Pulp Lifter: Modelling and Flow analysis

By Abhishek
 Contents

Quick about Mill

Pulp Lifter
Straight Arm Pulp Lifter
Curved Arm Pulp Lifter
Comparison
Discharge Performance
Measures.
Factors.
Grate Capacity Factors.
Performance Analysis Methodology
DEM Analysis
CFD Analysis
Case Study
Problem Statement
Problem Analysis
Approach
Findings
Customized Solution.
Design modification
DEM Simulation
Conclusion
 Quick about Mill

The overall process inside the mill can

be summarized as breakage,
classification, and discharge. The
material fed into the mill undergoes size
reduction, and is classified through the
grate according to fineness. The
material larger than grate aperture size
is retained inside the mill while the
material fine enough passes into the
pulp lifter channels. Then, the fine
material in the channels is discharged
out of the mill.

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 length of the straight radial arm is the

key factor for the performance of the pulp
lifter.
This determines the distance that the
material will travel from the periphery of
the mill to the discharge trunnion.
It also regulates the upper discharge cone
opening area.
The height of the vane wall is another key
factor as increased height will result in a
larger surface area and therefore
enhanced transportation capacity. The most conventional design type of
Pulp Lifters are with straight radial arms.
 Curved 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
particles only slide on the
surfaces of the radial arms or on
top of other particles. This is less
efficient than the curved one, as
the effect on the centripetal force
is very less, which drag down the
discharge velocity.
It can be used in bidirectional
operating mills.
Easy manufacturing as compared
to curved one.
The curved / spiral arm provide particles
more space to move in the direction of
gravity, hence creates additional vertical
velocity components. This weakens the
effects of centripetal forces and
eventually results into large discharge
velocities.
spiral geometry also acts like a scoop
that collects more particles than the
straight design do. The weight of
additional collected particles creates
extra pressure to accelerate the particles
underneath to exit faster.
 Pulp Lifter: Discharge Performance Measures

Discharge Performance Of Pulp Lifter

designs are evaluated against the
criteria's such as:
Discharge Rate.
Power Consumption.
Flow back / Carry Over
Working Life.

Flow back and carry over are the

drawbacks during mill operation.

Carry over occurs at higher speeds of

mill at which material collected by
vanes are not completely discharged
out thru the discharge trunnion for
one discharge cycle
 Pulp Lifter: Discharge Performance Factors

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:

Geometry of the vanes. RRP of grate holes.

Height of the vanes. Grate open area. (% of Mill area).
Quantity of the vanes. Maximum Grate Passage Size.
Grate Design. Recirculation Load.
Mill Diameter. Mill Diameter.
Mill RPM. Mill RPM.
Frictional Properties. Frictional Properties.
Particle Size Distribution. Physical Property of the Ore.
Percentage solid Content in the Slurry. Percentage solid Content in the Slurry.
 Grate : Capacity Factors

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

Methodology adopted for analyzing the Pulp

Lifter Discharge Performance.

DEM (Discrete Element Modelling).

CFD (Computational Fluid Dynamics).

The DEM is a numerical method developed

by P. A. Cundall in 1974, for the analysis of
the rock mechanics problem.

DEM tool is well known for the charge

simulation providing detailed information on
the interaction, energy spectra and hence
mill power draft.

Modeling of pulp flow in the pulp lifter

channel by CFD is beneficial in investigating
the flow back and carry over phenomenon.
 Pulp Lifter : DEM Analysis

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.

Momentum transfer by turbulence is modeled

by the standard kepsilon turbulence model,
which solves for the turbulent kinetic energy,
k and the dissipated energy, epsilon.
 Pulp Lifter : CFD Analysis

The simulation basically consists of pre-

processing, processing and post-processing
stages. First of all, the fluid domain model was
created from the original CAD model, followed
by the geometrical discretization process, also
known as meshing in the pre-processing stage.

The transient case set-up is configured by

assigning the models, material properties,
initial conditions, boundary conditions,
operating conditions, and the solution controls
in the processing stage. The transient case is
used in the analysis to plot the results at any
positions during the rotation.

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

Quick about Mill

Pulp Lifter
Straight Arm Pulp Lifter
Curved Arm Pulp Lifter
Comparison
Discharge Performance
Measures.
Factors.
Grate Capacity Factors.
Performance Analysis Methodology
DEM Analysis
CFD Analysis

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

DEM methodology was adopted to

analyze the dynamics of the granular
flow inside the pulp lifter chamber.

All particles larger than 1mm was

considered in the DEM analysis.

Hertz Mindlin contact law is used for

the particle interaction.

Material Properties like density, shear

modulus and poissons ratio is
defined.

Interaction properties like restitution

coefficient, friction coefficients are
defined
 Problem Analysis : Findings

The DEM analysis picture clearly

indicates that the charge build up is
getting created at the wall, where the
two channel merges to a single one.
The charge from the upper channel
falls to the lower one and
accumulates on the wall of it. This will
definitely result in higher sliding and
hence higher abrasive wear.

The carry over phenomenon is also

clearly visible from the DEM picture.
This will definitely affect the discharge
efficiency and will lead to more wear
of the UDC or other areas at Pulp
Lifter.

Power consumption was analyzed by

the torque curve. As the power
consumption is a function of torque Wear Prone areas was analyzed by plotting
and mill RPM. the shear contact energy distribution.
 Customized Solution: Design Modification

The Pulp Discharger assembly has been designed with the existing fixing holes.

Grate was also designed to meet the required capacity.

 Customized Solution: Design Modification

The straight arm profile of the pulp lifter is changed from radial to skewed. This eliminated
the carryback phenomenon observed in earlier design.

Grate RRP and total open area was optimized.

 Customized Solution: DEM Simulation

The carry over phenomenon was

very less in compare to older
design. This will lead to lesser
wear of the Pulp Lifter.

The slurry pooling issue was

minimized. As the pooling affects
the breakage field adversely by
softening the impact of balls and
rock particles.

The wear prone area (area where

the charge is building up) was
strengthened.

Power consumption is lesser as

compared to earlier design.

Shear contact energy was less in

compared to old one.
 Conclusion

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.