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Crushing of CDW: from Particle Breakage to Process Application
Luís Marcelo Tavares
Laboratório de Tecnologia Mineral - LTM
Department of Metallurgical and Materials Engineeing – E. Poli/COPPE
Universidade Federal do Rio de Janeiro - UFRJ
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Presentation
Introduction
Particle breakage
Crusher modeling and simulation
Grinding of CDW and application in mortars
Conclusions
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Presentation
Introduction
Particle breakage
Crusher modeling and simulation
Grinding of CDW and application in mortars
Conclusions
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
UFRJ
COPPE
PEMM
LTM
UFRJ
COPPE
PEMM
LTM
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Largest university of the federal system in Brazil
45.000 students / 3.200 faculty
4th ranking in Latin America – 3rd in Brasil (QS University Rankings: Latin America 2014)
Mainly located in the university island
Houses the Research Park of Rio
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Instituto Alberto Luiz Coimbra de Pesquisa e Pós-Graduação em Engenharia◦ Largest centre of research in engineering in Latin America
◦ Established in 1963 (52 years)
◦ 325 faculty / 350 technical and administrative staff
◦ 2.800 graduate students (1.200 D.Sc. & 1.600 M.Sc.)
◦ 200 PhD theses/year
◦ 500 M.Sc. theses/year
◦ 2.000 peer-reviewed publications/year
Hydrogen-powered bus
MAGLEV train Rio + 20
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Part of the Department of Metallurgical
and Materials Engineering
17 years in activity
850 m2 of built area (+250 m2 sample storage area)
Head: Prof. Luis Marcelo Tavares, Ph.D. (U of Utah, 1997)
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
31 people (2 faculty, 6 staff, 1 post-doc fellow)
18 M.Sc. and Ph.D. students
Research and Development◦ Modeling, simulation and control of mineral/powder processing
◦ Fundamentals of particle breakage
◦ DEM simulation in process industries
◦ Physical concentration methods
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Presentation
Introduction
Particle breakage
Crusher modeling and simulation
Grinding of CDW and application in mortars
Conclusions
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Size reduction is often an important step in CDW recycling
It allows control of particle size and (to a certain extent) also of particle shape and even composition…
Understanding particle breakage can shed light into some important aspects of CDW size reduction:◦ Breakage distribution and breakage energy
◦ Differential breakage
◦ Phase liberationFratura aleatória Fratura intergranular
Fraturadiferencial
Sampaio & Tavares, 2005. Beneficiamento Gravimétrico
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Presentation
Introduction
Particle breakage
Crusher modeling and simulation
Grinding of CDW and application in mortars
Conclusions
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Stressing of CDW particles in comminution devices occursunder a variety of conditions:
Number of stressing points:◦ Single (impact against a target)
◦ Double
Stressing rate:◦ Slow compression
◦ Impact
Single impact Double impact Slow compression
Drop weightPneumatic gun
Drop test Pendulum
Impact load cellRotary impact tester
Press Point-load tester
Rigidly-mounted roll mill
Tavares, 2007. Handbook of Powder Technology, vol. 12, ch. 1
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
The outcome of stressing can be either:◦ Surface breakage and internal damage
◦ Volume (body) breakage
Tavares, 2009. Powder Technol. v. 190, 327-339.
3
2
1Bodybreakage
Surfacebreakage
Surfacebreakage
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Testing devices◦ Impact load cell device
Tavares & King, 1998. Int. J. Miner. Process. v. 54, 1-28.
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Testing devices◦ Impact load cell device
0 200 400 600 800 1000 1200 1400
Time (ms)
0
20
40
60
80
100
Forc
e (
N) Particle primary
fractureRebreakage of
the fragments
2.4 mm Copper ore2.4 mm particle
Tavares & King, 1998. Int. J. Miner. Process. v. 54, 1-28.Mass-specific particle fracture energy - Em (J/kg)
1 10 100 1000 100000.1
1
10
30
50
70
90
99
99.9
Cum
ula
tive d
istr
ibution (
%)
90.0 - 75.0 mm
45.0 - 37.5 mm
16.0 - 13.3 mm
5.60 - 4.75 mm
2.83 - 2.36 mm
1.40 - 1.18 mm
0.70 - 0.59 mm
Tavares & Neves, 2008. Int. J. Miner. Process., v. 87, 28-41.
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Testing devices◦ Impact load cell device
Tavares & Cerqueira, 2006. Cem. Concr. Res., v. 36, 409-415.
CDW?
Multiple populations: heterogeity!
