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Optimization and Simulation of Balling Plant Processes: 2010 Research Summary

This document summarizes the key research activities related to the balling plant simulator conducted in 2010. It explores various simulation studies focusing on outlet design and optimization approaches, particularly for large-scale viscoplastic SPH models tailored for stiff granular materials. The studies include data collection efforts at LKAB, performance analysis, validation against collected data, and the effects of various parameters on balling plant dynamics. Research findings span parameters such as particle velocity, pressure distributions, and optimization strategies for drum processes.

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Optimization and Simulation of Balling Plant Processes: 2010 Research Summary

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  1. Balling plant simulation 2010-10-01

  2. Punkter • Summary of research activities 2010 • Balling plant simulator • Simulation study of outlet design • Consortium plan

  3. Summary of research activities 2010 • Block-parallel Cholesky factorization • PCG-solver – moving contacting rigid bodies to GPGPU • Merge/split algorithm • Viscoplastic SPH – for large-scale stiff granular matter • Pipeline for new methods & models (Octave + Asymptote = Octasy) • Pipeline for AgX simulation studies – balling plant, statistics • Analysis of performance and model validation

  4. Balling plant - recap In: - fines (ore + binding) - undersized pellets 100 ton/h • Mono-sizedspherical pellets • Understand flow patterns and forces • Outlet design • Control variables • Agglomeration process • 100K – 100M particles • Time scales 1ms – 5min • 1/10 fraction real vs simulated time Out: - green pellets Return: - undersized pellets - oversized pellets (crush)

  5. Balling plant simulator • Data collection at LKAB • Preparatory simulations on drum segment • Pipeline & statistics • Effects of nonsmooth approach, time step, solver, iterations • Effects of drum texture, particle size, model parameters, rotation speed • Validation with collected data • Outlet design studies • testing ideas • optimization

  6. Balling plant simulator

  7. Balling plant simulator Types of data from simulation • Particle data (sampling frequency) • trajectories • velocity, pressure, overlap • Statistics (space and time averaged) • distribution functions • average and standard deviation • correlation functions • Field data (time averaged, grid & interpolation) • mass density • pressure field • velocity field • shear rate • inertial number, granular temperature

  8. Drum Material Solver Damping time 5*h FIXERA double -> float Number iterations default flera threads men ejpålösare

  9. Observations - preliminary d / v = 0.05[m] / 2[m/s] = 0.02 [s]

  10. d / v = 0.03[m] / 2[m/s] = 0.015 [s]

  11. d / v = 0.015[m] / 2[m/s] = 0.0075 [s]

  12. Average velocity vs time step

  13. Velocity distribution functions

  14. Particle velocity r = 7.5 mmh = 0.01, 0.001, 0.0001 s

  15. Particle velocity r = 15 mmh = 0.01, 0.001, 0.0001 s

  16. Particle velocity r = 25 mmh = 0.01, 0.001, 0.0001 s

  17. Average pressure vs time step

  18. Pressure distribution functions

  19. Particle pressure r = 7.5 mmh = 0.01, 0.001, 0.0001 s

  20. Particle pressure r = 15 mmh = 0.01, 0.001, 0.0001 s

  21. Rotational velocity r = 25 mm, 15, 7.5 mm

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