Applying discrete element modelling to vertical and horizontal shaft impact crushers

The PFC3D (particle flow code) that models the movement and interaction of particles by the DEM techniques was employed to simulate the particle movement and to calculate the velocity and energy distribution of collision in two types of impact crusher: the Canica vertical shaft crusher and the BJD horizontal shaft swing hammer mill. The distribution of collision energies was then converted into a product size distribution for a particular ore type using JKMRC impact breakage test data. Experimental data of the Canica VSI crusher treating quarry and the BJD hammer mill treating coal were used to verify the DEM simulation results. Upon the DEM procedures being validated, a detailed simulation study was conducted to investigate the effects of the machine design and operational conditions on velocity and energy distributions of collision inside the milling chamber and on the particle breakage behaviour. (C) 2003 Elsevier Ltd. All rights reserved.

Modelling the size of the crushed zone around a blasthole

A new model to predict the extent of crushing around a blasthole is presented. The model is based on the back-analysis of a comprehensive experimental program that included the direct measurement of the zone of crushing from 92 blasting tests on concrete blocks using two commercial explosives. The concrete blocks varied from low, medium to high strength and measured 1.5 in in length, 1.0 m in width and 1.1 m in height. A dimensionless parameter called the crushing zone index (CZI) is introduced. This index measures the crushing potential of a charged blasthole and is a function of the borehole pressure, the unconfined compressive strength of the rock material, dynamic Young's modulus and Poisson's ratio. It is shown that the radius of crushing is a function of the CZI and the blasthole radius. A good correlation between the new model and measured results was obtained. A number of previously proposed models could not approximate the conditions measured in the experimental work and there are noted discrepancies between the different approaches reviewed, particularly for smaller diameter holes and low strength rock conditions. The new model has been verified with full scale tests reported in the literature. Results from this validation and model evaluations show its applicability to production blasting. (C) 2003 Elsevier Science Ltd. All rights reserved.

Discrete element modelling of power draw of tumbling mills

The power required to operate large mills is typically 5-10 MW. Hence, optimisation of power consumption will have a significant impact on overall economic performance and environmental impact. Power draw modelling results using the discrete element code PFC3D have been compared with results derived from the widely used empirical Model of Morrell. This is achieved by calculating the power draw for a range of operating conditions for constant mill size and fill factor using two modelling approaches. fThe discrete element modelling results show that, apart from density, selection of the appropriate material damping ratio is critical for the accuracy of modelling of the mill power draw. The relative insensitivity of the power draw to the material stiffness allows selection of moderate stiffness values, which result in acceptable computation time. The results obtained confirm that modelling of the power draw for a vertical slice of the mill, of thickness 20% of the mill length, is a reliable substitute for modelling the full mill. The power draw predictions from PFC3D show good agreement with those obtained using the empirical model. Due to its inherent flexibility, power draw modelling using PFC3D appears to be a viable and attractive alternative to empirical models where necessary code and computer power are available.