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Testing devices◦ Drop weight tester / drop testing
ho
DropweightCollection
box
AnvilParticle
Guide
Tavares, 2007. Handbook of Powder Technology, vol. 12
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Cunha, 2014. D.Sc. Thesis
0,0001
0,001
0,01
0,1
1
10
100
0,01 0,1 1 10 100
Pass
ante
(%)
Tamanho de partícula (mm)
0,010,010,030,100,200,280,300,320,340,360,390,410,440,470,501,012,032,162,302,45373,94
Impact tofracture
energy ratio
0,001
0,01
0,1
1
10
1 10 100 1000 10000 100000
% P
assi
ng
in d
/10
or
t10
ap
par
ent
Impact energy (J/kg)
max. 𝑡10
Region ofmaximumefficiency
volumetricbreakage
surface + volumetric
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Testing devices◦ Microcompression tester (MCT-W /SHIMADZU)
(a)
0 10 20 30 40 50
0
100
200
300
400
500
Fo
rce
(m
N)
Displacement (µm)
(1)
(2) (3)
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Testing devices◦ Microcompression tester (MCT-W /SHIMADZU)
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
1 10 100 1000
Cum
ula
tive d
istr
ibution
Particle strength (MPa)
Quartz
Blast furnace slag
Silicon carbide
Limestone
Rice husk ash
Coal shale
37-45 micron particles
Ribas, Toledo Filho & Tavares, 2014. Miner. Eng., v. 65, 149-165.
0
0,5
1
1,5
2
1 10 100 1000
Bre
aka
ge
rate
(1/m
in)
Particle strength (MPa)
Rate of breakage in a planetary mill
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Testing devices◦ Microcompression tester (MCT-W /SHIMADZU)
Ribas, 2014. D.Sc. thesis
0
10
20
30
40
50
60
70
80
90
100
0
10
20
30
40
50
60
70
80
90
100
1 10 100 1000 10000
Dis
trib
uiç
ão A
cum
ula
tiva
(%)
Tensão (MPa)
TJ
TL
C
0
10
20
30
40
50
60
70
80
90
100
0
10
20
30
40
50
60
70
80
90
100
1 10 100 1000 10000
Dis
trib
uiç
ão a
cum
ula
tiva
(%)
Energia de fratura (J/kg)
TJ
TL
C
37-45 micron particles
TJ: brickTL: tileC: ceramic
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Presentation
Introduction
Particle breakage
Crusher modeling and simulation
Grinding of CDW and application in mortars
Conclusions
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Carried out in a number of devices
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Application of comercial mineral processing plant simulators
Development of advanced models of comminution
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Prediction of circuit performance using plant simulators
◦ Case study of a natural aggregate plant
S3000Restolho
H4000
H3000
Brita 1
Brita 0
Pó
Original circuit
configuration
32 mm
Plant located in Matias Barbosa (MG)
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Prediction of circuit performance using plant simulators
◦ Case study of a natural aggregate plant
32 mm
S3000Restolho
H4000
H3000
Brita 1
Brita 0
Pó
Change in tertiary and
quaternary crusing
(proposed by
equipment
manufacturer)
VSI
Original circuit
configuration
32 mm
50 mm
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Prediction of circuit performance using plant simulators
◦ Case study of a natural aggregate plant
S3000Restolho
H3000
REMCO
Brita 1
Brita 0
Areia
VSI
50 mm
Change in tertiary and
quaternary crusing
(proposed by
equipment
manufacturer)
Brita 1 Brita 0 Pó ou
areia
(kWh/t) Variação
Original 3200 8 + 4,4 43,9 29,1 26,9 3980 1,24 - Condição original
Simul. 1 3200 8 + 4,0 45,3 28,1 26,6 3740 1,17 -6% Modif. APF H4000
Simul. 2 3200 8 + 4,0 45,6 28,0 26,4 3230 1,01 -19% Modif. AFPs S3000 e H4000
Simul. 3 2800 8 + 6,1 41,9 25,7 32,4 7220 2,58 108% H3000 + VSI
Consumo energ.
específico
ObservaçãoConsumo
energético
total diário
(kWh)
Condição Produção
diária (t)
Tempo de
operação
(h)
Produção (%)
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Prediction of circuit performance using plant simulators
◦ Case study of a natural aggregate plant
Change in tertiary and
quaternary crusing
(proposed by LTM)
S3000Restolho
H3000
REMCO
Brita 1
Brita 0
Areia
VSI
50 mm
38 mmH4000
Brita 1 Brita 0 Pó ou
areia
(kWh/t) Variação
Original 3200 8 + 4,4 43,9 29,1 26,9 3980 1,24 - Condição original
Simul. 1 3200 8 + 4,0 45,3 28,1 26,6 3740 1,17 -6% Modif. APF H4000
Simul. 2 3200 8 + 4,0 45,6 28,0 26,4 3230 1,01 -19% Modif. AFPs S3000 e H4000
Simul. 3 2800 8 + 6,1 41,9 25,7 32,4 7220 2,58 108% H3000 + VSI
Simul. 4 3200 8 + 4,0 45,2 26,2 28,6 6270 1,96 58% H4000 + VSI
Consumo energ.
