3978 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
Despite the simplification assumptions, computational
constraints, and the inherent complexity associated with
CAHM, MonoRoll, and HPGR applications, DEM has
proven to be an indispensable tool. It has provided criti-
cal insights at every stage of equipment design, from the
initial theoretical concepts to the design and optimization
of CAHM and MonoRoll, and even in the detailed design
and definition of operating conditions.
As demonstrated, the quantitative prediction of
CAHM and MonoRoll applications using DEM modeling
has relative errors of up to 25%. However, in the context
of developing a new platform technology such as CAHM,
these quantitative predictions are invaluable. They offer
crucial insights that guide the technology development
and design of comminution machinery, thereby playing a
pivotal role in enhancing the efficiency and effectiveness
of these applications. It is believed that the relative perfor-
mance variations will be significantly smaller.
Looking ahead, DEM will be used to develop CAHM
and MonoRoll Mark 2. This approach is expected to
shorten the technology development period for this revo-
lutionary comminution technology platform by more than
a decade compared to other technologies or the “trial and
error” prototyping model that has been used in the past.
This represents a significant advancement in the field and
underscores the transformative potential of DEM in the
design and optimization of comminution machinery.
Our modeling indicates that the CAHM technology
can be effectively scaled to process coarser feed material (up
to 250 mm top size) and higher feed rates (up to 2500 t/h).
Initial analyses suggest that upscaling will enhance com-
minution energy efficiency and achieve higher reduction
ratios. We are currently conducting further studies to vali-
date these findings and to explore the operational param-
eters and potential challenges associated with upscaling
CAHM.
Regarding the wear of CAHM liners, we acknowledge
that wear modeling is a complex aspect of CAHM technol-
ogy. To address this, we have implemented two modeling
approaches: progressive liner wear modeling and the col-
lection of liner surface shear work. These methods provide
insights into the relative wear resistance of CAHM liners.
However, due to the limited operational duration of the
CAHM prototype, experimental validation of the wear
models has not yet been possible. Ongoing testing and fur-
ther modeling efforts aim to accurately evaluate and extend
the CAHM liner wear life.
In conclusion, the CAHM technology platform, sup-
ported by DEM modeling, shows great promise in revo-
lutionizing the comminution process. The potential for
scale-up to handle higher tonnages and coarser materials,
combined with ongoing advancements in wear resistance,
highlights the robust and scalable nature of CAHM tech-
nology. Further research and development will continue to
refine and enhance this innovative platform, ensuring its
effectiveness and efficiency in industrial applications.
REFERENCES
Ballantyne, G.R., Peukert, W., and Powell, M.S. 2014. Size
Specific Energy (SSE)—Energy Required to Generate
Minus 75 Micron Material. International Journal of
Mineral Processing 139:2–6.
Canadian Mining Innovation Council. 2016. Comminution
Technology Appraisal. www.rethinkmining.org.
Mining Technology. 2019. Crushing comminution: decar-
bonising mining’s biggest energy user. www.mining
-technology.com.
Nordell, L., and Potapov, A. 2011. Novel Comminution
Machine May Vastly Improve Crushing-Grinding
Efficiency. In Proceedings of the SAG 2011 conference.
Nordell, L.K., Porter, B., and Potapov, A. 2016.
Comminution energy efficiency—understanding next
steps. In Proceedings of the XXVIII International
Mineral Processing Congress (IMPC 2016), Vol 5,
pp. 3307–3328.
Powell, M.S., Nurick, G.N., and Cleary, P.W. 2011. DEM
modelling of liner evolution and its influence on grind-
ing rate in ball mills. Minerals Engineering 24(3‑4):
341–348.
Schonert, K. 1996. The influence of particle bed configura-
tions and confinements on particle breakage. Mineral
Processing 44-45:1–16.
Shi, F., and Kojovic, T. 2007. Validation of a model
for impact breakage incorporating particle size
effect. International Journal of Mineral Processing
82(3):156–163.
Tavares, L.M., and de Carvalho, R.M. 2009. Modeling
breakage rates of coarse particles in ball mills. Minerals
Engineering 22(7–8): 650–659.
Vogel, L., and Peukert, W. 2005. From single particle
impact behaviour to modelling of impact mills.
Chemical Engineering Science 60(18):5164–5176.
