Abstract:

Bulk solids handling systems are the arteries of a mine operation and if bulk solids stop flowing, then the lifeblood of the mine is restricted, and emergency procedures begin. Re-establishing bulk solids flow takes time resulting in loss of production and can lead to unsafe work conditions going against ESG goals of desiring energy efficient operations and good working conditions.

To reduce or eliminate bulk solids handling problems requires an analysis of troublesome equipment – a transfer chute that experiences plugging, excessive wear, unacceptable dust generation, high belt wear, and product spillage, a stockpile that only functions at 10% live capacity, or a bin that plugs causing unreliable flow.

Simulation tools, such as calibrated Discrete Element Method (DEM) models, is a type of digital twin can be used to build a virtual model of material flow through the plant such as bins, stockpiles, and transfer chutes. Then changes can be made in these virtual models, such as flowrate and material characteristics (higher clay/fines/moisture), to evaluate how the changes will respond in the real world.

The input to simulation tools and requires flow properties data. Flow testing can provide answers before incurring the cost and time to implement changes. Different case studies will be presented to discuss how material flow testing and simulation tools can be used to guide plant design and operations to reduce downtime related to bulk solids handling flow issues.

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Carrie Hartford