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Implementation of Coupled DEM-FEM to Investigate Mechanical Behavior of Roller Screen Rolls in Classification of Green İron Ore Pellets

Document Type : Original Research Paper

Authors

1 School of Mining Engineering, University College of Engineering, University of Tehran, P.O. Box 14395-515, Tehran, Iran

2 Faculty of Mining, Petroleum & Geophysics Engineering, Shahrood University of Technology, Shahrood, Iran

10.22044/jme.2025.16201.3131

Abstract

Because roller screens are connected to the pelletizing discs on one side and the green iron ore induration furnaces on the other side in pelletizing plants, they play a crucial role in the plant's productivity and steel production process. Consequently, an optimal performance and structural design are essential in this context. A significant issue with roller screens during the classification of green pellets is the deformation of the rolls caused by the force exerted by the pellets during operation. This deformation disrupts the uniformity of the gap between the rolls, thereby reducing the efficiency of the screen, and the overall performance of the circuit, as well. Despite the importance of this issue, no studies have been conducted to investigate the force exerted by the pellets during classification on the screen or the subsequent mechanical behavior of the rolls. Therefore, this study employs the discrete element method–finite element method (DEM-FEM) coupling simulation technique to examine, for the first time, the mechanical behavior of rolls and to optimize their structural design. The results indicated that decreasing the roll diameter from 80 mm to 30 mm led to 1088 times increase in the average total deformation of the rolls. Furthermore, increasing the thickness of the polyurethane liner from 3 mm to 14 mm caused the average total deformation to rise by 54 times.

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References
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Journal of Mining and Environment
Volume 16, Issue 6
September and October 2025
Pages 1991-2004
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