38 COAL HANDLING

Designed for utmost reliability

Dr Brian Moore, James Fuata, Stephen Cole, Dr Richard LaRoche, Dr Andrew Grima
and Dr Peter Wypych look at maximising the reliability of bulk handling equipment

H
atch, a global engineering,
Table 1: moisture content for product coal and filter cake
construction and project
management (EPCM) company is Moisture
Sample Comment
working with developers of simulation content (%wb)
software to provide intuitive and Filter cake – HBF A 24.68 As received
integrated tools that will increase mine Filter cake – HBF B 23.05 As received
performance at the operational level. Filter cake – HBF A & B 23.92 As received, 50% HBF A/50% HBP B
A team of Hatch engineers specialising
Saturation moisture content,
in bulk materials handling and processing Filter cake – HBF A & B 28.96
50% HBF A / 50% HBP B
has been working with DEM Solutions,
and its partner, Bulk Materials Engineering Product coal 6.73 As received, bulk measurement

“The EDEM Australia (BMEA), to optimise the design

of equipment, identify problem areas and
BulkSim improve performance.
Solution DEM Solutions, a leader in discrete
element method (DEM) simulation software
includes for the engineering of bulk material
access to handling and processing equipment, and
DEM’s EDEM BMEA, a specialist in bulk materials
handling (including laboratory testing and
BulkSim soft- troubleshooting), have joined together to
ware, BMEA offer the EDEM BulkSim Solution. This is a
global infrastructure of expertise and test
material- facilities, which support enterprise-wide
testing deployment of DEM technology to large
services and mining companies and EPCMs.
The EDEM BulkSim Solution includes
DEM’s mat- access to DEM Solutions’ EDEM BulkSim
erial model software, BMEA material-testing services
and DEM Solutions’ material model-
calibration” calibration services.
Implementation of the EDEM BulkSim
Solution by mining companies and EPCMs
can increase the availability of high-quality,
calibrated DEM simulation, and transform
the traditional empirical approach used in
the engineering design of conveyor
transfer points and associated bulk
material-handling equipment.
In this article, we discuss a case study
showing the value provided by Hatch and
the DEM Solutions/BMEA partnership on a
project involving the upgrade of a critical
conveyor-transfer point for a mine in
Australia, operated by a global company.
The firm needed to increase capacity and
improve equipment performance in the
flow of product coal at its washing plant.
Fig 2: product
coal (left) and
filter cake (right)
samples
CASE STUDY:
TRANSFER CHUTE REDESIGN
The project formed part of an upgrade to
an existing coal-preparation plant, which
required equipment and infrastructure
improvements to accommodate increased
production. Within this scope, Hatch
was responsible for the transfer point to
the final product conveyor, which loads
the product to truck-loading bins (see
figure 1).
Fig 1: existing transfer chute. Receiving
conveyor (bottom right) discharges to
truck-loading product bins
Although a relatively small conveyor, at
1,200t/h, it is a critical component to ensure
constant product throughput. The existing
chute plugged at times as a result of
material build-up and surges in flow rate.
The transfer chute was redesigned
using calibrated EDEM material models
and EDEM BulkSim simulation. The
revamp included a new flop-gate to
increase reliability and throughput, and
lower maintenance costs. The EDEM
BulkSim simulation work enabled the new
designs to be virtually prototyped and for
Hatch to evaluate their performance
under a range of material-flow conditions
early in the process.
The transfer chute was designed to
transport coarse product coal and
dewatered filter cake in a coal-preparation
plant. The product coal is loaded on to
the conveyor belt first and then the filter
cake, conveyed from horizontal vacuum
belt filters, is layered on top of it.
MATERIAL TESTING
The first step of the EDEM BulkSim Solution
involves material testing. Samples of the
product coal and filter cake were collected
from the product coal-processing system
and two horizontal vacuum-belt filters (HBF).
The material samples, including 120L of
the product coal, were sent to the BMEA
laboratory for analysis (see figure 2).
Services provided by BMEA include
flow property testing and pneumatic
conveying testing, and the company has
access to the solids-handing facilities of
the University of Wollongong.
The company tested the the samples
to characterise the materials, including
measuring the moisture content (see table
1), size distributions and other properties.
To understand how the materials behave