Despite the simplification assumptions, computational
constraints, and the inherent complexity associated with
CAHM, MonoRoll, and HPGR applications, DEM has
proven to be an indispensable tool. It has provided criti-
cal insights at every stage of equipment design, from the
initial theoretical concepts to the design and optimization
of CAHM and MonoRoll, and even in the detailed design
and definition of operating conditions.
As demonstrated, the quantitative prediction of
CAHM and MonoRoll applications using DEM modeling
has relative errors of up to 25%. However, in the context
of developing a new platform technology such as CAHM,
these quantitative predictions are invaluable. They offer
crucial insights that guide the technology development
and design of comminution machinery, thereby playing a
pivotal role in enhancing the efficiency and effectiveness
of these applications. It is believed that the relative perfor-
mance variations will be significantly smaller.
Looking ahead, DEM will be used to develop CAHM
and MonoRoll Mark 2. This approach is expected to
shorten the technology development period for this revo-
lutionary comminution technology platform by more than
a decade compared to other technologies or the “trial and
error” prototyping model that has been used in the past.
This represents a significant advancement in the field and
underscores the transformative potential of DEM in the
design and optimization of comminution machinery.
Our modeling indicates that the CAHM technology
can be effectively scaled to process coarser feed material (up
to 250 mm top size) and higher feed rates (up to 2500 t/h).
Initial analyses suggest that upscaling will enhance com-
minution energy efficiency and achieve higher reduction
ratios. We are currently conducting further studies to vali-
date these findings and to explore the operational param-
eters and potential challenges associated with upscaling
CAHM.
Regarding the wear of CAHM liners, we acknowledge
that wear modeling is a complex aspect of CAHM technol-
ogy. To address this, we have implemented two modeling
approaches: progressive liner wear modeling and the col-
lection of liner surface shear work. These methods provide
insights into the relative wear resistance of CAHM liners.
However, due to the limited operational duration of the
CAHM prototype, experimental validation of the wear
models has not yet been possible. Ongoing testing and fur-
ther modeling efforts aim to accurately evaluate and extend
the CAHM liner wear life.
In conclusion, the CAHM technology platform, sup-
ported by DEM modeling, shows great promise in revo-
lutionizing the comminution process. The potential for
scale-up to handle higher tonnages and coarser materials,
combined with ongoing advancements in wear resistance,
highlights the robust and scalable nature of CAHM tech-
nology. Further research and development will continue to
refine and enhance this innovative platform, ensuring its
effectiveness and efficiency in industrial applications.
REFERENCES
Ballantyne, G.R., Peukert, W., and Powell, M.S. 2014. Size
Specific Energy (SSE)—Energy Required to Generate
Minus 75 Micron Material. International Journal of
Mineral Processing 139:2–6.
Canadian Mining Innovation Council. 2016. Comminution
Technology Appraisal. www.rethinkmining.org.
Mining Technology. 2019. Crushing comminution: decar-
bonising mining’s biggest energy user. www.mining
-technology.com.
Nordell, L., and Potapov, A. 2011. Novel Comminution
Machine May Vastly Improve Crushing-Grinding
Efficiency. In Proceedings of the SAG 2011 conference.
Nordell, L.K., Porter, B., and Potapov, A. 2016.
Comminution energy efficiency—understanding next
steps. In Proceedings of the XXVIII International
Mineral Processing Congress (IMPC 2016), Vol 5,
pp. 3307–3328.
Powell, M.S., Nurick, G.N., and Cleary, P.W. 2011. DEM
modelling of liner evolution and its influence on grind-
ing rate in ball mills. Minerals Engineering 24(3‑4):
341–348.
Schonert, K. 1996. The influence of particle bed configura-
tions and confinements on particle breakage. Mineral
Processing 44-45:1–16.
Shi, F., and Kojovic, T. 2007. Validation of a model
for impact breakage incorporating particle size
effect. International Journal of Mineral Processing
82(3):156–163.
Tavares, L.M., and de Carvalho, R.M. 2009. Modeling
breakage rates of coarse particles in ball mills. Minerals
Engineering 22(7–8): 650–659.
Vogel, L., and Peukert, W. 2005. From single particle
impact behaviour to modelling of impact mills.
Chemical Engineering Science 60(18):5164–5176.