específico
ObservaçãoConsumo
energético
total diário
(kWh)
Condição Produção
diária (t)
Tempo de
operação
(h)
Produção (%)
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Advanced simulation of crushing and grinding◦ Discrete Element Method
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Advanced simulation of crushing and grinding◦ Discrete Element Method
A mechanistic model has been proposed at UFRJ to describecomminution
0
10
20
30
40
50
60
70
80
90
100
0,1 1
Cu
mu
lati
ve p
assi
ng
(%)
Particle size (mm)
Tavares & Carvalho, 2009. Miner. Eng. , v. 22, 650-659.
Batch grinding
Los Angeles?Degradation during mixing?
0.5 min
5 min
2 min
1 min
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Advanced simulation of crushing and grinding◦ Discrete Element Method
VSI Crusher
Cunha, Carvalho & Tavares, 2014. Proc. Comminution 2014.
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Presentation
Introduction
Particle breakage
Crusher modeling and simulation
Grinding of CDW and application in mortars
Conclusions
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Background◦ Porosity and heterogeneity are major issues in application
of CDW
◦ Reducing size of CDW from coarse aggregate to fine offersa potential solution to the problem
Approach◦ Grind CDW to fine sizes in order to
Reduce porosity
“Reduce” heterogeneity
Preparation of mortars with 20% cement replacement
Ribas, 2014. D.Sc. Thesis.
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Fine and ultrafine grinding:◦ Brick
◦ Tile
◦ White ceramic tile
Ribas, 2014. D.Sc. Thesis.
30 micron10 micron1 micron
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Preparation of mortars using brick, tile or white ceramic◦ Formulation and mixing (Betonlab Pro3)
◦ Water demand
◦ Vibration and compaction
◦ Properties of mortars in fresh state
Consistency (addition of superplastifiers)
◦ Moulding and curing
◦ Properties in the hardened state
Compressive strength
Tensile strength
Durability (ion choride penetration tests)
Gas permeation
Mercury porosimetry
Water absorption (imersion and capilarity)
Ribas, 2014. D.Sc. Thesis.
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Preparation of mortars using brick, tile or white ceramic◦ Formulation and mixing (Betonlab Pro3)
◦ Water demand
◦ Vibration and compaction
◦ Properties of mortars in fresh state
Consistency (addition of superplastifiers)
◦ Moulding and curing
◦ Properties in the hardened state
Compressive strength
Tensile strength
Durability (ion choride penetration tests)
Gas permeation
Mercury porosimetry
Water absorption (imersion and capilarity)
Ribas, 2014. D.Sc. Thesis.
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Preparation of mortars using brick, tile or white ceramic◦ Formulation and mixing (Betonlab Pro3)
◦ Water demand
◦ Vibration and compaction
◦ Properties of mortars in fresh state
Consistency (addition of superplastifiers)
◦ Moulding and curing
◦ Properties in the hardened state
Compressive strength
Tensile strength
Durability (ion choride penetration tests)
Gas permeation
Mercury porosimetry
Water absorption (imersion and capilarity)
Ribas, 2014. D.Sc. Thesis.
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Preparation of mortars using brick, tile or white ceramic◦ Formulation and mixing (Betonlab Pro3)
◦ Water demand
◦ Vibration and compaction
◦ Properties of mortars in fresh state
Consistency (addition of superplastifiers)
◦ Moulding and curing
◦ Properties in the hardened state
Compressive strength
Tensile strength
Durability (ion choride penetration tests)
Gas permeation
Mercury porosimetry
Water absorption (imersion and capilarity)
Ribas, 2014. D.Sc. Thesis.
220 mm +/- 5 mm
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Preparation of mortars using brick, tile or white ceramic◦ Formulation and mixing (Betonlab Pro3)
◦ Water demand
◦ Vibration and compaction
◦ Properties of mortars in fresh state
Consistency (addition of superplastifiers)
◦ Moulding and curing
◦ Properties in the hardened state
Compressive strength
Tensile strength
Durability (ion choride penetration tests)
Gas permeation
Mercury porosimetry
Water absorption (imersion and capilarity)
Ribas, 2014. D.Sc. Thesis.
