Discrete element modelling of the influence of lifters on power draw of tumbling mills

Crushing and grinding are the most energy intensive part of the mineral recovery process. A major part of rock size reduction occurs in tumbling mills. Empirical models for the power draw of tumbling mills do not consider the effect of lifters. Discrete element modelling was used to investigate the effect of lifter condition on the power draw of tumbling mill. Results obtained with PFC3D code show that lifter condition will have a significant influence on the power draw and on the mode of energy consumption in the mill. Relatively high lifters will consume less power than low lifters, under otherwise identical conditions. The fraction of the power that will be consumed as friction will increase as the height of the lifters decreases. This will result in less power being used for high intensity comminution caused by the impacts. The fraction of the power that will be used to overcome frictional resistance is determined by the material's coefficient of friction. Based on the modelled results, it appears that the effective coefficient of friction for in situ mill is close to 0.1. (C) 2003 Elsevier Science 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.

Comparison of DEM and experiment for a scale model SAG mill

Predictions of flow patterns in a 600-mm scale model SAG mill made using four classes of discrete element method (DEM) models are compared to experimental photographs. The accuracy of the various models is assessed using quantitative data on shoulder, toe and vortex center positions taken from ensembles of both experimental and simulation results. These detailed comparisons reveal the strengths and weaknesses of the various models for simulating mills and allow the effect of different modelling assumptions to be quantitatively evaluated. In particular, very close agreement is demonstrated between the full 3D model (including the end wall effects) and the experiments. It is also demonstrated that the traditional two-dimensional circular particle DEM model under-predicts the shoulder, toe and vortex center positions and the power draw by around 10 degrees. The effect of particle shape and the dimensionality of the model are also assessed, with particle shape predominantly affecting the shoulder position while the dimensionality of the model affects mainly the toe position. Crown Copyright (C) 2003 Published by Elsevier Science B.V. All rights reserved.

The tree cut and merge algorithm for estimation of network reliability

This article presents Monte Carlo techniques for estimating network reliability. For highly reliable networks, techniques based on graph evolution models provide very good performance. However, they are known to have significant simulation cost. An existing hybrid scheme (based on partitioning the time space) is available to speed up the simulations; however, there are difficulties with optimizing the important parameter associated with this scheme. To overcome these difficulties, a new hybrid scheme (based on partitioning the edge set) is proposed in this article. The proposed scheme shows orders of magnitude improvement of performance over the existing techniques in certain classes of network. It also provides reliability bounds with little overhead.

An approach to verifying and debugging simulation models governed by ordinary differential equations: Part 2. Residuals analysis and a case study

In Part 1 of this paper a methodology for back-to-back testing of simulation software was described. Residuals with error-dependent geometric properties were generated. A set of potential coding errors was enumerated, along with a corresponding set of feature matrices, which describe the geometric properties imposed on the residuals by each of the errors. In this part of the paper, an algorithm is developed to isolate the coding errors present by analysing the residuals. A set of errors is isolated when the subspace spanned by their combined feature matrices corresponds to that of the residuals. Individual feature matrices are compared to the residuals and classified as 'definite', 'possible' or 'impossible'. The status of 'possible' errors is resolved using a dynamic subset testing algorithm. To demonstrate and validate the testing methodology presented in Part 1 and the isolation algorithm presented in Part 2, a case study is presented using a model for biological wastewater treatment. Both single and simultaneous errors that are deliberately introduced into the simulation code are correctly detected and isolated. Copyright (C) 2003 John Wiley Sons, Ltd.

Simulation supplements field studies to determine no-till dryland corn population recommendations for semiarid western Nebraska

In a 2-yr multiple-site field study conducted in western Nebraska during 1999 and 2000, optimum dryland corn (Zea mays L.) population varied from less than 1.7 to more than 5.6 plants m(-2), depending largely on available water resources. The objective of this study was to use a modeling approach to investigate corn population recommendations for a wide range of seasonal variation. A corn growth simulation model (APSIM-maize) was coupled to long-term sequences of historical climatic data from western Nebraska to provide probabilistic estimates of dryland yield for a range of corn populations. Simulated populations ranged from 2 to 5 plants m(-2). Simulations began with one of three levels of available soil water at planting, either 80, 160, or 240 mm in the surface 1.5 m of a loam soil. Gross margins were maximized at 3 plants m(-2) when starting available water was 160 or 240 mm, and the expected probability of a financial loss at this population was reduced from about 10% at 160 mm to 0% at 240 mm. When starting available water was 80 mm, average gross margins were less than $15 ha(-1), and risk of financial loss exceeded 40%. Median yields were greatest when starting available soil water was 240 mm. However, perhaps the greater benefit of additional soil water at planting was reduction in the risk of making a financial loss. Dryland corn growers in western Nebraska are advised to use a population of 3 plants m(-2) as a base recommendation.

On the evaluation of some differential formulations for the pom-pom constitutive model

In recent years, progress has been made in modelling long chain branched polymers by the introduction of the so-called pompom model. Initially developed by McLeish and Larson (1998), the model has undergone several improvements or alterations, leading to the development of new formulations. Some of these formulations however suffer from certain mathematical defects. The purpose of the present paper is to review some of the formulations of the pom-pom constitutive model, and to investigate their possible mathematical defects. Next, an alternative formulation is proposed, which does not appear to exhibit mathematical defects, and we explore its modelling performance by comparing the predictions with experiments in non-trivial rheometric flows of an LDPE melt. The selected rheometric flows are the double step strain, as well as the large amplitude oscillatory shear experiments. For LAOS experiments, the comparison involves the use of Fourier-transform analysis.

