Rodriguez, V.A.; Barrios, G.K.P.; Bueno, G.; Tavares, L.M. Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations. Minerals2021, 11, 801.
Rodriguez, V.A.; Barrios, G.K.P.; Bueno, G.; Tavares, L.M. Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations. Minerals 2021, 11, 801.
It has been known that the performance of the High-Pressure Grinding Rolls (HPGR) varies as a function of method used to confine laterally 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 pilot-scale HPGRs grinding pellet feed. It shows that rotating side plates, in particular when fitted with studs, allow reaching 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 relatively constant with 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 used in industry to compensate for roller wear by increasing the specific force and roll speed has then been demonstrated to be effective to maintain and potentially even increase product fineness and throughput, as long as the minimum safety gap is not reached.
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