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Preparation of mortars using brick, tile or white ceramic◦ Formulation and mixing (Betonlab Pro3)
◦ Water demand
◦ Vibration and compaction
◦ Properties of mortars in fresh state
Consistency (addition of superplastifiers)
◦ Moulding and curing
◦ Properties in the hardened state
Compressive strength
Tensile strength
Durability (ion choride penetration tests)
Gas permeation
Mercury porosimetry
Water absorption (imersion and capilarity)
Ribas, 2014. D.Sc. Thesis.
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Preparation of mortars using brick, tile or white ceramic◦ Formulation and mixing (Betonlab Pro3)
◦ Water demand
◦ Vibration and compaction
◦ Properties of mortars in fresh state
Consistency (addition of superplastifiers)
◦ Moulding and curing
◦ Properties in the hardened state
Compressive strength
Tensile strength
Durability (ion choride penetration tests)
Gas permeation
Mercury porosimetry
Water absorption (imersion and capilarity)
Ribas, 2014. D.Sc. Thesis.
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Results
0
10
20
30
40
50
60
0
10
20
30
40
50
60
0 1000 2000 3000 4000
Resi
stên
cia
a co
mpr
essã
o (M
Pa)
Deformação (µƐ)
CTRL A10TJ30A10C30 A10TL30
0
10
20
30
40
50
60
0
10
20
30
40
50
60
0 1000 2000 3000 4000
Resi
stên
cia
a co
mpr
essã
o (M
Pa)
Deformação (µƐ)
A20TJ30 A20TL30A20C30 CTRL
0
10
20
30
40
50
60
0
10
20
30
40
50
60
0 1000 2000 3000 4000
Resi
stên
cia
a co
mpr
essã
o (M
Pa)
Deformação (µƐ)
CTRL A10TL10A10C10 A0TJ10
0
10
20
30
40
50
60
0
10
20
30
40
50
60
0 1000 2000 3000 4000
Resi
stên
cia
a co
mpr
essã
o (M
Pa)
Deformação (µƐ)
A20TJ10 A20TL10A20C10 CTRL
0
10
20
30
40
50
60
0
10
20
30
40
50
60
0 1000 2000 3000 4000
Resi
stên
cia
a co
mpr
essã
o (M
Pa)
Deformação (µƐ)
CTRL A10TJ1A10TL1 A10C1
0
10
20
30
40
50
60
0
10
20
30
40
50
60
0 1000 2000 3000 4000
Resi
stên
cia
a co
mpr
essã
o (M
Pa)
Deformação (µƐ)
CTRL A20TJ1A20TL1 A20C1
19,82 22,09
15,87 16,02
0
5
10
15
20
25
CTRL A10C30 A10TJ30 A10TL30
Carg
a El
étri
ca (1
0³ C
)
AltaModeradaBaixaMuito baixa
19,82
15,77
5,167,14
0
5
10
15
20
25
CTRL A20C30 A20TJ30 A20TL30
Carg
a El
étri
ca (1
0³ C
)
AltaModeradaBaixaMuito baixa
19,82
14,8013,11
17,68
0
5
10
15
20
25
CTRL 2 A10TJ30 A10TL30 A10C30
Carg
a El
étri
ca (1
0³ C
)
AltaModeradaBaixaMuito baixa
19,82
6,67
1,44
3,71
0
5
10
15
20
25
CTRL A20C10 A20TJ10 A20TL10
Carg
a El
étri
ca (1
0³ C
)
AltaModeradaBaixaMuito baixa
19,82
9,42
13,7915,72
0
5
10
15
20
25
CTRL A10C1 A10TJ1 A10TL1
Carg
a El
étri
ca (1
0³ C
)
AltaModeradaBaixaMuito baixa
19,82
2,00
4,64
2,34
0
5
10
15
20
25
CTRL A20C1 A20TJ1 A20TL1
Carg
a El
étri
ca (1
0³ C
)
AltaModeradaBaixa
Muito baixa
30 micron
10 micron
1 micron
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Results
Ribas, 2014. D.Sc. Thesis.
Component Nominal size (micron) Energy consumption in grinding (kWh/h)
Brick 30 35.7
10 121
1 1197
Tile 30 20.1
10 110.2
1 1200
White ceramic 30 37.0
10 127.1
1 1263
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Presentation
Introduction
Particle breakage
Crusher modeling and simulation
Grinding of CDW and application in mortars
Conclusions
Luís Marcelo Tavares Comminution of CDW: from particle breakage to process application
Single particle breakage characterization could help assessing potential of differential comminution of CDW…
Present-day crusher models can be used to optimize CDW crushing in industry
Advanced (DEM-based) crusher models can be used to predict CDW crushing and degradation during mixing
Ultrafine grinding of CDW could be used to deal with porosity/heterogeneity issues