Peter Wypych, University of Wollongong, New Design Methods to Improve Efficiency of Handling Operations

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 [email protected]

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


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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


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2 4 6 8 10 12 14 16 18 20

20

18

16

14

12

10

8

6

4

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)


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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


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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


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Calibration for DEM Material Model(New “Swing Arm” Slump Tester: Bauxite)

Video Video

Shape, friction and moisture/cohesion

Other Calibration Tests


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Dynamic Validation of DEM for Design

Conveyor TransferResearch Facility

7 m/s

Video

Dynamic Validation of DEM for Design(Hood-Spoon Conveyor Transfer)


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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


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Existing Design

Design Problems:

Off-Centre Loading

Reduced Capacity

Non-Symmetrical Wear Patterns

FeedChute

Design Problems


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Solution Option for Re-Design

DeflectorPlate

Design Improvements:

Central Loading

Increased Capacity

Symmetrical Wear Patterns

Feed Chute

Design Improvements


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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


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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


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Calibrated EDEM Material Modelused to Optimise Design Solution:

Modification B

Modificationof Hood

Modificationof Mid Chute

Modificationof Feed Chute

Modification B:


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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+


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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


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Product Coal Filtercake (dried)

Some Calibration Tests

Product Coal

Filtercake


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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 !!