OPTIMIZATION OF RAW MATERIAL TRANSPORT IN A TRANSFER CHUTE USING EDEM

8/19/2019 OPTIMIZATION OF RAW MATERIAL TRANSPORT IN A TRANSFER CHUTE USING EDEM

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OPTIMIZATION OF RAW MATERIAL

TRANSPORT IN A TRANSFER CHUTEUSING EDEM

Magno A. Calil Resende Silveira, Usiminas

Gustavo Lucas Rocha de Oliveira, Usiminas

Bráulio Viegas da Silva, Usiminas

Daniel Schiochet Nasato, ESSS


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SUMMARY

• Overview - Usiminas

• Introduction

• Objectives

• Chute optimization – step by step

• Conclusion


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Overview - Usiminas

• Usiminas acts in different segments in the steel chain,

delivering high quality products and services, integrating

solutions and adding value to the customer;

• Usiminas works in four business units: mining and logistics,steel works, steel transformation and capital assets;

• With a modern steel processing infra-structure, Usiminas is

prepared to attend, in a tailored way, the demands of the

automobile, auto parts, civil construction, electro-electronic,capital assets, domestic devices, among other segments


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Introduction

• Raw material transport using conveyor transfer and chutes

may become critical due to details not covered in the design

phase or the low maintenance frequency in the process.

• Problems such as material spillage, belt misalignment,breakage and premature wear of peripherals associated with

the system can cause damage to the process.

• Currently, part of the raw material is lost in transportation in

the Ipatinga ironmaking plant (Usiminas)

http://localhost/var/www/apps/conversion/tmp/scratch_2/Calha_Sinter_Pelota%20015.avi


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Step 1 – Data calibration

• Sequence of fast and well established experiments allows

the user to easily capture the parameters;

• Free fall test, static friction, critical rolling angle and repose

angle were mesured;• Simulations were performed on EDEM to calibrate data


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•Particle factory form reproduce particle dynamic angle

• Particle size: 12 mm diameter

• Mass flow: 278 kg/s

– 4 hours to simulate 10s in a quad core machine

Material data and initial conditions

Interaction data pellet/pellet pellet/rubber pellet/steel

Coeff. of restitution 0.2 0.5 0.09

Coeff. Os static friction 0.55 0.5 0.3

Coeff. Of rolling friction 0.28 0.2 0.15

Material data Pellet Rubber Steel

Posisson's Ratio 0.25 0.25 0.25

Shear modulus 1.00E+06 1.00E+07 1.00E+10

Density (Kg/m3) 3900 1500 7800


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Step 2 – Experimental validation

• Real case was video recorded and compared to the

simulated case;

• Simulation showed good agreement with real case;

• Flow through the chute and conveyor misalignment could beaccurately reproduced.


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Real Case


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Step 3 – Modification – Initial idea

• Initially was proposed to insert a internal deflector to adjust

material flow;

• The idea was rejected because the accumulation changed

side, but the misalignment remained;• Expensive solution high wear on deflector.


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Modification – Initial idea


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Step 4 – Final solution

• It was proposed to move the right guide from bottom chute

40 mm to the left;

• Solution showed good alignment in the conveyor;

• Cheaper solution.

Proposed modification on detail


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Final solution


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Conclusions

• EDEM captured real case phenomena to identify the causes

of the problem;

• Proposed solution (internal deflector) would be expensive

and would not align conveyor misalignment: – Discarded before implemented.

• Validated changes:

– Changes were implemented on Usiminas and solved the problem.

•Final solution cheap to implement! – Saved costs of trial and error!

OPTIMIZATION OF RAW MATERIAL TRANSPORT IN A TRANSFER CHUTE USING EDEM

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