Industrial Vertical Stirred Mills Screw Liner Wear Profile Compared to Discrete Element Method Simulations

Esteves, Priscila M.; Mazzinghy, Douglas Batista; Galéry, Roberto; Machado, Luís C. R.

doi:10.3390/min11040397

Cited by 16 publications

(11 citation statements)

References 16 publications

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“…In EDEM [23], the geometrical plastic deformation technique is related to the Archard wear model [24] based on a mesh deformation approach [25]. The Archard wear model is widely used both for the particles and geometries [14,16,17,19,20,[25][26][27], such as the evaluation of the wear of ballast and abrasive grain [26,27], the prediction of the wear of mill lifters [28] and local failure prediction of abrasive wear on tipper bodies [29]. The Archard wear model can be denoted as Equation (3).…”

Section: Geometrical Plastic Deformation Techniquementioning

confidence: 99%

“…Kalala et al [ 18 ] applied DEM to estimate adhesion, abrasion and impact wear in dry ball mills with further validation with industrial wear measurement. Esteves et al [ 19 ] compared the industrial vertical stirred mills screw liner wear profile to the measurements after more than 3000 h by using scaling-up procedures for rotational velocities. The predicted wear volumes obtained from the DEM model have a good agreement with the measured results when using a specific velocity.…”

Section: Introductionmentioning

confidence: 99%

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Pin-on-Disc Modelling with Mesh Deformation Using Discrete Element Method

2022

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The pin-on-disc test is a standard sliding wear test used to analyse sliding properties, including wear contour and wear volume. In this study, long-term laboratory test performance is compared with a short-term numerical model. A discrete element method (DEM) approach combined with an Archard wear model and a deformable geometry technique is used. The effect of mesh size on wear results is evaluated, and a scaling factor is defined to relate the number of revolutions between the experiment and the numerical model. The simulation results indicate that the mesh size of the disc has a significant effect on the wear contour. The wear depth and wear width follow a normal distribution after experiencing a run-in phase, while the wear volume has a quadratic relation with the number of revolutions. For the studied material combination, the calibration of the wear coefficient shows that the wear volume of the pin-on-disc test accurately matches the simulation results for a minimum of eight revolutions with a wear coefficient lower than 2 × 10−11𝑃a−1.

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Section: Geometrical Plastic Deformation Techniquementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Pin-on-Disc Modelling with Mesh Deformation Using Discrete Element Method

2022

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“…The discrete element method (DEM) has been used in the optimization of mining processes for several decades [18,19]. Initially, the optimizations were very simplified, but modern computers have enough computing power to allow attempts at simulating large-scale processes [20]. The method of discrete elements enables simulations of both the behavior of bulk materials and interactions of each particle with other particles and with the elements of the analyzed system separately.…”

Section: Introductionmentioning

confidence: 99%

“…While other publications focus on individual stages [8][9][10][11][12][13][14][20][21][22] of preparing or using a numerical model, this article describes the entire process from its first stage (sample collection) to its last stage (application of the model). An additional difficulty addressed in this work and not present in other publications lies in the complexity of the lithology of the modeled ore [17], which required the parameterization and the calibration schemes of numerical models to be adapted to this specific case.…”

Section: Introductionmentioning

confidence: 99%

Industry Scale Optimization: Hammer Crusher and DEM Simulations

Doroszuk

Król

2022

Minerals

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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.

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“…For the mining industry, the process of transferring bulk solids leads to surface wear of shovel buckets [2]. The vertical stirred mills are applied widely in mineral industries and the liner wear plays a significant role in the maintenance and operational costs [3]. Severe wear has been found in several locations on bulk handling equipment, for example, silo walls and bottom sections of the transfer chute [4].…”

Section: Introductionmentioning

confidence: 99%

The Influence of Particle Size on Sliding Wear of a Convex Pattern Surface

2022

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Sliding wear of bulk handling equipment (e.g., shovel bucket, mill and transfer chute) can be dramatically reduced by using a convex pattern surface compared to a flat surface, by adjusting the flow behavior of particles moving along the convex pattern surface. To study the effect of particle size relative to the dimensions of the convex pattern surface, a coarse graining technique is applied. Comparisons of bulk flow and wear behavior between the convex pattern and flat surfaces illustrate the two-sided effect of the convex pattern surface on sliding wear. The bulk flow behavior indicates that the particle size has a minor effect on the velocity and angular velocity of particles for the flat surface, while it has a significant effect on those of the convex pattern surface. The wear results show that the particle size has negligible influence on the sliding wear of a flat surface and a linear relationship with the sliding wear of the convex pattern surface. The convex pattern surface can reduce the sliding wear through influencing the flow behavior of the bulk material when the equivalent radius of the convex is larger than r50 of particles. This research reveals the relationship between the dimensions of the convex pattern and the particle size on the sliding wear caused by the interaction between bulk material and bulk handling equipment. The relationship should be carefully considered for the applications of the convex pattern surface to bulk handling equipment.

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Industrial Vertical Stirred Mills Screw Liner Wear Profile Compared to Discrete Element Method Simulations

Cited by 16 publications

References 16 publications

Pin-on-Disc Modelling with Mesh Deformation Using Discrete Element Method

Pin-on-Disc Modelling with Mesh Deformation Using Discrete Element Method

Industry Scale Optimization: Hammer Crusher and DEM Simulations

The Influence of Particle Size on Sliding Wear of a Convex Pattern Surface

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