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Neftalí Rojas - Tega - Pulp Lifter
Neftalí Rojas - Tega - Pulp Lifter
By Abhishek
Contents
The material transport is critical in the sense that failure to efficiently transport of the slurry
out of the mill affects the breakage field adversely inside the mill and hence, softening the
impact of balls and rock particles. As a result, the milling efficiency is reduced.
About Pulp Lifter
Pulp Lifter is the important component at the discharge end of Grate Discharge Grinding Mills.
Construction: Pulp Lifters are radial array of channels, separated by a channel wall, known as
vanes. Each channel is open to the mill at the outer end to allow material inflow through
grates and at the inner end to direct discharge out of the mill, through the mill trunnion.
Depending on mill types, the vane walls can be straight or curved.
Working Principle: Pulp Lifters operate through a lifting and bailing action. They behave like a
reversed centrifugal pump which collects material from its periphery and transports them out
via center.
Straight Arm Pulp Lifter
The Curved design betters the performance of the Pulp Lifter as the curved portion accelerates
the material towards the discharge trunnion.
The performance of the pulp lifter in conjunction with the grate design determines the ultimate
flow capacity of the grate discharge grinding mills.
Comparison
In straight pulp lifters, the The curved / spiral arm provide particles
particles only slide on the more space to move in the direction of
surfaces of the radial arms or on gravity, hence creates additional vertical
top of other particles. This is less velocity components. This weakens the
efficient than the curved one, as effects of centripetal forces and
the effect on the centripetal force eventually results into large discharge
is very less, which drag down the velocities.
discharge velocity.
spiral geometry also acts like a scoop
It can be used in bidirectional that collects more particles than the
operating mills. straight design do. The weight of
additional collected particles creates
Easy manufacturing as compared extra pressure to accelerate the particles
to curved one. underneath to exit faster.
Pulp Lifter: Discharge Performance Measures
The discharge performance of the pulp lifter The discharge performance through the
are sensitive to specific design and grate are sensitive to the below parameters
operating parameters such as: such as:
Morrell and Stephenson proposed below two eqns. Relating the hold-up in the grinding
media and pool zone with flow rate, grate design, mill diameter.
Performance Analysis : Methodology
The DEM analysis clearly shows the dynamic free surface profiles of the ore particle carried
by the pulp lifter channel.
This also shows the motion of the ore particles at various angular positions of the mill.
This also helps in analyzing both quantitative and qualitative means, the ore particle failed
to discharge. (carry over Phenomenon)
The analysis is helpful in plotting the normal and tangential contact energy at the wall
surface.
Pulp Lifter : CFD Analysis
The discharge for any pulp lifter comprises of two flow components: fluid flow of fine
rock slurry (analyzed thru CFD) and the other pebble flow (thru DEM).
The subsequent motion of the two components is different and they discharge at
different points in mill rotation.
Pulp Lifter : CFD Analysis
The fluid pulp rotating inside the mill is mainly subjected to gravitational force, centrifugal
force, pressure force, and viscous forces. The gravitational force and the centrifugal force
are the predominant one.. Navier Stokes equations (mass, momentum and energy
Conservation equation) and the continuity equation are used for the flow dynamics
calculations, characterizing the pulp flow in the pulp lifter channel.
The multiphase flow (Air and slurry) is considered for the analysis. In the multiphase flow,
the phases are separated by a distinct interface. The volume of the fluid (VOF) model is
used as the multiphase model, while k-epsilon model is used for the turbulence model for
the flow analysis.
The VOF method is used for determining the location of the interface between the air and
slurry phases. The VOF formulation applies to models involving two or more immiscible
fluids, representing each phase by a volume fraction in the computational cell. In each
control volume, the volume fractions of all phases sum to unity.
Finally, the simulation results are viewed and reported using post processing tools. CFD
analysis shed light on the detailed understanding of the physics of flow through pulp lifter
channels and helps in predicting all flow related results such as volumetric flow rate, free
surface profile of the flow, phase volume fraction, velocity distribution, and stress at the
walls, etc.
Contents
Case Study
Problem Statement
Problem Analysis
Approach
Findings
Customized Solution.
Design modification
DEM Simulation
Conclusion
Problem Statement
Parameters Details
Mill Type SAG (22' X 36.5' Long)
Mill RPM 80 % of Critical (13.2 RPM)
Total charge volume % 30%
Fresh TPH 420
Circulating Load 200%
P80 (from Mill) 6.3 mm
High wear in UDC and other areas
Ore Specific Gravity 2.8 at Pulp Lifter
Problem Analysis: Approach
The Pulp Discharger assembly has been designed with the existing fixing holes.
The straight arm profile of the pulp lifter is changed from radial to skewed. This eliminated
the carryback phenomenon observed in earlier design.
DEM tool can be effectively used for performing the dynamics of the charge
simulation.
DEM provides detailed information on the interaction, energy spectra and hence
mill power draft.
DEM provides qualitative and quantitative information about the carry over / flow
back.
DEM is helpful in analyzing the complete particle shape and size distribution.
Coupling between the CFD and DEM analysis allows us to get the
comprehensive information about the specifics of the mill operation.