Volume 99
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Zhang, C., Zou, Y., Cheng, G., Liu, D., Yang, R., & Yu, A. (2025). Quantify the edge effect of HPGR mills with DEM modelling. Particuology, 99, 60-68. https://doi.org/10.1016/j.partic.2025.02.013
Quantify the edge effect of HPGR mills with DEM modelling (Open Access)
Chengwei Zhang a, Yudong Zou b, Guojian Cheng c, David Liu d, Runyu Yang b *, Aibing Yu c e f *
a School of Energy and Environment, Southeast University, Nanjing, 210096, China
b School of Materials Science and Engineering, University of New South Wales, Sydney, 2052, Australia
c Monash Suzhou Research Institute, Monash University, Suzhou, 215000, China
d School of Physics and Mathematics, Xi'an Jiaotong-Liverpool University, Jiangsu, 215213, China
e Southeast University-Monash University Joint Research Institute, Centre for Simulation and Modelling of Particulate Systems, Suzhou, 215213, China
f ARC Research Hub for Smart Process Design and Control, Department of Chemical and Biological Engineering, Monash University, Clayton, VIC, 3800, Australia
10.1016/j.partic.2025.02.013
Volume 99, April 2025, Pages 60-68
Received 23 December 2024, Revised 7 February 2025, Accepted 18 February 2025, Available online 5 March 2025, Version of Record 17 March 2025.
E-mail: r.yang@unsw.edu.au; aibing.yu@monash.edu

Highlights

• DEM simulations are conducted to investigate the edge effect of HPGR mills.

• Edge effect is most significant to particle size, followed by particle-roll force and the least to throughput.

• Edge effect is enhanced/reduced by roll thickness and diameter but not grinding pressure.

• A unified equation is proposed for the different profiles of mill properties.


Abstract

High pressure grinding rolls (HPGR) mills are an energy efficient comminution device widely used in the cement and mineral processing industries. Uneven roll wear and particle breakage near edges causes significant variation in grinding pressure along the axial direction. This study aimed to quantify the edge effect on mill performance through discrete element method (DEM) modelling. The DEM model, coupled with a multi-body dynamics (MBD) model for the motion of the floating roll and a particle fracture model, was calibrated and validated by the experimental data from a lab-scale HPGR mill. The simulations showed that the edge effect had the most significant impact on particle-particle compressive force and product size (characterised by the median particle size d50), followed by particle-roll force, and the least on throughput. Increasing roll length amplified the edge effect, causing larger variations in throughput, particle-roll force, and product size, while increasing roll size mitigated the edge effect, resulting in a more uniform product sizes and particle-wall interaction. On the other hand, varying grinding pressure had a minimal impact on the edge effect. A unified equation was proposed to quantify changes from parabolic to trapezoidal profiles. The proposed unified equation offers a new approach to predict changes in the wear and particle size profiles.

Graphical abstract
Keywords
High pressure grinding rolls; Edge effect; Discrete element method; Multi-body dynamics model; Particle breakage