Study on laminated crushing characteristics of W-ore with dual-roller crusher

doi:10.3785/j.issn.1006-754X.2023.00.012

Chin J Eng Design

2023, Vol. 30

Issue (2): 212-225 DOI: 10.3785/j.issn.1006-754X.2023.00.012

Modeling, Simulation, Analysis and Decision

Study on laminated crushing characteristics of W-ore with dual-roller crusher

Yangbo LI^1,^2,³(

),Gaipin CAI^3,⁴(

),Liao RUAN³

^1.State Key Laboratory of Mineral Processing, BGRIMM Technology Group, Beijing 100160, China
^2.BGRIMM Machinery & Automation Technology Co. , Ltd. , Beijing 100160, China
^3.School of Mechanical and Electrical Engineering, Jiangxi University of Science and Technology, Ganzhou 341000, China
^4.Jiangxi Province Engineering Research Center for Mechanical and Electrical of Mining and Metallurgy, Ganzhou 341000, China

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Abstract

Aiming at the complexity of rock crushing process and the limitations of traditional simulation models, which reflects the little information about the replacement particle groups and can not locate a particle in the replacement particle groups, resulting in the simulated particles can not be broken continuously and the simulation accuracy is low, an improved crushing model developed by the discrete element application program interface is proposed, which is the bonded particle model (BPM) with multiple replacements. This method realizes the multiple continuous replacements of particles during the crushing process, which is closer to the actual crushing process and can improve the simulation accuracy. Based on the three-dimensional model of dual-roller crusher and the W-ore particle groups after parameter calibration, the visual simulation analysis of laminated crushing of W-ore particle groups in crusher was carried out, and the laminated crushing characteristics of the dual-roller crusher were studied through indoor tests to verify the effectiveness of numerical simulation. The results showed that: the relationship between the force on W-ore particles and the crushing rate obtained through simulation indicated that the dual-roller crusher could achieve laminated crushing; the error of particle size distribution after crushing was 0.889?1.940 mm, and the particle size distribution after crushing met the normal distribution, which verified the simulation analysis was accurate and effective. The laminating crushing test results of W-ore with different particle size ratios showed that the influence of particle interaction on crushing efficiency was greater than that of particle low porosity. The research results provide a basis for improving the production efficiency of dual-roller crusher, and the proposed improved crushing model also provides a new method for the study of material crushing.

Key words： improved crushing model bonded particle model dual-roller crusher visual simulation lamination crushing test

Received: 20 June 2022 Published: 06 May 2023

CLC:

TH 11

Corresponding Authors: Gaipin CAI E-mail: 2827648047@qq.com;cgp4821@163.com

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Cite this article:

Yangbo LI,Gaipin CAI,Liao RUAN. Study on laminated crushing characteristics of W-ore with dual-roller crusher. Chin J Eng Design, 2023, 30(2): 212-225.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2023.00.012 OR https://www.zjujournals.com/gcsjxb/Y2023/V30/I2/212

对辊破碎机对钨矿石的层压破碎特性研究

针对岩石破碎过程的复杂性以及传统仿真模型的局限性——反映替换颗粒群信息少且无法定位替换颗粒群中某一颗粒，使得所模拟的颗粒无法被连续破碎，导致仿真精度较低等问题，提出了通过离散元应用编程接口开发的改进破碎模型——多次替换的颗粒黏结模型（bonded particle model, BPM）。该方法能实现颗粒在破碎过程中的多次连续替换，更加贴近实际破碎过程，可提升仿真精度。基于对辊破碎机的三维模型与参数标定后的钨矿石颗粒群，对破碎机内的钨矿石颗粒群进行层压破碎可视化仿真分析，并结合室内试验研究了对辊破碎机的层压破碎特性，以验证数值仿真的有效性。结果表明：通过仿真得到的钨矿石颗粒受力与破碎速率的关系说明对辊破碎机可实现层压破碎；钨矿石碎后粒径分布误差为0.889~1.940 mm，且碎后粒径分布满足正态分布，说明仿真分析准确且有效。不同粒径配比下的钨矿石层压破碎试验结果表明，颗粒间相互作用力对破碎效率的影响程度大于颗粒低孔隙率。研究结果为进一步提高对辊破碎机的生产效率提供了依据，且所提出的改进破碎模型为物料的破碎研究提供了一种新方法。

关键词： 改进破碎模型, 颗粒黏结模型, 对辊破碎机, 可视化仿真, 层压破碎试验

Table 1 Material intrinsic parameters of steel and W-ore

Fig.1 Comparison between simulation results and experimental results of stacking angle of W-ore particles

Table 2 Contact parameters of W-ore

Fig.2 Extrusion test instrument

Fig.3 Crushing results of W ore by compression

Fig.4 Continuous crushing model of multi-shape W-ore particles

Table 3 Particle size distribution of W-ore after compression crushing

Fig.5 Schematic of discrete element Hertz-Mindlin contact model

Fig.6 Uniaxial compression test results of W-ore

Fig.7 Changes of force chain of W-ore during uniaxial compression simulation

Table 4 Setting of bonding parameters for W-ore particles

Fig.8 Comparison of stress-strain curves of W-ore during uniaxial compression

Table 5 Error between simulation and experimental values of stress of W-ore under different bonding parameters

Fig.9 Continuous replacement process of W-ore particles in the crushing chamber of dual-roller crusher

Fig.10 W-ore particle clusters and grid division of rollers in dual-roller crusher

Table 6 Setting of particle size and mass of W-ore particles in simulation analysis

Fig.11 Visual simulation of W-ore particles crushing process

Fig.12 Variation curves of maximum pressure on W-ore particles and rollers during crushing process

Fig.13 Crushing information of W-ore particles within a certain time

参数	数值
$q 0$	73.68
$q 1$	2 752
$q 2$	193.4
$q 3$	-2 316
$q 4$	997.6
$q 5$	-114.9

Table 7 Fitting parameter values of net force on W-ore particles and time

参数	数值
$a 0$	3.415
$a 1$	5.029×10⁴
$b 0$	1.245
$b 1$	0.003 16
c₁	-5.028×10⁴

Table 8 Fitting parameter values of W-ore particle quantity and time

Fig.14 W-ore crushing test platform and corresponding tools

Fig.15 Comparison of proportion and quality of particles with different sizes of W-ore after crushing

Table 9 Fitting parameters values of particle size distribution of W-ore after crushing

Table 10 Error between simulation results and experimental results of mass fraction of W-ore after crushing

Table 11 Feed particle size ratio of W-ore (mass fraction) %

Fig.16 W-ore raw materials for laminated crushing test and their crushed particles

Fig.17 Particles size distribution of W-ore after crushing under different feed particle size ratios

Table 12 Feed particle size ratio of W-ore and corresponding porosity


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