Metso Products and services Services Process optimization and connected services Physics-based simulations

Metso physics-based simulations

By using physics-based numerical simulation models combined with our minerals processing expertise we can improve the energy efficiency and performance of your comminution equipment.

Introduction to physics-based models

For new comminution product development, we leverage the physics-based models. The models influence the design process from start to finish and predict the performance at full scale utilizing lab-scale and pilot-scale data. The simulation models also help our customers to predict the outcomes when or if changes are made in design or operating conditions.
 
  • Our in-house numerical models simulate solids and slurry through two-way coupling of Discrete Element Method (DEM) with particle breakage and Smoothed Particle Hydrodynamics (SPH)
  • The models have been extensively validated against field data for the last 20 years and has proven to represent the real-world behavior accurately
  • The physics-based simulations are also used to develop equipment performance models in our HSC Chemistry® flowsheet simulation tool, for instance the models for cone crushers MP100, MP1250, and HPGR HRC™
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Simulation of primary, secondary and tertiary crusher
Primary secondary and tertiary crusher simulator
The simulator tool is for design of crushers for optimal performance and energy efficiency
 
  • Used for gyratory, jaw, impactor and cone crushers
  • Applying Discrete Element Method (DEM) with particle breakage
  • Prediction of power, throughput, particle size distribution and wear, for which the models have been validated with field data
  • Uses non-spherical particles to ensure volume/mass conservation
 
Mill shell liner simulator

Designs mill liners with optimal performance

  • Prediction of charge profile, power and energy spectra, liner wear life, which has been validated with field data
  • Simulates various particle shapes including spherical particles and non-spherical ones like tetrahedra
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Mill shell liner simulator
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Mill flow-through-the-grates simulator
Mill flow-through-the-grates simulator

Enables design of mill discharge systems for optimal performance and energy efficiency

  • Simulates mill discharge systems including the grates and pulp-lifters
  • Prediction of discharge rates, hold- up in the pulp- lifters, power, and energy spectra, all validated with field data
  • Comprehensive wear model validated with field data
Mill discharge simulator

Solution for evaluating optimal pulp lifter design configurations with pre-defined discharge rate

  • Simulates flow profile, including flowback, carry-over, shear work at mill backend to determine how well any pulp lifter configuration works
  • Comprehensive wear model validated with field data
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Mill discharge simulator
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Mill discharge system with trommel simulator
Mill discharge system with trommel simulator

Designs the mill trommel for optimal performance

  • Classification of discharge material on the trommel
  • Simulates the effect of impact plate & dam height-position on the trommel performance
  • Prediction of wear validated with extensive field data
Bulk material handling units simulator

Tool to design bulk material handling (BMH) units to capture particle flow characteristics

  • Simulates chutes, conveyors, sizer systems, feeders, reclaimers
  • Wear prediction validated by field data
  • Effect of moisture incorporated in the model
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Bulk material handling units simulator
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Screen simulator
Screen simulator

Designs screens for optimal material flow and mechanical performance

  • Modelling various screen types & motions including multi-deck screens, with elliptical, linear and circular motion
  • Simulation of material flow through each screen panel
  • Realistic prediction of material classification
  • Bed depth and particle speed predictions
HPGR physics-based performance calculator

Designs full scale HRC™ HPGR for optimal performance and energy efficiency

  • Combines the physics of the machine, process dynamics, and lab-scale ore characterization data
  • Mechanics of the HPGR is represented by a plastic rolling resistance model and based on Packed Bed Test (PBT) stress-strain and cake density relationships
  • Prediction of gap, PSD, throughput, and power over a full range of operating conditions
HPGR physics-based performance calculator
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Vertimill simulator
Vertimill simulator

Designs Vertimill liners

  • Prediction of liner wear life, power and energy spectra validated with field data
  • The code implementation is flexible such that constraints, manipulated/controlled variables can be added to mimic the real-life operating practices - automatically adds media in order to keep the power constant

Development for more than two decades

Metso's Advanced Simulations group started in 2001 when Svedala acquired J. A. Herbst and Associates. Originally, Herbst & Associates used the comminution Population Balance Models (PBM) to optimize grinding circuits with a combination of lab experiments and simulation. At that time, Herbst & Associates were selling MinOOcad, a mine-to-mill dynamic simulator incorporating these models. A year later, Svedala and Metso announced merger plans. After the merger was completed in 2002, Metso acquired the intellectual property rights to their DEM code base of Conveyor Dynamics (CDI).
Since then, Metso's Advanced simulation group has continued to develop and improve the techniques and tools with and for our customers.

Our advanced simulation team has a diverse background, with degrees covering Engineering Mechanics, Metallurgical Engineering, Mineral Processing Engineering, Chemical Engineering, and Physics. The team brings the best practices and experiences from both academia and the industry. The variety of backgrounds and skillsets allows for collaboration over a range of projects with a specified focus on practical computational applications of physics-based solutions.

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