Simulating a laboratory-scale cone crusher in DEM using polyhedral particles.

Until now computer simulation has already successfully assisted in improving the design and operation of cone crushers in the mining and aggregate industries. However, simulations using the discrete element method, coupled to realistic breakage models, are the next step towards designing confidently these machines in a fully virtual environment. The work shows the application of a novel breakage model fitted using single-particle breakage information and polyhedral particles to simulate a laboratory-scale cone crusher. Simulations of crushing three materials with widely different characteristics were in good agreement with experiments for throughput and only reasonably good for specific energy and product size. Sensitivity of simulations to closed side setting, stroke and frequency showed good qualitative agreement to experience. Simulations of crushing of blends containing mixtures of tough and soft components then demonstrated that crusher throughput does not drop proportionally to the increase in the amount of tough material in the feed. Unlabelled Image • Simulation of a laboratory-scale cone crusher using DEM with polyhedral particles. • Good agreement between measured and simulated capacity for three materials. • Reasonable agreement between measured and simulated specific energy and size. • Studied effect of CSS, eccentric throw and speed on crusher performance. • Crushing binary mixtures simulated, showing impact of tough component on throughput. [ABSTRACT FROM AUTHOR]