performance cobalt-free Ni-rich cathode materials

Recently, due to high price, resource shortage and unstable supply of cobalt, the development of low-cost cobalt-free Ni-rich cathodes has attracted extensive attention with the ever-increasing lithium-ion batteries (LIBs) industry. Selecting cost-effective elements to replace cobalt in Ni-rich cathodes is urgent. However, the principle of structural design of Ni-rich cathode remains unclear, hampering the selection of alternative elements. Herein, the cobalt-free cathodes of LiNi0.95Mg0.05O2 (NiMg) and LiNi0.95Mn0.05O2 (NiMn) are designed as alternatives to LiNi0.96Co0.04O2 (NiCo). NiMg has comparable cycle stability with NiCo, while NiMn has inferior cycle performance. Reverse Monte Carlo modelling was used to generate structural model and uncover local structure by fitting pair distribution function. It reveals Mn causes more severe Jahn-Teller distortions and disordered lattice host framework (Ni0.95M0.05O2, M = Co/Mn/Mg) than Co and Mg due to the strong size effect and coulomb interactions of Mn in Ni0.95Mn0.05O2 layer. The outstanding cycle stability of NiMg and NiCo originates from the ordered lattice host frameworks, which relieve stress and inhibit particle breakage during cycle. Meanwhile, the ordered lattice host framework induced guest Li+ disordering reduces Li+ diffusion energy barrier, improving the rate capability. This study provides a new perspective for the structural design of cobalt-free Ni-rich cathodes.

Breakage Indices for Constitutive Models to Track the Evolution of Particle Crushing Under Continuous Shearing

Researchers have developed numerous breakage indices, predominantly relying on comparisons between pre- and post-test Grain Size Distribution (GSD) curves determined through conventional sieve analysis. Although these indices enable a precise estimation of particle breakage extent, a significant limitation arises when attempting to integrate them into constitutive models, especially when those models cannot consider GSD as an input. This paper addresses the need for tailored breakage indices designed to suit the specific requirements of different families of constitutive models. The new indices have been developed based on stress and strain tensor invariants or combinations thereof, ensuring the future ease of implementation into various constitutive models. The proposed equations have been validated using five different sets of experiments performed on rockfill material, calcareous, and quartz sands. The comparison between the available experimental data and the estimated degree of particle breakage using the suggested indices demonstrates their adequate performance. The novel indices can be integrated into different constitutive models, including hypoplastic, elastoplastic, and thermodynamically consistent approaches, as well as tested for their practical applicability for boundary value problems.

Enhancing Encapsulation Efficiency of Chavir Essential Oil via Enzymatic Hydrolysis and Ultrasonication of Whey Protein Concentrate-Maltodextrin.

This study focused on the characterization of emulsions and microparticles encapsulating Chavir essential oil (EO) by application of modified whey protein concentrate-maltodextrin (WPC-MD). Different physical, chemical, morphological, thermal, and antioxidant properties and release behavior of spray-dried microparticles were assessed. Antioxidant, solubility, emulsifying, and foaming activities of modified WPC were increased compared to those of primary material. The results indicated that the particle size distribution varied depending on the type of carriers used, with the smallest particles formed by hydrolyzed WPC (HWPC). Binary blends of modified WPC-MD led to improved particle sizes. The spray-drying yield ranged from 64.1% to 85.0%, with higher yields observed for blends of MD with sonicated WPC (UWPC). Microparticles prepared from primary WPC showed irregular and wrinkled surfaces with indentations and pores, indicating a less uniform morphology. The UWPC as a wall material led to microparticles with increased small cracks and holes on their surface. However, HWPC negatively affected the integrity of the microparticles, resulting in broken particles with irregular shapes and surface cracks, indicating poor microcapsule formation. Encapsulating EO using WPC-MD increased the thermal stability of EO significantly, enhancing the degradation temperature of EO by 2 to 2.5-fold. The application of primary WPC (alone or in combination with MD) as wall materials produced particles with the lowest antioxidant properties because the EO cannot migrate to the surface of the particles. Enzymatic hydrolysis of WPC negatively impacted microparticle integrity, potentially increasing EO release. These findings underscore the crucial role of wall materials in shaping the physical, morphological, thermal, antioxidant, and release properties of spray-dried microparticles, offering valuable insights for microencapsulation techniques.

Investigation of particle size effect on particle breakage of carbonate sand under one-dimensional compression

Previous studies on the particle-size effect have indicated that larger particles tend to exhibit lower strength under equivalent loading conditions; however, the underlying mechanism remains unclear. This study investigated the influence of particle size on the macrocompression behavior of carbonate sand by performing one-dimensional compression tests on various uniformly graded samples. The variations in particle size and shape resulting from particle breakage during compression were quantitatively analyzed. In addition, X-ray micro-tomography (μCT) is employed to obtain microstructural insights into the intra-particle porosity of carbonate sand particles, and its role in the particle size effect was further discussed.

