3831
Dynamic Simulation of Multicomponent Grinding Circuits
Using Dyssol
Rodrigo de A. Prates, Luís Marcelo Tavares, Rodrigo M. de Carvalho
Department of Metallurical and Materials Engineering,
Universidade Federal do Rio de Janeiro–COPPE/UFRJ, Rio de Janeiro, RJ, Brazil
ABSTRACT: Dynamic simulation of multicomponent systems is a challenge, but a key tool for realistic
simulation of industrial processing circuits. Fortunately, a new simulator, called Dyssol, now provides a robust
representation of multicomponent granular streams composed of properties such as density, particle shape and
grade and a capable solver that allows simulating complex circuits. The work demonstrates the capabilities of
the simulator by first modeling size reduction of mixtures of clinker, gypsum and limestone in a dry ball mill
circuit. The work then analyzes a wet ball mill circuit grinding iron ore fed by a blend of iron ore lithologies,
also in closed circuit operation. Build-up of the tougher component in the mill and selective classification were
predicted for both circuits.
INTRODUCTION
Comminution, a common operation in various industries
such as mining, chemical, and pharmaceutical, involves
reducing particle sizes of a solid to generate a finer product.
A comminution circuit consists of multiple stages where
the material is reduced in size by passing through crushers
and mills, with the final product often obtained through
size separation stages that can be performed typically using
screens, air classifiers or hydrocyclones.
In these operations, one of the challenges is predict-
ing their performance by calculating the process variables of
interest. To achieve this, mathematical formulations based
on the population balance model (King, 2001) are typi-
cally employed. In some cases, a dynamic approach is essen-
tial for a better representation and understanding of the
process, especially in circuits in the presence of surge bins,
sumps, silos, flow controllers, etc (Asbjörnsson et al., 2022).
However, simulations of processes involving solid materials
are particularly complex due to the difficulty in accurately
describing granular flows. Consequently, most dynamic
process simulators available lack the necessary tools to han-
dle comminution circuits, being mostly dedicated to pro-
cesses involving only liquids and gases. Additionally, these
simulators are often very costly.
Dyssol was created as an open-source dynamic process
simulator, being developed by researchers at the Hamburg
University of Technology with support from the German
Research Foundation (DFG), with the main focus to deal
with solid particulate materials (Skorych et al., 2020). The
program’s structure stands out for its detailed description
of granular material properties, enabling the representation
of different interdependent parameters such as size, shape,
composition, and moisture, most of which highly relevant
in the context of multicomponent simulations of commi-
nution circuits.
This study aims to demonstrate and verify the use of
Dyssol in the dynamic simulation of multicomponent
comminution circuits. To achieve this, mathematical
Dynamic Simulation of Multicomponent Grinding Circuits
Using Dyssol
Rodrigo de A. Prates, Luís Marcelo Tavares, Rodrigo M. de Carvalho
Department of Metallurical and Materials Engineering,
Universidade Federal do Rio de Janeiro–COPPE/UFRJ, Rio de Janeiro, RJ, Brazil
ABSTRACT: Dynamic simulation of multicomponent systems is a challenge, but a key tool for realistic
simulation of industrial processing circuits. Fortunately, a new simulator, called Dyssol, now provides a robust
representation of multicomponent granular streams composed of properties such as density, particle shape and
grade and a capable solver that allows simulating complex circuits. The work demonstrates the capabilities of
the simulator by first modeling size reduction of mixtures of clinker, gypsum and limestone in a dry ball mill
circuit. The work then analyzes a wet ball mill circuit grinding iron ore fed by a blend of iron ore lithologies,
also in closed circuit operation. Build-up of the tougher component in the mill and selective classification were
predicted for both circuits.
INTRODUCTION
Comminution, a common operation in various industries
such as mining, chemical, and pharmaceutical, involves
reducing particle sizes of a solid to generate a finer product.
A comminution circuit consists of multiple stages where
the material is reduced in size by passing through crushers
and mills, with the final product often obtained through
size separation stages that can be performed typically using
screens, air classifiers or hydrocyclones.
In these operations, one of the challenges is predict-
ing their performance by calculating the process variables of
interest. To achieve this, mathematical formulations based
on the population balance model (King, 2001) are typi-
cally employed. In some cases, a dynamic approach is essen-
tial for a better representation and understanding of the
process, especially in circuits in the presence of surge bins,
sumps, silos, flow controllers, etc (Asbjörnsson et al., 2022).
However, simulations of processes involving solid materials
are particularly complex due to the difficulty in accurately
describing granular flows. Consequently, most dynamic
process simulators available lack the necessary tools to han-
dle comminution circuits, being mostly dedicated to pro-
cesses involving only liquids and gases. Additionally, these
simulators are often very costly.
Dyssol was created as an open-source dynamic process
simulator, being developed by researchers at the Hamburg
University of Technology with support from the German
Research Foundation (DFG), with the main focus to deal
with solid particulate materials (Skorych et al., 2020). The
program’s structure stands out for its detailed description
of granular material properties, enabling the representation
of different interdependent parameters such as size, shape,
composition, and moisture, most of which highly relevant
in the context of multicomponent simulations of commi-
nution circuits.
This study aims to demonstrate and verify the use of
Dyssol in the dynamic simulation of multicomponent
comminution circuits. To achieve this, mathematical