11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
11th Bulk Materials Handling Conference, 29-30 April 2014, Perth
Peter Wypych, Bulk Materials Engineering Australia
© Wypy...
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Peter Wypych, University of Wollongong, New Design Methods to Improve Efficiency of Handling Operations

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Peter Wypych delivered the presentation at 2014 Bulk Materials Handling Conference.

The 11th annual Bulk Materials Handling Conference is an expert led forum focusing on the engineering behind the latest expansions and upgrades of bulk materials facilities. This conference will evaluate the latest engineering feats that are creating record levels of throughput whilst minimising downtime.

For more information about the event, please visit: http://www.informa.com.au/bulkmaterials14

Published in: Engineering, Business, Technology
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Peter Wypych, University of Wollongong, New Design Methods to Improve Efficiency of Handling Operations

  1. 1. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 1 New Design Methods to Improve Efficiency of Solids Handling and Processing Peter Wypych wypych@uow.edu.au Aim: Improve Efficiency of Bulk Materials 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
  2. 2. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter 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 Typical Flow Properties  Dangerous to Extrapolate or Assume!! Internal Friction Wall Friction Internal Strength Compressibility
  3. 3. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 3 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 Dimension (m) Moisture Content (% wb) Effect of Moisture on Process Requirements DEMC Saturation Max Strength Conical Wedge Range Flow BMEA Dustiness Tester (AS4156.6-2000)
  4. 4. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter 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 Methods 1. Experience (including “rule-of-thumb”) 2. Trial-and-Error 3. Copy-and-Paste 4. Analytical or “Continuum” Models 5. Physical Scaled-Down Models 6. “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
  5. 5. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter 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 EDEM BulkSim Calibrated Material Model Calibration for DEM Material Model (New “Swing Arm” Slump Tester: Coal) Video Video  Shape, friction and moisture/cohesion
  6. 6. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter 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
  7. 7. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 7 Dynamic Validation of DEM for Design Conveyor Transfer Research Facility 7 m/s Video Dynamic Validation of DEM for Design (Hood-Spoon Conveyor Transfer)
  8. 8. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter 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 of Feed Belt 2 deg Chute Liner Ceramic Tile Moisture Content 9% wb
  9. 9. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 9 Existing Design Design Problems: Off-Centre Loading Reduced Capacity Non-Symmetrical Wear Patterns Feed Chute Design Problems
  10. 10. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 10 Solution Option for Re-Design Deflector Plate Design Improvements: Central Loading Increased Capacity Symmetrical Wear Patterns Feed Chute Design Improvements
  11. 11. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter 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 Liner Ceramic Tile Moisture Content 10% wb Case Study No. 2: Iron Ore Stacker Transfer Chute Existing Design
  12. 12. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter 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 Complex Velocity Profiles and Flow PatternsContinuum Models: ● Particle Velocity ● Trajectory ● Cohesion ? Continuum Models ??? Chute Modelling and Analysis
  13. 13. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 13 Calibrated EDEM Material Model used to Optimise Design Solution: Modification B Modification of Hood Modification of Mid Chute Modification of Feed Chute Modification B:
  14. 14. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter 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 Flow and Capacity+
  15. 15. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter 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
  16. 16. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 16 Product Coal Filtercake (dried) Some Calibration Tests Product Coal Filtercake
  17. 17. 11th Bulk Materials Handling Conference, 29-30 April 2014, Perth Peter Wypych, Bulk Materials Engineering Australia © Wypych, 2014 17 Modified Chute Video 900tph Coal + 300tph Filtercake Existing Chute Video Calibrated EDEM Material model: 900tph Coal + 300tph Filtercake Thanks to NEW Calibrated and Validated DEM  Useful Design and Troubleshooting Tool !!

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