Particle fracture regimes from impact simulations.

We introduce an approach to particle breakage, wherein the particle is modeled as an aggregate of polyhedral cells with their common surfaces governed by the Griffith criterion of fracture. This model is implemented within a discrete element code to simulate and analyze the breakage behavior of a single particle impacting a rigid plane. We find that fracture dynamics involves three distinct regimes as a function of the normalized impact energy ω. At low values of ω, the particle undergoes elastic rebound and no cracks occur inside the particle. In the intermediate range, the particle is damaged by nucleation and propagation of cracks, and the effective restitution coefficient declines without breakup of the particle. Finally, for values of ω beyond a well-defined threshold, the particle breaks into fragments and the restitution coefficient increases with ω due to kinetic energy carried away by the fragments. We show that particle damage, restitution coefficient, and fracture efficiency (the amount of energy input consumed for particle fracture) collapse well as a function of dimensionless scaling parameters. Our data are also sufficiently accurate to scale fragment size and shape distributions. It is found that fragment masses (volumes) follow a power-law distribution with an exponent decreasing with fracture energy. Interestingly, the average elongation and flatness of fragments are very close to those observed in experiments and lunar samples at the optimal fracture efficiency.

Continuously compressing crushing towards a dry processing method, a testing for graphite ore

In this study the comminution methods of graphite bearing ore were compared by using five different crushing methods, namely a jaw crusher, a roll crusher, uniaxial compression tests, and a new type of continuously compressing crushers. These new continuously compressing crushers were available in laboratory and pilot scales. The particles in the + 1700 µm size class produced by continuously compressing crushing were coarser and rougher in texture compared to the rounded particles produced traditionally by a jaw crusher. In the size class −100 µm, most of the graphite flakes were observed independently in the products of each of these crushing methods. The liberation of ultra-coarse-grained graphite flakes in size class + 300 µm was most observed after pilot-scale continuously compressing crusher. The shape and enrichment of the graphite flakes were very similar after both laboratory and pilot scale continuously compressing crushers. In contrast, the graphite flakes produced by jaw crusher appeared as broken particles in the form of accumulation of several layered and non-independent graphite flake structures. The results of this study demonstrate that the new innovative continuously compressing crushing method enables the enrichment of coarser and cleaner graphite, which has a much higher value and wider industrial applications compared to amorphous and fine-grained graphite.

Stiffness Anisotropy and Micro-Mechanism of Calcareous Sand with Different Particle Breakage Ratios Subjected to Shearing Based on DEM Simulations

Stress-induced anisotropy in calcareous sand can cause an uneven displacement in island reef engineering. In this study, stiffness, as a quantitative indicator, is explored to reveal the stress-induced anisotropy in calcareous sand. Based on the discrete element method, the stiffness anisotropic characteristics of calcareous sand during shearing, as well as the impact of particle breakage, are investigated by numerical simulations. Both the macro and micro responses, i.e., the maximum shear modulus, contact normal, strong and weak contact normal force, and the direction of particle breakage, are explored for calcareous sand with different particle breakage ratios. The results show that calcareous sand exhibits notable anisotropy during shearing, with the maximum shear modulus in the vertical direction (deviatoric stress direction) being significantly greater than that in the horizontal direction. Moreover, the higher the particle breakage rate, the lower the stiffness and its anisotropy. The micro-mechanism results indicate that the primary particle breakage during the shearing process occurs in the vertical direction. That is, the particle breakage weakens the strong contact force in the vertical direction, leading to a redistribution of the strong contact forces from the vertical direction to other directions. This redistribution mainly manifests in a decrease in the anisotropy of contact normal and contact vector within the sample, as well as a decrease in the proportion of strong contact forces in the overall contacts. This, in turn, reduces the shear strength and stiffness of calcareous sand, particularly in the vertical direction, and results in a decrease in the maximum shear modulus and its anisotropy. The maximum reduction can be up to 50% of the original value. These insights can provide a certain theoretical support for the uneven displacement and long-term stability of calcareous sand for islands and reefs.

Research on the Grinding Process of Superhard Particles in the Fluidized Bed Opposed Jet Mill Based on the CFD-DEM Methodology

