Critical Assessment of Novel Developments in HPGR Technology Using DEM.

Area of Science:

• Mineral Processing
• Mechanical Engineering
• Materials Science

Background:

• High-pressure grinding roll (HPGR) technology has advanced with new wear protection and confinement systems to improve product homogeneity.
• Modeling and simulation tools are maturing, enabling detailed analysis of novel HPGR developments.

Purpose of the Study:

• To critically assess two recent advances in HPGR technology: spring-loaded cheek plates and the offset roller press.
• To evaluate the effectiveness of these advancements using a hybrid simulation approach.

Main Methods:

• A hybrid approach combining discrete element method (DEM), particle replacement model, and multibody dynamics was applied to a phenomenological population balance model.
• Advanced simulations utilized force and torque controllers within EDEM 2022.1 software to model material-geometry interactions.

Main Results:

• Spring-loaded cheek plates significantly reduced lateral material bypass by up to 65% under severe wear conditions.
• The offset roller press demonstrated the capability to produce finer products compared to traditional designs, albeit with lower throughput and higher potential wear.

Conclusions:

• Spring-loaded cheek plates offer a viable solution for mitigating material bypass and wear in HPGR operations.
• The offset roller press presents a trade-off between product fineness and operational efficiency, requiring careful consideration for specific applications.