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11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 1
New Design Methods toImprove Efficiency of Solids
Handling and Processing
Peter Wypychwypych@uow.edu.au
Aim: Improve Efficiency of BulkMaterials Handling and Processing
1. Reliability: Consistent and predictable start-up, flow, capacity, behaviour
2. O&M Costs
3. Service Life: Wear, process damage
4. Quality Control: Product integrity
5. Sustainable Operation: Spillage, dust, environment, economics, community…
6. Relevant Design Method/s: integrated total solution or systems approach
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 2
1) Bins, hoppers, stockpiles, feeders, bin wall loads…
Arch/rathole dimensions Bin/hopper design graphs Stockpile/bin live capacity Transport moisture limit
Flow patterns: mass-flow, funnel-flow and expanded-flow
Review and Comparison of Design and Modelling Techniques
Application & Product Dependent
Quasi-static applications Traditional FP (sub 4mm): b, , t, w, FF
TypicalFlow
Properties
Dangerous toExtrapolateor Assume!!
Internal Friction
Wall Friction
Internal Strength
Compressibility
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 3
2 4 6 8 10 12 14 16 18 20
20
18
16
14
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10
8
6
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2
Flow Functions – Coal 10% wb(effect of time storage)
FF, t = 0
FF, t = 2 days
1 (kPa)
c(kPa)
5 days ??
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0 5 10 15
Hopper Outlet Dim
ension (m)
Moisture Content (% wb)
Effect ofMoisture
on ProcessRequirements
DEMC Saturation
Max Strength
Conical
Wedge
RangeFlow
BMEADustiness Tester(AS4156.6-2000)
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 4
Conventional FP Not applicable
Physical size of FP testers Inadequate
Friction, cohesion and adhesion Difficult to scale (dynamic applications)
Fine/sticky/clay ores Special impact tests
Traditional design methods…
2) CTs (hood-spoon, impact plate, rock-box, micro-ledge), “rapid-flow” chutes, trajectories, process equipment, wear… “Dynamic” applications:
Review and Comparison of Design and Modelling Techniques…
Traditional Design Methods1. Experience (including “rule-of-thumb”)2. Trial-and-Error3. Copy-and-Paste4. Analytical or “Continuum” Models5. Physical Scaled-Down Models6. “Traditional” DEM Research…● Time consuming and expensive● Assumptions and fine-tuning● Also Lack of validation
At UOW New Calibration Technology (with dynamic validation) for DEM Design
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 5
Full‐Scale Designs
Representative Dynamic Tests
New Calibration Technology for DEM Design
Industrial Application
Customer Know‐How
EDEMBulkSimCalibrated
Material Model
Calibration for DEM Material Model(New “Swing Arm” Slump Tester: Coal)
Video
Video
Shape, friction and moisture/cohesion
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 6
Calibration for DEM Material Model(New “Swing Arm” Slump Tester: Bauxite)
Video Video
Shape, friction and moisture/cohesion
Other Calibration Tests
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 7
Dynamic Validation of DEM for Design
Conveyor TransferResearch Facility
7 m/s
Video
Dynamic Validation of DEM for Design(Hood-Spoon Conveyor Transfer)
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 8
Dynamic Validation of DEM for Design
Exp VideoDEM Video
Case Study No. 1:Iron Ore Transfer Chute
Parameter Value
Capacity 2,300 tph
Belt Width 1,200 mm
Feed Belt Speed 2.6 m/s
Receiving Belt Speed 2.8 m/s
Bulk Density 2 t/m3
Troughing Angle 45 deg
Inclination Angle ofFeed Belt
2 deg
Chute Liner Ceramic Tile
Moisture Content 9% wb
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 9
Existing Design
Design Problems:
Off-Centre Loading
Reduced Capacity
Non-Symmetrical Wear Patterns
FeedChute
Design Problems
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 10
Solution Option for Re-Design
DeflectorPlate
Design Improvements:
Central Loading
Increased Capacity
Symmetrical Wear Patterns
Feed Chute
Design Improvements
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 11
Parameter Value
Capacity 11,000 tph
Belt Width 1,800 mm
Feed Belt Speed 4.6 m/s
Boom Belt Speed 4.8 m/s
Luff Angle 15 deg
Slew Angle 45 deg
Bulk Density 1.9 t/m3
Troughing Angle 45 deg
Feed Belt Inclination 15 deg
Chute LinerCeramic
Tile
Moisture Content 10% wb
Case Study No. 2:Iron Ore Stacker Transfer Chute
Existing Design
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 12
Design Problems:• Dead Zones• Potential Blockage• High Wear on Boom
Costs to Business:• Downtime• Limited Capacity (incl. surges)• Maintenance – Skirting, Spillage
and Belt Replacement• Overall Poor Reliability
Problems and Costs
ComplexVelocity Profiles
and Flow PatternsContinuum Models:● Particle Velocity● Trajectory● Cohesion ?
ContinuumModels
???
Chute Modelling and Analysis
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 13
Calibrated EDEM Material Modelused to Optimise Design Solution:
Modification B
Modificationof Hood
Modificationof Mid Chute
Modificationof Feed Chute
Modification B:
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 14
Acceleration on Boom
0
50000
100000
150000
200000
250000
300000
0 5 10 15 20
Tangential Cumulative Energy (J)
Simulation Time (s)
Original Design
Modification B
Improved Belt Life (20%)
Cumulative Wear on Boom
Improved Flowand Capacity+
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 15
Case Study No. 3: WSO Chute Blockages
Full-Scale Calibration Tests On-Site+ Special Impact Consolidation Tests
Case Study 4: 900tph Coal + 300tph Filtercake(wear and fines build-up)
Video
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 16
Product Coal Filtercake (dried)
Some Calibration Tests
Product Coal
Filtercake
11th Bulk Materials Handling Conference, 29-30 April 2014, PerthPeter Wypych, Bulk Materials Engineering Australia
© Wypych, 2014 17
Modified ChuteVideo
900tph Coal + 300tph Filtercake
Existing ChuteVideo
Calibrated EDEM Material model:
900tph Coal + 300tph Filtercake
Thanks to NEW Calibrated and Validated DEM Useful Design and
Troubleshooting Tool !!