Skip to content
HD Engineering & Design
Menu

Discrete Element Modelling

Discrete Element Modelling is used to approximate the motion and mechanical interactions within a system. This is achieved by simulation of the bulk material as a discontinuous system of particles within the physical constraints of interest. The simulation then provides a detailed description of the velocities, positions, and forces acting in the system throughout the entire analysis.

DEM simulation of material flowing through a chute

Why DEM?

DEM allows for designs to avoid typical problems such as plugging, dust creation, material degradation, premature belt and chute wear, and off-center belt loading. DEM is a tool used to allow visualization of a variety of loading scenarios, such as upset conditions and various flow rates prior to fabrication. This approach is used to eliminate the traditional approach of trial-and-error testing, saving on fabrication costs while providing improved system operation.

Granular Reclaim Chute

Scope of project involved evaluating the design of a transfer chute designed by others (prior to fabrication and install). The new transfer point had to fit within a confined space and discharge onto a steep angle (~17°) conveyor that is oriented at an angle (plan view) greater than 90° from the belt conveyor discharge direction.

The project scope included the following:

  • Use DEM to evaluate the design of the proposed transfer point
  • Design new transfer point and use DEM to optimize performance
  • Prepare mechanical drawings for the transfer chute and update existing general arrangement drawings
DEM simulation of skip loading

Skip Loading Study

Skip loading is producing considerable dust and spillage. A study was performed to understand the cause of the problem and identify solutions to reduce dust, spillage, and loading time.

Loading times were reviewed in order to maximize product loading resulting in increased ore transfer.

DEM simulation of the apron feeder transfer chute

Apron Feeder Transfer Point Design

Raw ore is loaded onto an inclined belt on surface facilities. Dust, caking, plugging, and off-centered loading have been consistent issues in the past. Our new chute has improved performance in all aspects.

Isometric render of the redesigned product storage chute

Product Storage Chute Redesign

The existing transfer points allowed product to freefall from one conveyor to the next. This resulted in dust creation and material spillage in a small and difficult to maintain area.

New deflectors and bottom chutes were added. This minimized dust creation and product spillage. The project scope included the analysis of product flow through the existing chute system, design of chute inserts to keep fabrication costs low and to minimize the amount of field work required for installation, and new skirting design.

Isometric render of the reclaim gate and loading chute

Reclaim Gate Redesign

The goal of this project was to increase the flow capacity through the reclaim gates from 700 tph to 900 tph while also reducing dust creation and product spillage. Initial thoughts were that larger grizzlies, chutes, and gates would need to be installed which would require significant concrete and steel modifications as well as extended down time and more complicated installation and safety issues.

Flow simulations allowed us to determine that the existing gates could be slightly modified and reused when paired with a new loading chute and skirting design to achieve the desired flow rate. With over 20 gates on the length of the conveyor there were significant financial savings by avoiding the installation of larger equipment.