刘 权a，蔡改贫b，吴昌萍a，郝书灏a
江西理工大学 a.机电工程学院， b.电气工程与自动化学院， 江西 赣州 341000
引用格式：
刘权， 蔡改贫， 吴昌萍， 等. 对辊破碎机产物粒度分布特性［J］. 中国粉体技术， 2026， 32（3）： 1-11.
LIU Quan， CAI Gaipin， WU Changping， et al. Particle size distribution characteristics of double-roll crusher products［J］. China Powder Science and Technology， 2026， 32（3）： 1-11.
DOI：10.13732/j.issn.1008-5548.2026.03.015
收稿日期： 2025-11-24， 修回日期： 2025-12-31，上线日期： 2026-02-01。
基金项目： 国家自然科学基金项目， 编号： 52364025。
第一作者： 刘权（2002—），男，硕士生，研究方向为散体物料破碎。E-mail：2724017556@qq.com。
通信作者： 蔡改贫（1964—），男，教授，博士，博士生导师，江西省中青年学科带头人，研究方向为物料高效破碎先进技术研究与装备开发。E-mail：1123615286@qq.com。
摘要：【目的】 为了改善对辊破碎机破碎产物粒度分布、 提升破碎机产能，探究其破碎产物粒度分布特性。 【方法】结合Tavares破碎模型及室内试验， 分析不同的排料口间隙、 转速及物料密实度对对辊破碎机破碎产物粒度分布的影响规律。【结果】 辊缝隙从3 mm减小至1 mm，粒径为1~3 mm的产物累积质量分数提升22.5%，产物平均粒度从2.89 mm减小到1.56 mm；产量随转速升高而增加，但产量增加速率会随着转速增加而降低；物料密实度提高会使细粒级（<2 mm）占比提高、粗粒级（>4 mm）占比降低。【结论】 破碎产物在接近辊缝尺寸的粒级范围富集，破碎产物主体粒级占比主要由辊缝大小决定；提高物料密实度可增加破碎比，物料粒度过小会导致对辊破碎机对颗粒的破碎效率降低。
关键词： 对辊破碎机； 粒度分布； 离散元法； 破碎性能
Abstract
Objective In industrial sectors such as mineral resource development and metallurgy， material crushing serves as a critical process，and crushing efficiency directly affects the energy consumption of the entire production line.The double-roll crusher，as the core equipment for achieving medium and fine crushing of ores in mineral processing， primarily relies on the squeezing and shearing forces of its two rolls to perform crushing operations. In actual production， the particle size distribution of the crushed product not only directly affects mineral separation efficiency but also serves as a core indicator for evaluating crusher performance and capacity. Therefore， investigating the particle size distribution of crushed materials under different operating parameters of the double-roll crusher is of significant importance. To optimize the particle size distribution of crushed materials and enhance crusher productivity， this study determines the maximum theoretical feed particle size for double-roll crushers based on force characteristics and bite angle analysis. It further explores the influence of tooth roll structural parameters， operating conditions， and feed density on the final particle size distribution. The research methodology and conclusions facilitate the regulation of product particle size distribution and the optimization of crusher performance， thereby achieving efficient crushing operations with double-roll crushers.
Methods This study employed a coordinated research framework integrating discrete element method （DEM） simulations with systematic laboratory experiments. A rigorous mechanical analysis of the double-roll crushing principle was first conducted to define operating conditions， ensuring experimental reliability. The maximum theoretical feed particle size was derived based on the critical engagement angle. Subsequently， a numerical model was constructed using EDEM software， integrating the Tavares crushing model to accurately reproduce the dynamic evolution of the crushing process and quantitatively characterize the properties of the crushed product. This model simulated the dynamic crushing process of material particles and particle-equipment interactions. It was then employed to investigate the influence of various kinematic and structural parameters， roll gap， and rotational speed on the final particle size distribution. To complement the numerical simulation results， the third phase involved laboratory testing to independently examine the influence of feed density on the particle size distribution and crushing characteristics of the crushed product. Finally， through comprehensive quantitative analysis of both simulated and experimental datasets， the interaction mechanisms among roll gap， rotational speed， and material density were elucidated. This analysis revealed the collective influence of these factors on the product particle size distribution and equipment processing capacity， as well as the underlying patterns affecting the post-crushing particle size distribution.
Results and Discussion Based on the established simulation model and experiments， computational results indicated that crushed products were predominantly concentrated within the particle size range close to the roll gap dimension， demonstrating that the roll gap exerted a dominant constraining effect on the particle size distribution. When the roll gap size decreased from 3 mm to 1 mm， the negative cumulative yield rate for the 1~3 mm particle size increased by 22.5%， and the average product particle size decreased significantly from 2.89 mm to 1.56 mm. Regarding processing capacity， this study found that while increasing rotational speed initially enhanced throughput effectively， the rate of output growth gradually stabilized as speed continued to rise. This phenomenon indicated that although high rotational speeds initially increased material feed rates， mechanical limitations and particle slippage at extreme speeds hindered linear growth in processing capacity. Furthermore， increased feed density intensified interactions between particles during crushing. Enhanced material compaction promoted finer particle content while effectively reducing the proportions of coarse particles. A denser material bed elevated inter-particle stress， thereby enhancing the crushing ratio. However， excessively small initial feed particle size weakened inter-particle forces due to poor meshing， thereby reducing the crushing efficiency of the double-roll crusher.
Conclusion This study investigates the influence of different structural configurations and material parameters on the particle size distribution of products from double-roll crushers. Through a combined approach of numerical simulation and experimental research， analysis of structural and feed parameters indicates that the roll gap size is the key factor determining the proportion of particle size distribution. Reducing the roll gap alters the proportion of dominant particle sizes in the product， enhancing the fineness of the crushed materials， but this effect has a threshold. Increasing the rotational speed of the double-roll crusher initially raises output.However， beyond a certain speed， the rate of output increase diminishes， limiting the effectiveness of further speed increases. Increasing material density intensifies inter-particle compression and crushing， further refining crushed particles and enhancing the crushing ratio. Crushed products tend to concentrate heavily within the particle size range close to the roll gap dimension. Modifying material density has a limited impact on the proportion of the main particle size in the crushed product， and the roll gap dimension remains the primary determinant of this proportion， consistent with simulation results. Excessively fine particle size reduces the forces between particles， diminishing the crushing efficiency of the rolls on ore particles and hindering material fragmentation. Therefore， proper control of material particle size is essential for enhancing crushing efficiency.
Keywords： double-roll crusher； particle size distribution； discrete element method； crushing performance
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