The process of superhard particle breakage in the grinding zone of the fluidized bed opposed jet mill is investigated using the CFD-DEM (computational fluid dynamics-discrete element method) coupling method with the Tavares UFRJ Breakage Model in the present study. The effects of structural and operational parameters, such as target plate structure, nozzle position, air inlet velocity, and feed rate, on the equipment stress distribution, airflow velocity, pressure field, particle velocity, and cumulative particle size distribution are thoroughly studied to determine the optimal structural and operational parameters. Experimental validation is conducted, including scanning electron microscope (SEM) observation of particle morphology and analysis of particle size distribution of ground product particles. The simulation results indicate that the wear rate of the structure without a target plate is lower than that of the structure with a target plate in the grinding central zone. Therefore, the structure without a target plate is chosen for further investigation. The cumulative particle size distribution after grinding is influenced by nozzle position, air inlet velocity, and feed rate. The particle D50 is positively correlated with nozzle spacing and feed rate, while it is negatively correlated with air inlet velocity. The optimal grinding effect is achieved when the distance between the nozzle and the center of the grinding zone ranges from 52.5 mm to 72.55 mm, the air inlet velocity is 950 m/s, and the feed rate is 10.5 g/s. Through experimental investigation, it has been observed that when the feed rate is 10 g/s, the particle size distribution becomes more uniform. Furthermore, consistent trends in the cumulative particle size distribution in the experiment and simulation results can be found, which validates the present numerical model. It was observed that particles at low feed rates retain certain angular edges, while particle roundness increases at high feed rates.

Time-dependent soil–structure interaction analysis using a macro-element foundation model

The delayed settlement of foundations due to soil consolidation, creep or particle breakage can alter the internal load distribution and differential settlements in a superstructure through soil–structure interaction (SSI). The study introduces a novel methodology to simulate time-dependent SSI that overcomes the complexity of incorporating the time-dependent behaviour of foundations into routine SSI analysis. The proposed approach represents the superstructure as a condensed stiffness matrix, and replaces the foundations and underlying soils with macro-element foundation models that encapsulate the foundation–soil interaction into load–displacement relationships derived from constitutive models. To examine the performance of the proposed method, a macro-element model for time-dependent analysis of shallow foundations on sand was integrated with structural analysis to simulate two tests performed in a geotechnical centrifuge on a 3D-printed aluminium framed structure supported by footings on sand. The simulated responses of the superstructure and foundations were found to agree well with those observed in the centrifuge tests. Parametric analyses were conducted to investigate the effect of loading history, load level on the superstructure, and creep tendency of soil on post-construction load redistribution and differential settlements. The findings suggest that creep of foundations on sand facilitates load redistribution in the structure from heavily loaded sections to lightly loaded sections. Moreover, post-construction load redistribution depends on the differential creep between footings and should be considered for structures that are quickly constructed or at high levels of strength mobilisation (low factor of safety). Overall, the study highlights the potential of the proposed methodology in analysing the time-dependent SSI and its applicability in practical SSI analysis.

A Discrete Element Model of High-Pressure Torsion Test to Assess the Effect of Particle Characteristics in the Interface

Abstract Sand particles have been used since the early stages of the railway industry to increase adhesion at the wheel–rail contact. However, there is a limited understanding of how sand particle characteristics affect the tribological performance of the wheel–rail contact. In this work, the high-pressure torsion test used as a small-scale simulation of the interface is numerically modeled using the discrete element method (DEM). The DEM model is then utilized to investigate the effect of different particle characteristics on the frictional performance of wheel–rail contact which can provide more insight into micromechanical observations. The effects of various particle characteristics including their size, their number, the number of fragments the particles break into, and the parameters defining the behavior of the bonds between particle fragments on the coefficient of traction (COT) are systematically investigated. Results show that, in dry contacts, the coefficient of traction decreases when the size or number of sand particles increases. This can be attributed to the formation of weak shear bands between the fragments. Further investigation is needed for wet- and leaf-contaminated contacts. It is also found that the COT is more sensitive to the stiffness of the bond between the fragments of a broken particle compared to the strength of the bond. A limiting value for bond strength was identified, beyond which the sand particles exhibited ductile behavior rather than the expected brittle fracture. The findings from this study can be useful for future research on adhesion management in wheel–rail contact and the modeling approach can be scaled up to the full contact.

Pilot-scale investigation of high-temperature thermochemical energy storage based on the material system CaO/Ca(OH)2 in a bubbling fluidized bed

Utilizing fluidized bed technology for thermochemical energy storage with CaO/Ca(OH)2 is promising for temperatures from 400 °C to 600 °C in industrial-scale applications. Much progress has been made on laboratory scale to develop this technology in recent years. Continuously changing material properties throughout storage cycles, mainly due to particle breakage, are identified to be challenging for scale-up. Transferability to large-scale systems needs to be examined.Investigations on a pilot scale (di = 257 mm, h = 600 mm, steam for fluidization, 700 °C, 6 barg) are done. A temperature-induced (456 °C discharging and 586 °C charging) and a pressure-induced (1.5 barg discharging and 3.5 barg charging) cyclization is performed. The applicability of standard scaling rules (scaling factor of 17) is possible. Fluidization regimes and breakage rates are transferrable. A detailed experimental characterization of the storage materials fluidization properties that are crucial for scale-up is done using a fluidization test rig (di = 140 mm, h = 658 mm, nitrogen for fluidization, ambient temperature and pressure).