crushing of cdw: from particle breakage to process application recycling...

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


UFRJ

COPPE

PEMM

LTM

UFRJ

COPPE

PEMM

LTM


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


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


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)


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


Presentation

Introduction

Particle breakage



Conclusions


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


Presentation

Introduction

Particle breakage



Conclusions


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


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


Testing devices◦ Impact load cell device

Tavares & King, 1998. Int. J. Miner. Process. v. 54, 1-28.



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.



Tavares & Cerqueira, 2006. Cem. Concr. Res., v. 36, 409-415.

CDW?

Multiple populations: heterogeity!


Testing devices◦ Drop weight tester / drop testing

ho

DropweightCollection

box

AnvilParticle

Guide

Tavares, 2007. Handbook of Powder Technology, vol. 12


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


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)



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



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


Presentation

Introduction

Particle breakage



Conclusions


Carried out in a number of devices


Application of comercial mineral processing plant simulators

Development of advanced models of comminution


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)




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




S3000Restolho

H3000

REMCO

Brita 1

Brita 0

Areia

VSI

50 mm


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 (%)





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 (%)


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



VSI Crusher

Cunha, Carvalho & Tavares, 2014. Proc. Comminution 2014.


Presentation

Introduction

Particle breakage



Conclusions


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.


Fine and ultrafine grinding:◦ Brick

◦ Tile

◦ White ceramic tile


30 micron10 micron1 micron


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)




◦ Water demand







Tensile strength


Gas permeation

Mercury porosimetry



220 mm +/- 5 mm



◦ Water demand







Tensile strength


Gas permeation

Mercury porosimetry




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


Carg

a El

étri

ca (1

0³ C

)


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

)


19,82

6,67

1,44

3,71

0

5

10

15

20

25


Carg

a El

étri

ca (1

0³ C

)


19,82

9,42

13,7915,72

0

5

10

15

20

25


Carg

a El

étri

ca (1

0³ C

)


19,82

2,00

4,64

2,34

0

5

10

15

20

25


Carg

a El

étri

ca (1

0³ C

)

AltaModeradaBaixa

Muito baixa

30 micron

10 micron

1 micron


Results


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


Presentation

Introduction

Particle breakage



Conclusions


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


Obrigado

Merci

Thank you

www.ltmcoppe.com

UFRJ

crushing of cdw: from particle breakage to process application recycling...

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