Abstract

The discrete element method (DEM) is a widely used numerical approach for simulating and analyzing the behavior of granular materials in various applications. This research focuses on the iron ore beneficiation process, addressing the clumping issue in cohesive iron ores from existing crushing processes through a novel double-layered disperser design. The significance of this study lies in its potential to enhance the efficiency of the existing crushing phase and improve the linkage to subsequent purification stages that target smaller-sized iron ore pellets, thereby enhancing the overall efficiency of the ore beneficiation process and achieving significant energy savings. This research adopts Altair EDEM to predict material behavior and assess disperser functionality. To ensure the accuracy of the simulation results, this study employs dropping, incline, and tumbling tests to calibrate and validate frictional contact parameters between particles and between particles and their contacting steel surfaces. Additionally, this study uses the Bonded Particle Method (BPM) approach to simulate clump breakage, which enhances the visualization and analysis of dispersion results. The initial design, Disperser A, incorporates a cylindrical outer shell and double-layered counter-rotating blades controlled by a single motor, achieving over 94% particle dispersion efficiency. Further enhancements in Disperser C include a hexagonal outer shell and an umbrella-shaped divider at the top of the rotating axis, increasing the crushing efficiency to above 97%. Keywords: Discrete Element Method (DEM), Iron Ore Beneficiation, Double-Layered Disperser Design, Calibration, Clump Breakage Simulation

Committee Chair

Mark Jakiela

Committee Members

David Peters; Eric Veikle; Guy Genin; Marcus Foston

Degree

Doctor of Philosophy (PhD)

Author's Department

Mechanical Engineering & Materials Science

Author's School

McKelvey School of Engineering

Document Type

Dissertation

Date of Award

12-20-2024

Language

English (en)

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