Application of discrete element method for simulating feeding conditions and size reduction in cone crushers

Paper in proceeding, 2010

The objective of this paper is to simulate the effects of segregation of the feed material entering the hopper on top of a typical cone crusher. A commercially available Discrete Element Method (DEM) software has been used to simulate and demonstrate some important aspects and phenomena and problems that are common in cone crushers. The first phenomenon of interest is segregation and uneven distribution of the feed entering a cone crusher. This is a common problem in many applications and leads to decreased comminution performance, poor product quality, uneven wear of the crusher manganese liners, high stress amplitudes and premature fatigue failures. This problem has been observed in many different applications and can sometimes severely affect the crusher performance in a negative way. A range of possible solutions to address the segregated feed is studied. The internal size reduction process occurring in a cone crusher is also modelled an simulated by applying DEM. The results of the simulations show the dynamics of the crusher and the interaction of the rock material and the machine as well as the breakage and the size reduction process of the rock particles. The results from the DEM simulations of the crushing process are confirming earlier results retrieved by analytical models and simulations. The number of compressive crushing zones is confirmed to be around 10-11 in the studied crusher. The capacity of the crusher is controlled by the choke level. The two different breakage modes, inter and single particle, is clearly seen in the simulations. In addition, some new insights in the internal size reduction process are gained.