Abstract
In this work, a nucleation model that includes nuclei breakage/fragmentation is proposed. The model is based on the nucleation model of Hapgood and the Stokes deformation number calculated from the granule dynamic yield strength from the previously reported granule breakage work. It is proposed that breakage or fragmentation of primary nuclei from binder spray will occur if the Stokes deformation number exceeds a certain critical number. In the case where breakage occurs the model for secondary nuclei size distribution is proposed. To validate the model, the characteristics of the primary nuclei formed from nickel laterite ores with diluted sulphuric solutions as a binder were investigated. The nuclei were produced by dropping the binder solution onto a stationary powder bed. The mechanical integrity of the primary nuclei formed, the relationship between the nuclei diameter and binder drop diameter were studied. The Stokes deformation numbers for nickel laterite powders with different particle size in a lab scale drum granulator were calculated and the nuclei size distributions with different nickel laterite feed powders are predicted.