Fundamental_Models_Comminution_Presentation.pptx

Fundamental_Models_Comminution_Presentation.pptx

1. Fundamental Models in Comminution: Advanced Techniques in Mineral Processing Presented by: Professor in Metallurgy Target Audience: Metallurgical Engineering Students

2. Learning Objectives 1. Understand the application of Discrete Element Modeling (DEM) and Computational Fluid Dynamics (CFD) in comminution. 2. Learn how these advanced techniques improve the design and operation of comminution units. 3. Explore the potential for reduced downtime and increased energy efficiency through these models.

3. Introduction to Fundamental Models Fundamental models like DEM and CFD are increasingly used in modeling comminution units in mineral processing. Key Techniques: - Discrete Element Modeling (DEM): Simulates the behavior of particles within a mill. - Computational Fluid Dynamics (CFD): Simulates fluid behavior within the comminution units.

4. Discrete Element Modeling (DEM) Definition: DEM simulates discrete particles' behavior within a comminution unit. Applications: - Tumbling Mills: Improved understanding of charge dynamics. - Crushers and Stirred Mills: Reliable modeling of breakage processes. Advantages: DEM aids in designing mill internals and optimizing operations.

5. Computational Fluid Dynamics (CFD) Definition: CFD models the flow of fluids within comminution units. Applications: - Stirred Mills: Identification of the role of shear forces in size reduction. - Continuous Operations: Simulation of slurry movement and effects on charge motion. Benefits: CFD enhances the design by providing insights into fluid-particle interactions.

6. Combining DEM and CFD Integrated Modeling Approach: Combining DEM and CFD for comprehensive simulation of comminution processes. Examples: - Tumbling Mills: Interaction between particles and slurry. - Stirred Mills: Prediction of particle breakage and size reduction. Current Research: Includes continuous operation simulation and direct particle breakage prediction.

7. Visualization in DEM/CFD Models 3D Cutaway Images: DEM provides visualizations of particle motion within comminution units. Examples: - Pilot SAG Mill: Visualization of charge motion (e.g., Figure 5.6 from the text). - Stirred Mills: Series of images showing charge dynamics. Importance: Visualizations aid in designing and optimizing comminution units.

8. Validation of DEM/CFD Models Importance of Validation: Ensuring simulations match real-world behavior is critical. Validation Techniques: - Visual Inspection: Observing charge motion through transparent walls (e.g., Figure 5.7). - PEPT: Non-invasive tool for tracking particle motion. - Acoustic Monitoring: Detecting ball strikes in industrial-scale units. Outcome: Validated models provide reliable insights into comminution processes.

9. Case Study: Application of DEM in Tumbling Mills Problem: High downtime and inefficient energy use in traditional tumbling mills. Solution: Applying DEM to model charge dynamics and optimize mill internals. Outcome: Reduced downtime and improved energy efficiency, leading to cost savings and increased throughput.

10. Interactive Quiz Question 1: What is Discrete Element Modeling (DEM) primarily used for in mineral processing? A. Simulating fluid flow B. Modeling particle motion and breakage C. Designing chemical reagents D. Measuring ore hardness Answer: B Explanation: DEM models particle motion and breakage within comminution units.

11. Interactive Quiz (continued) Question 2: Which validation technique is used to compare DEM/CFD model predictions with real-world behavior? A. Visual Inspection B. Chemical Analysis C. X-Ray Diffraction D. Thermal Imaging Answer: A Explanation: Visual inspection, along with PEPT and acoustic monitoring, is used to validate DEM/CFD models.

12. Conclusion Summary: Advanced modeling techniques like DEM and CFD are revolutionizing the design and operation of comminution units in mineral processing. Next Steps: Further reading on DEM/CFD applications in continuous operations and ongoing research in the field.