An effective sphere-based model for breakage simulation in DEM

Breakage occurs in several particulate systems that are simulated using the discrete element method (DEM), namely crushing and grinding as well as inadvertently in several others that include transportation, handling, mixing, separation and geotechnical applications. Different approaches may be used to describe particle breakage using DEM, but in cases in which particle breakage influences significantly the flow behaviour of the material, imbedding the breakage description in DEM provides the only valid alternative. This study describes the implementation of a detailed breakage model based on particle replacement with spheres in the commercial software EDEM. It accounts for variability and size-dependency in particle fracture energies, weakening of particles by unsuccessful stressing events, as well as addressing several reported shortcomings in sphere replacement schemes. The model is verified in great detail on the basis of single-particle breakage information and validated using measurements in unconfined particle beds of mineral ores. [Display omitted] •A particle replacement scheme involving spherical particles is proposed.•A detailed breakage model has been implemented in EDEM as an API.•Model involves three classes of particles: resolved breakable, resolved unbreakable and dummy.•The model has been properly verified on the basis of single-particle breakage.•The model has been validated on the basis of unconfined particle bed experiments.