Some benefits of using studded surfaces in high pressure grinding rolls

Lim, Woochul; Weller, K.R.

doi:10.1016/s0892-6875(98)00131-9

Cited by 19 publications

(5 citation statements)

References 4 publications

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“…Typically, surface wear patterns within HPRGs follow the pressure profile along the roll length, thus providing a more pronounced wear in the center of the rolls, often with parabolic and trapezoidal shapes [36]. The prevention of roll surface wear involves proper material selection [9], surface wear protection designs [37] and understanding the different wear patterns formed along the rolls, which have been achieved in the present work and in previous works by the authors [22]. In this regard, the results presented in Sections 3.1 and 3.2 show the different regions along the roll length that are more susceptible to significant roll surface wear when analyzing the different technologies.…”

Section: Analysis From a Materials Perspectivementioning

confidence: 99%

“…However, its first application to hard rock (UCS > 300 MPa) in the Cyprus Sierrita copper concentrator in the United States proved to be a challenge [6], owing to the intensive wear of the rolls and, in consequence, the low mechanical availability of the machine. These challenges were only overcome through innovations in the technology, namely the implementation of rolls fitted with tungsten carbide studs, as well as Hexadur ® technology, which dramatically improved the lifetime of rolls in hard rock applications [3,[7][8][9].…”

Section: Introductionmentioning

confidence: 99%

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Critical Assessment of Novel Developments in HPGR Technology Using DEM

Rodriguez,

Barrios,

Campos

et al. 2024

Materials

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Advances in high-pressure grinding roll (HGPR) technology since its first commercial application in the cement industry include new roll wear protection techniques and new confinement systems. The latter contribute to reductions in the edge effects in an attempt to reach a more homogenous product size along the rolls. Additional advances in this technology have been made in recent years, while modeling and simulation tools are also reaching maturity and can now be used to subject such novel developments to detailed scrutiny. This work applies a hybrid approach combining advanced simulations using the discrete element method, the particle replacement model and multibody dynamics to a phenomenological population balance model to critically assess two recent advances in HPGR technology: spring-loaded cheek plates and the offset roller press. Force and torque controllers, included in the EDEM 2022.1 software, were used to describe the responses of the geometries in contact with the granular material processed. Simulations showed that while the former successfully reduced the lateral bypass of the material by as much as 65% when cheek plates became severely worn, the latter demonstrated lower throughput and higher potential wear but an ability to generate a finer product than the traditional design.

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Section: Analysis From a Materials Perspectivementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Critical Assessment of Novel Developments in HPGR Technology Using DEM

Rodriguez,

Barrios,

Campos

et al. 2024

Materials

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“…For details, refer to Dhawan et al (2012). The nip angle, depending entirely on the feed characteristics and roll surface pattern, ranges from 4 degrees up to 10 or 11 degrees (Schewechten and Mulburn, 1990;Schönert, 1991;Lim and Weller, 1999).…”

Section: Scale-up and Sizing Of Hpgrmentioning

confidence: 99%

A Review of the Modeling of High Pressure Grinding Rolls

Rashidi

Rajamani

Fuerstenau

2017

KONA

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High Pressure Grinding Rolls (HPGR) technology is accepted as an energy-efficient and cost-effective alternative for treating specific mineral ore types. HPGR technology has been advancing within manufacturing facilities and research centers since its first installation in 1985. Over the last three decades much of the literature on HPGR have focused on the industrial applications and trade-off studies in comparison with semi-autogenous and ball milling circuits. Literature on fundamental studies of HPGR technology has been very limited. This paper aims to provide a review of the modeling of high pressure grinding rolls.

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“…The studded rolls mainly consist of three parts, the roller shaft, the stud-lining and the stud. Lim [21] discovering some benefits of using stud embedded surfaces in HPGR. Rashidi [22] actually processes cement materials by embedding cylindrical studs into the rolls surface.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Roller Press Surface and Stud Based on FEM Simulation

Wang,

Du,

2023

Applied Sciences

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As an emerging grinding equipment, roller presses are widely used in Cement industry. The current problem with roller press is that the rolls surface is prone to wear and needs to be replaced regularly. This greatly reduces the service life of the roller press and affects the development of the roller press. Therefore, how to reduce the wear on the surface of the roller press and increase the service life of the roller press is an urgent problem that needs to be solved for the current roller press. Current research mainly focuses on the mechanism research of roller press wear and the optimization of rolls surface structure. In this paper, the extrusion force between the stud-lining and the material is calculated by analyzing the stress of the studded rolls under actual working conditions and the compression and rebound characteristics of material layer. The failure modes of studded rolls are mainly divided into two parts. On the one hand, it is fatigue cracking of the roller shaft and stud-lining. On the other hand, it is cracking at the contact between the stud-lining and the stud, and the fracture of the stud. Because the failure modes of the studded rolls are divided into two parts, the studded rolls are divided into two parts for simulation by using ANSYS 18.0. Firstly, the static analysis is carried out on the roller shaft and the stud-lining, and the distribution cloud diagram of the stress and contact pressure of the roller shaft and the stud-lining is obtained, and the stress concentration area is optimized. After optimization, the contact pressure between the roller shaft and the stud-lining is reduced by about 50%. The maximum equivalent stress of the roller shaft and stud-lining has also been reduced. Secondly, a static analysis was conducted on the stud-lining and studs. Since the stud-lining of the studded rolls are composed of stud holes arranged in a certain order. Therefore, stress concentration is prone to occur around the stud hole. The simulation experiment was carried out by changing the optimization schemes such as the assembly method of the stud and the stud-lining, the distance between the studs, and the length of the stud. To reduce the stress concentration of stud and stud-lining. After optimizing the model of the stud and stud-lining, the maximum equivalent stress of the stud-lining and stud decreased by about 10% and 25% respectively. Through the optimized design of roller shafts, stud-lining and studs. The service life of the studded rolls can be effectively improved and the production cost can be reduced. This can provide a reference for the design of the studded rolls.

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Some benefits of using studded surfaces in high pressure grinding rolls

Cited by 19 publications

References 4 publications

Critical Assessment of Novel Developments in HPGR Technology Using DEM

Critical Assessment of Novel Developments in HPGR Technology Using DEM

A Review of the Modeling of High Pressure Grinding Rolls

Investigation of Roller Press Surface and Stud Based on FEM Simulation

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