Gu Ruijie, Qin Zhenzhong, Zhao Shuaifeng, Xing Hao, Chen Liaoyuan, Yang Fang
School of Mechatronics Engineering, Henan University of Science and Technology, Luoyang, 471003, China.
Longmen Laboratory, Luoyang, 471000, China.
Sci Rep. 2025 Jan 4;15(1):771. doi: 10.1038/s41598-024-84734-0.
The application of high-pressure grinding rolls (HPGR) for ore crushing is considered to be one of the effective ways to save energy and reduce emissions in the ore processing industry. The crushing effect is directly determined by the forces of ore material during roll crushing. However, the mechanical state of ore material in roll crushing and the effect of roll structure, process parameters, feed particle size, on the force during the crushing of ore material needs to be expanded. Therefore, this paper intends to use the discrete element method to study the mechanical characteristics of roll crushing of ore materials. Firstly, the iron ore breakage model parameters are calibrated according to compression and impact crushing tests. Then, considering different roll structures, process parameters, and feed particle sizes of high-pressure grinding rolls, a simulation of the industry high-pressure grinding roll crushing process is developed. The particle velocity is innovatively used to study the force of particles in different regions of the compression zone. Considering the force and wear of ore particles, rollers, and cheek plates, the breakage process of HPGR is analyzed comprehensively. The results show that the material in the roll-crushing process is mainly subject to the normal force. The forces on particles at different locations in the compression zone are related to average velocity. To improve the crushing effect of HPGR, the crushing process of the ore should be combined with the wear of the roller and cheek plates. The vulnerable zone between the roller and cheek plates is indicated, and the extrusion pressure of the roller is slightly lower than the shear force between the particles.
高压辊磨机（HPGR）在矿石破碎中的应用被认为是选矿行业节能降耗的有效途径之一。破碎效果直接取决于辊压过程中矿石物料所受的力。然而，矿石物料在辊压过程中的力学状态以及辊子结构、工艺参数、给料粒度对矿石物料破碎时受力的影响仍有待深入研究。因此，本文旨在采用离散元方法研究矿石物料辊压的力学特性。首先，根据压缩和冲击破碎试验对铁矿石破碎模型参数进行标定。然后，考虑高压辊磨机不同的辊子结构、工艺参数和给料粒度，开展工业高压辊磨机破碎过程的模拟。创新性地利用颗粒速度研究压缩区内不同区域颗粒的受力情况。综合考虑矿石颗粒、辊子和侧护板的受力及磨损情况，对高压辊磨机的破碎过程进行全面分析。结果表明，辊压过程中物料主要受法向力作用。压缩区内不同位置颗粒所受的力与平均速度有关。为提高高压辊磨机的破碎效果，应将矿石的破碎过程与辊子和侧护板的磨损相结合。指出了辊子与侧护板之间的易损区域，且辊子的挤压压力略低于颗粒间的剪切力。
