Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations

It has been known that the performance of high-pressure grinding rolls (HPGR) varies as a function method used to laterally confine rolls, their diameter/length (aspect) ratio well condition, if new or worn. However, quantifying these effects through direct experimentation in machines with reasonably large dimensions is not straightforward, given challenge, among others, guaranteeing feed material remains unchanged. The present work couples discrete element (DEM) multibody dynamics (MBD) and novel particle replacement model (PRM) simulate pilot-scale HPGR pellet feed. shows rotating side plates, particular when fitted studs, will result more uniform forces along bed, which also translates constant product size higher throughput. edge effect affected by roll length, leading substantially larger proportional regions for high-aspect rolls. On other hand, from center region such was found be finer pressed at identical specific forces. Finally, were have throughput, but generate coarser worn following commonly observed trapezoidal profile. approach often industry compensate roller wear increase force speed. demonstrated effective maintaining fineness long minimum safety gap reached.