Crushing of CDW: from Particle Breakage to

Transcrição

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
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Presentation
Introduction
Particle breakage
Crusher modeling and simulation
Grinding of CDW and application in mortars
Conclusions
Comminution of CDW: from particle breakage to process application
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Presentation
Introduction
Particle breakage
Conclusions
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UFRJ
UFRJ
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COPPE
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PEMM
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LTM
COPPE
PEMM
LTM
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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
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Instituto Alberto Luiz Coimbra de Pesquisa e
Pós-Graduação em Engenharia
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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
MAGLEV train
Rio + 20
Hydrogen-powered bus
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Part of the Department of Metallurgical
and Materials Engineering
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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)
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31 people (2 faculty, 6 staff, 1 post-doc fellow)
18 M.Sc. and Ph.D. students
Research and Development
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Modeling, simulation and control of mineral/powder processing
Fundamentals of particle breakage
DEM simulation in process industries
Physical concentration methods
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Presentation
Introduction
Particle breakage
Conclusions
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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 liberation
Fratura intergranular
Fratura aleatória
Fratura
diferencial
Sampaio & Tavares, 2005. Beneficiamento Gravimétrico
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Presentation
Introduction
Particle breakage
Conclusions
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Stressing of CDW particles in comminution devices occurs
under a variety of conditions:
Number of stressing points:
◦ Single (impact against a target)
◦ Double
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Stressing rate:
◦ Slow compression
◦ Impact
Drop test
Pneumatic
gun
Drop weight
Pendulum
Press
Point-load
tester
Rotary impact tester
Impact load cell
Rigidly-mounted roll mill
Single impact
Double impact
Slow compression
Tavares, 2007. Handbook of Powder Technology, vol. 12, ch. 1
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The outcome of stressing can be either:
◦ Surface breakage and internal damage
◦ Volume (body) breakage
Body
1
breakage
Surface
2
breakage
Tavares, 2009. Powder Technol. v. 190, 327-339.
Surface
3
breakage
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Testing devices
◦ Impact load cell device
Tavares & King, 1998. Int. J. Miner. Process. v. 54, 1-28.
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Testing devices
99.9
100
2.4
mm
Copper
ore
2.4
mm
particle
Particle primary
Cumulative distribution (%)
Force (N)
80
60
Rebreakage of
fracture
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
99
the fragments
40
20
90
70
50
30
10
1
0
0
200
400
600
800
1000
1200
1400
Time (ms)
Tavares & King, 1998. Int. J. Miner. Process. v. 54, 1-28.
0.1
1
10
100
1000
Mass-specific particle fracture energy - Em (J/kg)
10000
Tavares & Neves, 2008. Int. J. Miner. Process., v. 87, 28-41.
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Testing devices
CDW?
Multiple populations: heterogeity!
Tavares & Cerqueira, 2006. Cem. Concr. Res., v. 36, 409-415.
Testing devices
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◦ Drop weight tester / drop testing
Drop
weight
Collection
box
Guide
ho
Particle
Anvil
Tavares, 2007. Handbook of Powder Technology, vol. 12
% Passing in d/10 or t10
apparent
max. 𝑡10
10
volumetric
breakage
1
0,1
surface +
volumetric
0,01
Region of
maximum
efficiency
0,001
1
10
100
1000
Impact energy (J/kg)
10000 Impact to100000
fracture
energy ratio
100
Passante (%)
10
1
0,1
0,01
0,001
0,0001
Cunha, 2014.
D.Sc. Thesis
0,01
0,1
1
10
Tamanho
de
partícula
(mm)
Comminution of CDW: from
100
0,01
0,01
0,03
0,10
0,20
0,28
0,30
0,32
0,34
0,36
0,39
0,41
0,44
0,47
0,50
1,01
2,03
2,16
2,30
2,45
373,94
particle breakage to process application
Testing devices
◦ Microcompression tester (MCT-W /SHIMADZU)
500
400
Force (mN)
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300
200
(3)
(2)
100
0
(1) 0
(a)
10
20
30
40
50
Displacement (µm)
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Testing devices
1,0
Quartz
37-45 micron particles
0,9
Blast furnace slag
Silicon carbide
0,7
Rate of breakage in a planetary mill
Limestone
0,6
Rice husk ash
0,5
Coal shale
2
Breakage rate (1/min)
Cumulative distribution
0,8
0,4
0,3
0,2
0,1
0,0
1
10
1,5
1
0,5
100
Particle strength (MPa)
1000
0
1
10
100
1000
Particle strength (MPa)
Ribas, Toledo Filho & Tavares, 2014. Miner. Eng., v. 65, 149-165.
Testing devices
100
Distribuição Acumulativa (%)
37-45 micron particles
100
TJ
90
90
TL
80
80
C
70
70
60
60
50
50
40
40
30
30
20
20
10
10
0
1
100
90
(%)
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80
Luís Marcelo
Tavares
10
100
Tensão (MPa)
1000
TJ: brick
TL: tile
C: ceramic
0
10000
100
Ribas, 2014. D.Sc. thesis TJ
TL
90
Comminution of CDW: from particle breakage80to process application
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Presentation
Introduction
Particle breakage
Conclusions
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Carried out in a number of devices
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Application of comercial mineral processing plant simulators
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Development of advanced models of comminution
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Prediction of circuit performance using plant simulators
◦ Case study of a natural aggregate plant
Original circuit
configuration
Restolho
S3000
Plant located in Matias Barbosa (MG)
32 mm
H4000
H3000
Brita 1
Brita 0
Pó
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Original circuit
configuration
Change in tertiary and
quaternary crusing
(proposed by
equipment
manufacturer)
Restolho
S3000
50 mm
32 mm
H4000
H3000
Brita 1
VSI
Brita 0
Pó
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Restolho
S3000
Change in tertiary and
Condição Produção Tempo de
Produção (% )
quaternary
crusing
diária (t) operação
Brita 1 Brita 0 Pó ou
(proposed by(h)
areia
Original
equipment
3200
8 + 4,4
manufacturer)
Consumo
Consumo energ.
energético
específico
H3000
50 mm
total diário (kWh/t) Variação
(kWh)
43,9
29,1
26,9
3980
1,24
-
Simul. 1
3200
8 + 4,0
45,3
28,1
26,6
3740
1,17
-6%
Simul. 2
3200
8 + 4,0
45,6
28,0
26,4
3230
1,01
-19%
Simul. 3
2800
8 + 6,1
41,9
25,7
32,4
7220
2,58
108%
Observação
Condição original
REMCO
VSI
Modif. APF H4000
Brita 1 AFPs S3000 e H4000
Modif.
Brita 0
H3000 + VSI
Areia

