Simulation analysis of the crushing performance of a double-toothed roll crusher based on the Tavares model

To estimate the crushing performance of the double-toothed roller crusher used in the semi-continuous stripping process at the Baorixile Open-pit Coal Mine, a crushing performance simulation method based on the Tavares crushing model is proposed. The study employs the EDEM discrete element simulation software, with particle flow rate, particle size distribution, and crushing load-bearing capacity as evaluation criteria, to establish a crushing simulation system for a 9 000 t/h double-toothed roller crusher. The simulation input particle size is set at 100-2 000 mm, based on statistical data from the coal mine site. The results indicate that the power response of the double-toothed roller crusher aligns well with the designed power, confirming that the simulation system operates normally at the intended capacity. The average particle size before crushing is 1 121 mm, which reduced to 28.95 mm after crushing, yielding a crushing ratio of 38.7, meeting the safety requirements for subsequent belt conveyor transportation. The ratio of the mass increase rate in the crusher hopper to the mass change rate of the discharge is 4.6, demonstrating that the crusher can achieve a crushing capacity of 9 000 t/h under the condition of truck unloading cycles of 5 minutes per trip.