Simulation of particle flows and breakage in crushers using DEM: Part 2 – Impact crushers

• DEM with a particle breakage model has been used to successfully model crushers.
• Impact crushers such as hammer mills, VSI and HIS have been simulated.
• Energy absorbed determines breakage with geometric rules for progeny generation.
• Predictions include power draw, liner stresses and wear, product size and throughput.
• Classification and discharge design affect recirculating load and performance.

DEM simulation using a breakage model is applied to study a broad range of existing impact based crushers to better understand machine level operation and to demonstrate that such modelling is now possible. Predictions for a range of types of hammer mills, vertical and horizontal shaft impactors are presented. The breakage method used is based on fracture of particles using geometric rules for progeny generation and estimates of the stress applied to the particles as they flow through the crusher. From these simulations, estimates of power, product size, throughput rate and crusher wear are made.

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