Restolho
S3000
Condição Produção Tempo de
diária (t) operação
(h)
Produção (% )
Brita 1 Brita 0
Original Change
3200
in tertiary
and
8 + 4,4
43,9
quaternary crusing
Simul. 1 (proposed
3200
8 + LTM)
4,0
45,3
by
Simul. 2
3200
8 + 4,0
45,6
Pó ou
areia
Consumo
Consumo energ.
H4000
energético
específico
38
mm
total diário (kWh/t)
H3000
50 mm Variação
(kWh)
29,1
26,9
3980
1,24
-
28,1
26,6
3740
1,17
-6%
28,0
26,4
3230
1,01
-19%
Observação
Condição original
REMCO
VSI Modif. APF H4000
Modif. AFPs S3000 e H4000
Brita 1
Simul. 3
2800
8 + 6,1
41,9
25,7
32,4
7220
2,58
Simul. 4
3200
8 + 4,0
45,2
26,2
28,6
6270
1,96
108%
58% Areia
Brita 0 H3000 + VSI
H4000 + VSI
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Advanced simulation of crushing and grinding
◦ Discrete Element Method
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 A mechanistic model has been proposed at UFRJ to describe
comminution
Batch grinding
100
Cumulative passing (%)
90
80
70
60
5 min
50
40
2 min
30
1 min
0.5 min
20
10
0
0,1
Tavares & Carvalho, 2009. Miner. Eng. , v. 22, 650-659.
1
Particle size (mm)
Los Angeles?
Degradation during mixing?
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VSI Crusher
Cunha, Carvalho & Tavares, 2014. Proc. Comminution 2014.
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Presentation
Introduction
Particle breakage
Conclusions
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Background
◦ Porosity and heterogeneity are major issues in application
of CDW
◦ Reducing size of CDW from coarse aggregate to fine offers
a potential solution to the problem
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Approach
◦ Grind CDW to fine sizes in order to
 Reduce porosity
 “Reduce” heterogeneity
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Preparation of mortars with 20% cement replacement
Ribas, 2014. D.Sc. Thesis.
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Fine and ultrafine grinding:
◦ Brick
◦ Tile
◦ White ceramic tile
30 micron
10 micron
1 micron

