Investigating operational parameters that would affect the performance of a laboratory impact crusher

Abstract

Impact crushers are widely used in the mining and construction industries to crush and size various types of materials. However, their performance can be affected by several operational parameters, including the rotor speed, rotor position, number of rotors and relative direction of rotors. The aim of this study is to investigate the impact of these parameters through a numerical model, Discrete Element Method (DEM). A Laboratory scale impact crusher was simulated using various configurations while also making use of a range of materials with known breakage data to predict expected grinding rates in the crusher. The Discrete Element Method (DEM) algorithm is a computational approach utilized to solve complex problems that involve numerous interacting bodies. In this technique, the dissipative forces (such as normal, tangential or frictional forces) at contact points are simulated using a spring-slider-dashpot model. While the movement of particles is computed using Newton's laws of motion. During simulations, the information about contact events are captured and saved in output files, which can later be used for various purposes. The energy spectra, a record of energy involved in every contact event of one such output that is utilised to predict the breakage of particles of different materials provided their breakage characteristics are known. Using the DEM simulation various equipment configurations of a laboratory impact crusher were conducted. The results showed that the rotor speed, number of rotors, rotor direction and rotor position significantly influenced the number of impacts and energy spectrum produced by the crusher. The crusher operation configuration significantly affected the energy spectra obtained. Additionally, the comparison of the crushing characteristics of the double rotor impact crusher to those of the single rotor impact crusher revealed differences in their performance that can be attributed to their design and operating parameters. - 3 - [OFFICIAL] The findings of this study provide valuable insights into the design and operation of impact crushers, and can be used to improve their efficiency and productivity when processing a variety of materials with different operational parameters.