A utilização da modelagem computacional semiquantitativa no estudo do sistema mola-massa

O artigo apresenta resultados da investigação sobre a integração de ambientes de modelagem computacional ao aprendizado exploratório de Física. Os resultados aqui apresentados são relativos ao estudo da interação e desempenho de alunos de ensino superior durante a utilização do ambiente de modelagem computacional semiquantitativo WLinkIt em uma atividade de conteúdo específico em Física: o sistema mola-massa. Os resultados mostram que os estudantes apresentaram habilidades para desenvolver um modelo sobre a situação proposta e relacionar o comportamento apresentado pelo modelo com o esperado por eles, alterar o modelo e explicar o comportamento apresentado pelas variáveis. Os resultados mostram também que as dificuldades apresentadas foram relacionadas à delimitação do sistema a ser estudado, ao entendimento da influência de uma variável sobre a outra, ao entendimento de quem é o agente causal do sistema, ao entendimento da função de uma ligação entre duas variáveis e ao entendimento dos conceitos envolvidos. Assim, o mapeamento desses aspectos é fundamental para o delineamento de pesquisas futuras no sentido de promover, na prática, a integração de Ambientes de Modelagem Computacional Semiquantitativos na sala de aula, mais especificamente para o estudo de tópicos de Física.

Modelagem da dispersão de odores em ambientes urbanos

O presente trabalho investigou o problema da modelagem da dispersão de compostos odorantes em presença de obstáculos (cúbicos e com forma complexa) sob condição de estabilidade atmosférica neutra. Foi empregada modelagem numérica baseada nas equações de transporte (CFD1) bem como em modelos algébricos baseados na pluma Gausseana (AERMOD2, CALPUFF3 e FPM4). Para a validação dos resultados dos modelos e a avaliação do seu desempenho foram empregados dados de experimentos em túnel de vento e em campo. A fim de incluir os efeitos da turbulência atmosférica na dispersão, dois diferentes modelos de sub-malha associados à Simulação das Grandes Escalas (LES5) foram investigados (Smagorinsky dinâmico e WALE6) e, para a inclusão dos efeitos de obstáculos na dispersão nos modelos Gausseanos, foi empregado o modelo PRIME7. O uso do PRIME também foi proposto para o FPM como uma inovação. De forma geral, os resultados indicam que o uso de CFD/LES é uma ferramenta útil para a investigação da dispersão e o impacto de compostos odorantes em presença de obstáculos e também para desenvolvimento dos modelos Gausseanos. Os resultados também indicam que o modelo FPM proposto, com a inclusão dos efeitos do obstáculo baseado no PRIME também é uma ferramenta muito útil em modelagem da dispersão de odores devido à sua simplicidade e fácil configuração quando comparado a modelos mais complexos como CFD e mesmo os modelos regulatórios AERMOD e CALPUFF. A grande vantagem do FPM é a possibilidade de estimar-se o fator de intermitência e a relação pico-média (P/M), parâmetros úteis para a avaliação do impacto de odores. Os resultados obtidos no presente trabalho indicam que a determinação dos parâmetros de dispersão para os segmentos de pluma, bem como os parâmetros de tempo longo nas proximidades da fonte e do obstáculo no modelo FPM pode ser melhorada e simulações CFD podem ser usadas como uma ferramenta de desenvolvimento para este propósito. Palavras chave: controle de odor, dispersão, fluidodinâmica computacional, modelagem matemática, modelagem gaussiana de pluma flutuante, simulação de grandes vórtices (LES).

Molecular dynamics computer simulation of scratch resistance testing of polymers: visualization

Experimental scratch resistance testing provides two numbers: the penetration depth Rp and the healing depth Rh. In molecular dynamics computer simulations, we create a material consisting of N statistical chain segments by polymerization; a reinforcing phase can be included. Then we simulate the movement of an indenter and response of the segments during X time steps. Each segment at each time step has three Cartesian coordinates of position and three of momentum. We describe methods of visualization of results based on a record of 6NX coordinates. We obtain a continuous dependence on time t of positions of each of the segments on the path of the indenter. Scratch resistance at a given location can be connected to spatial structures of individual polymeric chains.

Simulating scratch behavior of polymers with mesoscopic molecular dynamics

Part replacement and repair is needed in structures with moving parts because of scratchability and wear. In spite of some accumulation of experimental evidence, scratch resistance is still not well understood. We have applied molecular dynamics to study scratch resistance of amorphous polymeric materials through computer simulations. As a first approach, a coarse grain model was created for high density polyethylene at the mesoscale. We have also extended the traditional approach and used real units rather than reduced units (to our knowledge, for the first time), which enable an improved quantification of simulation results. The obtained results include analysis of penetration depth, residual depth and recovery percentage related to indenter force and size. Our results show there is a clear effect from these parameters on the tribological properties. We also discuss a "crooked smile" effect on the scratched surface and the reasons for its appearance.