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under dynamic conditions, unique tests
were conducted to study the dynamic flow
of the two materials to aid in the calibration
of the EDEM BulkSim simulations.
The variation in moisture content of the
filter cake in samples HBF A and B was
relatively minor, (table 1). The moisture
content of the filter cake suggests the
bulk solid was close to maximum strength
conditions; ie 60-80% of saturation
moisture.
Table 2 lists the measured solid and
loose-poured bulk density of the materials
that were used as guidance when
selecting the solids density of the coal
for use in the calibrated material model.
DEM MODEL CALIBRATION
The next step in the EDEM BulkSim
Solution is to link the physical bulk
material tests of the product coal and
filter cake with material models in the
DEM simulations.
In this process, the simulation
parameters were determined such that
the physical test results are replicated in
the DEM simulations of the BMEA tests.
The result of this step was two
calibrated EDEM Material Models for the
product coal and filter cake, respectively.
Model calibration ensures the simulated
material behaviour will reflect the real
material bulk behaviour, providing
confidence in the simulation.
Traditionally, the calibration of a
material model is a time-consuming
process that requires the user to manually
input a wide range of material shapes and
friction parameters, and perform an
assessment on the simulation results.
To address these issues, DEM Solutions
has implemented automated parameter
sweeps and optimisation on a Microsoft
Windows Azure cloud computing platform,
making it possible to create a calibrated
EDEM Material Model fast and efficiently
while not affecting project timelines.
SIMULATION SCENARIOS
In the final step of the EDEM BulkSim
Solution, a series of simulation scenarios
were run to examine material flow
behaviour in the existing and proposed
designs. The process flow included:
• Importing CAD models of the existing
and updated transfer chutes;
• Loading the calibrated EDEM Material
Models, and
• Assigning the required mass flow rate
of material to the transfer chute.
The first scenario simulated the conditions
in the existing transfer chute design. The
images taken from the simulation of the
existing design (see figures 4 and 5) show
the product coal coloured black and the
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COAL HANDLING 39
Fig 3: comparison
of simulation and
experiment for
product coal
Table 2: solid and bulk density for product coal
and filter cake
Product coal Filter cake
Solid density
1,172-1,313 1,043-1,163
(kg m-3)
Loose-poured
bulk density 681-804 791-833
(kg m-3)
Fig 4: simulated material flow
for the existing set-up, showing
open and closed flop-gates
filter cake gray. The velocity profile is also
indicated. Simulation analysis of the
existing transfer point operating at the
design flow rate shows the same
behaviour as observed in the field, such as
the trajectory of the material and the
clumping of the highly cohesive filter cake
as it passes through the flop-gate.
Four additional simulation scenarios for
the proposed new flop-gate design were
then performed to troubleshoot and verify
it. These scenarios included the updated
equipment model running at design and
maximum material flow rates. In addition,
simulations were performed of the The judgement of the team is that this
‘worst-case scenarios’, including highly minor flow separation was caused by a “The transfer
cohesive materials and surge in-flow rates combination of slight differences in the
(see figures 6-8). CAD geometry versus the actual fabricated chute was
These scenarios did show the potential design, along with the team being very redesigned
of material flow separation and a small conservative on the nature of the most
amount of spillage at the head roller difficult material that the transfer point was
using cali-
region. For flow rates higher than those likely to handle. The information provided brated EDEM
designed, separation was seen for the from these cases allowed the robustness of material
material leaving the head roller, causing the proposed design to be explored.
the edges of the material flow to avoid the The simulation results also show the models
flop gate and load chute. predicted relative wear behaviour of the and EDEM
The simulation indicated that under existing and updated designs, under
certain conditions this could cause spillage, normal operating conditions (see figures
BulkSim
which prompted the team to review the 9-10). In addition, the proposed design simulation”
design in the field. performed better than expected when
40 COAL HANDLING

dealing with highly cohesive materials and
at surge in-flow rates, with lower wear
rates indicated.
The design flow and verification of
process equipment involves an iterative
process of preliminary, internal and client
review sessions.
The availability of both 3D images and
dynamic video streams as a part of the
transfer chute design has proved to be an
effective review element. Further, the
ability to explore ‘what if’ scenarios allows
The benefits of BulkSim
worst-case situations to be investigated
and operational robustness ensured.
The updated design improved the
functionality of the transfer chute and
reliability of material flow by optimising
the geometry of the equipment.
Modifying the shape of the flop-gate
and loading chute allowed the angles of
incidence between the coal stream and
equipment to be decreased in order to
reduce the deceleration of the material
upon impact and minimise material
build-up and wear.
Troublesome issues such as spillage
and material build-up in the conveyor
load zone were also examined in the DEM
simulations in order to reduce future
maintenance costs and downtime.
Based on these results, Hatch was able
to verify the performance of the new
chute design and select the configuration
for production of it.
The mining company client benefitted
from Hatch’s understanding of the
reliability improvement required for
increasing conveyor performance.

