Acoustic emissions simulation of tumbling mills using charge dynamics

Knowledge of the internal variables of a mill is of importance in design and performance optimization of the mill, notwithstanding the difficulty in measuring these variables within the harsh mill environment. To overcome this problem, the research has focused on measuring the internal parameters through non-invasive measurement methods such as the use of the vibration/acoustic signal obtained from the mill. Alternatively, virtual instruments, such as discrete element methods (DEM), are employed. Here, a methodology is developed to simulate on-the-shell acoustic signal emitted from tumbling mills using the information extracted from a DEM simulator. The transfer function which links the forces exerted on the internal surface of the mill and the acoustic signal measured on the outer surface is measured experimentally. Given this transfer function and the force distribution obtained from the DEM simulation, and assuming a linear time-invariant response, the on-the-shell acoustic of a laboratory scale ball mill has been simulated. Comparison of this simulated signal with the signal measured experimentally can be used as a criterion to judge the validity of the DEM simulations, and as a tool for enhancing our understanding of both DEM simulations and the use of acoustics within the context of mineral processing. The results derived from preliminary experiments on a laboratory scale mill shows satisfactory agreement between the actual measurement and the simulated acoustic signal.

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► Dynamic forces on a ball mill shell are extracted from a discrete element simulator.
► A method is developed to link shell forces to vibration signal of the mill shell.
► Experimental acoustic signal is compared to simulated one in time/frequency domain.
► This comparison provides a tool to evaluate the accuracy of the DEM simulator.
► Extending this work, forces in the mill may be estimated using the acoustic signal.