Modeling Iron Ore Breakage with the Tavares Model and DEM Simulation of a Laboratory Jaw Crusher

Selection of jaw crushers to be used in the first size reduction stages can be a challenge in the design of comminution circuits, given the impossibility of conducting tests at full scale and the limited representativity of small-scale tests. An alternative that has emerged is advanced simulation using the discrete element method (DEM). However, it requires detailed testing with very coarse particles, which can be challenging. The work presents detailed characterizations of particle shapes, breakage model, and contact parameters for simulations in Rocky DEM of an iron ore from Brazil. Validation consisted in comparing predictions to laboratory jaw crushing test results. Good agreement was found between measured and predicted throughputs, whereas simulations marginally underpredicted power and some overpredicted product fineness.