The EDEM BulkSim Solution provides the essential components needed to deploy DEM ENGINEERING WITH CONFIDENCE
technology throughout an organisation. Hatch has a long history of including
With easy-to-use EDEM software, customised for the mining industry, outsourced innovative technologies that enable
materials-testing services and the highly-optimised material calibration provided by clients to improve their equipment
simulation experts, DEM Solutions and its partner, BMEA, provide an enterprise- performance and raise production levels.
wide, scalable engineering solution, which enables engineers to deliver superior Over the past several years, Hatch has
designs. been integrating EDEM simulation
Hatch can now test a higher percentage of designs virtually before installation, and technology and services into design
disseminate simulation analysis and investigations throughout the organisation, thus projects, and has achieved a high level of
offering simulation expertise to the majority of its clients around the globe. Additional confidence in materials-handling
benefits include: equipment designs.
• The security features of the Calibrated Material Model. Here, the material parameters This results in substantial benefits
cannot be modified, except by authorised users, reducing the design risk of around design robustness, equipment
unsubstantiated DEM simulations; and reliability in plant start-up and commis-
• Designers engaged in 3D surface modelling of transfer points can deploy DEM sioning, and boosting plant quality, yield
simulation confidently, to deliver a robust design, by combining 3D CAD and EDEM and performance.
BulkSim simulation and analysis within their design environment. Deployment of the EDEM BulkSim
Solution allows Hatch to integrate DEM

Fig 7: simulated
Fig 5a material flow for
the new design,
running at design
rate (1,200t/h)
with extra-
cohesive material,
showing velocity
profile. Reliable
flow is maintained

Fig 5b

Fig 8: close-up view of a ‘worst case’

Fig 6: simulated material flow for the
new design running at surge in-flow
Fig 5: simulated material flow for the existing set-up, rate (1,228t/h), showing velocity
showing velocity profile profile. Reliable flow is maintained
scenario, showing clumping of highly
cohesive material discharging to
conveyor, running at design rate
(1,200t/h). Even with clumping,
steady flow is maintained

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 COAL HANDLING 41

Fig 9: wear experienced by the existing flop gate (9a) and

transfer chute (9b), expressed as the tangential component of
the contact energy

Fig 9b

Fig 9a

technology into the design of new mines Fig 10: wear

and redesign of problematic transfer experienced by the
chutes without the need to establish updated flop gate (10a)
internal DEM simulation expertise across and transfer chute (10b)
the organisation.
As seen in this case study, DEM
Solutions and its partner, BMEA,
provide the material testing and
highly-optimised material calibration
technology that is essential to ensuring
high-quality DEM simulations that are fit
for purpose.
The resulting high-quality simulations
provide clients with a reliable operating
envelope for each transfer point,
including simulation scenarios that
account for varying particle size and
moisture content, tonnage and belt
speeds.
The simulations also help clients to Fig 10a
identify those areas experiencing the
highest impact and abrasion forces, and
to compare projected wear patterns
between different designs or operational
scenarios.
By integrating the EDEM BulkSim
Solution into the design workflow, Hatch
has moved beyond traditional empirical
methods of conveyor design to offer the
highest quality DEM simulation results
possible and with the speed necessary
to fit into tight mining project timelines.
As a result, mine operators will see
maximised profitability of their bulk
materials-handling equipment through
increased uptime, lower operating costs,
and extended equipment life – leading to
increased mine productivity and Fig 10b
performance.

Dr Brian Moore is lead engineer, bulk materials handling, South East Australian Hub, with more than 30 years’ experience, specialising in bulk materials-handling systems
and equipment. James Fuata is a graduate engineer. His experience includes belt-conveyor analysis and transfer-chute design utilising EDEM. Dr Richard LaRoche is vice-
president of engineering and US general manager of DEM Solutions. He has over 25 years’ experience as an expert consultant in engineering simulation, and the manage-
ment of technical support and engineering consulting teams. Stephen Cole is a senior consulting engineer at DEM Solutions who focuses on DEM project management
for the mining industry. Dr Andrew Grima is a principal design engineer at BMEA. He is an expert on the deployment of EDEM for the design and troubleshooting of
equipment for handling ores in overland and in-plant conveying. Dr Peter Wypych is general manager of BMEA and an associate professor of mechanical, materials &
mechatronic engineering at the University of Wollongong. For more information: www.dem-solutions.com; www.hatch.ca; www.uow.edu.au/eng/research/bmea

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