Preparation of mortars using brick, tile or white ceramic
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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)

◦
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Water demand
 Gas permeation
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Water demand
 Gas permeation

◦
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◦
◦
Water demand
 Consistency (addition of superplastifiers) 220 mm +/- 5 mm
 Gas permeation

◦
◦
◦
◦
Water demand
 Gas permeation
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◦
◦
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◦
Water demand
 Gas permeation
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◦
◦
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◦
Water demand
 Gas permeation
A10TL10
A0TJ10
RL
0TL1
50
20
10
0
4000
60
50
40
30
20
10
2000 (µƐ) 3000
formação
20
10
0
4000
15,87
16,02
15
10
20
5
10
00
1000
2000
3000
Deformação
(µƐ) A10TL30
CTRL
A10C30
A10TJ30
60 25
40
30
40
30
0
50
Baixa
Muito baixa
A20TJ10
19,82 A20C10
20
14,80
A20TL10
Alta
CTRL
Moderada
17,68
Baixa
Muito baixa
50
40
13,11
15
30
20 10
20
10
10
5
20
15,77
15
30 micron
10
0
4000
60
Alta
Moderada
Baixa
Muito baixa
19,82
Carga Elétrica (10³ C)
30
60
30
A10TJ1
A10C1
40
0
4000
40
2000 (µƐ) 3000
formação
20
25
7,14
5,16
5
0
CTRL
A20C30
A20TJ30 A20TL30
25
Alta
Moderada
Baixa
Muito baixa
19,82
20
10
60
A20TL30 Alta
CTRL
Moderada50
A20TJ30
22,09
A20C30
15
10 micron
10
6,67
3,71
5
1,44
0
0
0
1000 Deformação
2000 (µƐ) 3000
CTRL 2 A10TJ30
A10TL30 A10C30
60 25
50
40
30
19,82
A20TJ1
A20C1
20
15,72
0
0
Alta
Moderada
50
Baixa
Muito baixa
40
30
9,42
20
10
5
0
60
13,79
15
20 10
10
CTRL
A20TL1
0
4000
1000 Deformação
2000 (µƐ) 3000
CTRL
A10C1
A10TJ1 A10TL1
0
4000
0
CTRL
A20C10
A20TJ10 A20TL10
25
Alta
Moderada
Baixa
Muito baixa
19,82
20
20
50
30
19,82
40
25
Results
2000 (µƐ) 3000
formação
L
C10
50
60
Resistência a compressão (MPa)

60
A10TJ30
A10TL30
L
C30
15
1 micron
10
4,64
5
2,34
2,00
0
CTRL
A20C1
A20TJ1
A20TL1

Results
Component
Brick
Tile
White ceramic
Nominal size (micron)
Energy consumption in
grinding (kWh/h)
30
35.7
10
121
1
1197
30
20.1
10
110.2
1
1200
30
37.0
10
127.1
1
1263
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Presentation
Introduction
Particle breakage
Conclusions
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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

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Obrigado
Merci
Thank you
www.ltmcoppe.com
UFRJ

Crushing of CDW: from Particle Breakage to

Transcrição

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