The mining and mineral processing industry operates in a very high tonnage range which makes the equipment more prone to damage and wear. This also means that testing new designs at plant scale would lead to material wastage and time loss.
Another aspect that differentiates the mining and mineral industry from others is the fact that the raw material keeps changing from season to season. In the rainy season, the material will be wet and sticky and in summer it will be dry. This requires the design engineers and researchers to come up with a design that can work in both these conditions.
Discrete Element Method is a proven tool for designing and troubleshooting equipment. Mining and Mineral companies across the globe have included DEM in their development process and routinely use them for troubleshooting. In this blog,
What value will a DEM tool add?
Any simulation technology will help the user to get a deeper insight into their equipment/process. Testing at the plant scale also becomes an easy task as there will not be any material loss and downtime of the plant required.
Let’s take a very simple example of a chute. In case of a decrease in throughput of the chute, it becomes difficult to understand the underlying reason sometimes. Identifying the right area where material clogged will be really helpful in increasing the throughput. A DEM simulation can show the velocity profiles of all the particles inside the chute which help us identify the faulty region. Getting this type of insight from the real chute will be difficult as that would require us to have a chute made of transparent material which is impractical at plant scale.
What processes will I be able to design/troubleshoot?
Almost all mining-related processes can be handled using DEM. Here is a non-exhaustive list:
- Excavation at the mining site
- Wagon loading and unloading
- Primary crushing
- Conveying operations
- Blast furnace
- Fluidized beds
- Packed beds
Is DEM capable of handling real-life material loading conditions? RockyDEM uses the power of multi-GPU processing to make plant scale simulations reasonable. Figure X shows a comparison of CPU vs GPU vs multi-GPU. Using multi-GPU will help us make these simulations way faster when compared to CPU. But that’s not it, with the new modules being introduced inside RockyDEM, the data saving time has decreased which would lead to total time-saving. Also, the advanced contact detection method helps reduce overall simulation time. We can further reduce the simulation time by using the Coarse Grain Model.
Figure x- Scalability using CPUs, GPUs, and multi- GPU`s
How can I be sure that the simulation results are accurate?
All the models are implemented in Rocky are well-validated which means that we do not have to worry about the models predicting the behavior if supplied with accurate inputs. The most important input required will be material properties. To extract the material properties and correlate them to simulation parameters, calibration is required. For example, an angle of repose test which can be performed in the lab should also be performed with RockyDEM virtually and the same behavior should be replicated. Properly calibrated material properties will provide us with a highly accurate result.
I would also like to understand the effect of particle flow on my equipment, how can RockyDEM help me with that?
RockyDEM has some in-built post-processing capabilities which can be used to plot contours of stress and force on the equipment. RockyDEM is also integrated with ANSYS products like ANSYS Mechanical. So, the force maps from RockyDEM can be transferred to ANSYS Mechanical and a structural simulation can be performed to evaluate deformation, etc.., We can also perform a transient coupled analysis with ANSYS Mechanical.
We answered a few questions which any mining company might have while thinking about adopting simulations. Keep an eye on this space.