Use of the advanced discrete element method (DEM) to enhance the design and performance of the iron ore crusher used by Baffinland Company

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Crushing is the first step of mineral processing where the ores/rocks from the mine site are fed into a crusher to reduce the size for the subsequent stages and thus liberate the valuable mineral from the gangue. In the proposed research project, an advanced simulation technique called discrete element method (DEM) will be utilized to upgrade the design of the crushers used by Baffinland Iron Mines. These crushers are not functioning properly due to the variations in iron ores characteristics such as the size and shape distributions. To cope with an increase in the production capacity, it is also vital to modify the design of these crushers. In order to enhance the quality of the product, it is essential to understand how iron ore breakage and the capacity of the crusher are affected by changing the critical operating conditions such as the eccentric speed and the close size setting (CSS). Therefore, the main objectives of this research project are to modify the design of the existing crusher and to enhance the performance of the crusher at the optimal operating conditions. The DEM model developed in the proposed project will be employed to assess the crusher wear and to analyze the blockage issue. This vital information will be used to upgrade the design of these crushing units. Applying the results of this research project will contribute to the employment opportunities for the people of Nunavut, increased revenues to the Government of Nunavut, and increased economic activity of the Canadian mining industry. Canadian mining industry, and equipment designers and manufacturers can implement the DEM approach to assess many scenarios on a computer without the additional cost of constructing and testing prototype models or modifying current design via trial and error. This will lead to capital cost savings, improved equipment design, increased throughput for existing plant, improved quality of products, and more efficient use of power. Thus, the proposed research will contribute to the increased economic activity of the Canadian mining industry, and will impact our society, quality of life, health and environment.