DEM Simulation — Particle Velocity Visualization
System Details & Operating Parameters
| Parameter | Discharge Conveyor (BC-12A) | Feeding Conveyor (13B) | Unit |
|---|---|---|---|
| Bulk Material | Coal | Coal | — |
| Belt Speed | 3.4 | 3.4 | m/s |
| Belt Capacity | 1,400 | 1,400 | TPH |
| Transfer Point ID | TP-13 | — | |
| Chute Orientation | Near-vertical drop chute | — | |
| Velocity Range Captured | 0.00 | 6.00 | m/s |
| Analysis Software | EDEM (DEM Solutions) | — | |
Executive Summary
This case study presents a Discrete Element Method (DEM) simulation study of Transfer Point TP-13, the chute system connecting the BC-12A discharge conveyor to the 13B feeding conveyor. The analysis was performed using EDEM software to evaluate bulk coal material flow behavior, verify particle trajectory through the curved chute geometry, identify high-velocity impact zones, and assess the overall operational stability of the transfer point design at the rated capacity of 1,400 TPH.
The DEM simulation demonstrates a steep, vertically-oriented transfer chute carrying coal from the BC-12A conveyor down through a near-vertical drop into the 13B conveyor below. Particle velocity distributions are captured using the EDEM solver with a velocity color-map ranging from 0.00 m/s to 6.00 m/s.
Study Objectives
The DEM simulation study of Transfer Point TP-13 was conducted with the following primary objectives:
DEM Simulation Observations
Stable Transport on BC-12A Approach Belt
Coal particles travel along the BC-12A conveyor at a stable, low velocity matching the belt speed of 3.4 m/s. The yellow-green coloration on the approach belt confirms uniform, well-distributed material transport with no evidence of surging or uneven loading prior to entering the drop chute.
Significant Particle Acceleration in Vertical Drop
As material enters the near-vertical drop chute, particles accelerate rapidly under gravity. The velocity color-map shows a clear progression from green/yellow (2.0–3.0 m/s) near the top of the chute to deep red (5.0–6.0 m/s) in the lower section, confirming significant free-fall acceleration through the steep transfer geometry.
Peak Impact Zone at Lower Chute Wall
The highest particle velocities (5.0–6.0 m/s, red zone) are concentrated along the lower section of the drop chute where the accelerated material stream strikes the chute wall before redirecting toward Conveyor 13B. This concentrated impact region is the primary wear-critical zone identified in the simulation and requires targeted wear protection.
Controlled Discharge onto Conveyor 13B
Following impact and redirection at the base of the drop chute, the material decelerates and settles onto Conveyor 13B with a yellow-green particle distribution indicating near-belt-speed loading (approximately 3.4 m/s). The loading pattern appears centrally distributed across the 13B belt width, consistent with a properly aligned discharge geometry.
Velocity Analysis — Particle Velocity Profile
The EDEM simulation captures particle velocities across the full TP-13 transfer path, from the BC-12A approach belt through the vertical drop chute to the 13B receiving belt. The velocity color-map (0.00 – 6.00 m/s) reveals a clear acceleration profile driven by the near-vertical chute geometry.
Performance Evaluation Matrix
Problem Statement & Root Cause Analysis
The DEM simulation of Transfer Point TP-13 was conducted to characterize particle behavior through the steep vertical drop geometry and to identify any operational or wear-related concerns prior to long-term service. The table below summarizes identified issues and their root causes:
| Issue | Root Cause | Status (Current Design) |
|---|---|---|
| High particle impact velocity | Near-vertical chute geometry permits unrestricted free-fall acceleration | Identified — liner protection required |
| Localized wear risk | Direct high-velocity particle-wall impact at lower chute | Pending — AR liner installation |
| Moderate dust generation | High-velocity impact at base of drop chute | Pending — skirt sealing recommended |
| Material build-up risk | Adequate flow area through chute profile | Low — no blockage observed |
| Belt loading uniformity (13B) | Discharge geometry aligned with belt centerline | Resolved — centralized loading |
| Approach belt stability (BC-12A) | Consistent feed rate and belt speed | Resolved — stable transport |
Engineering Recommendations
Wear Protection — High-Impact Liner Zone
Install heavy-duty abrasion-resistant (AR400/AR500 grade) ceramic or chromium carbide overlay liners at the following locations:
- Lower chute impact wall (primary wear location — peak 6.0 m/s)
- Mid-chute transition section (secondary wear zone — 3.5–4.5 m/s)
- Conveyor 13B loading point and skirting region
Impact Energy Dissipation
Given the steep vertical drop and resulting high free-fall velocities, the following design features are recommended to reduce direct wall impact severity:
- Consider a rock-box or dead-bed cushioning arrangement at the base of the drop chute
- Evaluate a stepped or cascading chute profile to break the fall into shorter segments
- Assess feasibility of a deflector plate to redirect flow before final impact
Maintenance Access — Inspection Doors
Incorporate hinged inspection doors to facilitate routine inspection and liner replacement without major dismantling at:
- Upper chute section (entry zone from BC-12A)
- Impact region at the lower chute wall
- Loading zone above Conveyor 13B
Dust & Spillage Control
Given the moderate dust generation potential identified at the high-velocity impact zone, the following measures are recommended:
- Install rubber skirting seals along Conveyor 13B loading zone (minimum 1.5 m length)
- Seal all chute wall gaps and access openings to contain fine coal particles
- Consider local dust suppression given the elevated impact velocity
- Monitor spillage and dust levels during initial operation
Conclusion
The DEM simulation of Transfer Point TP-13, connecting the BC-12A discharge conveyor to the 13B feeding conveyor, was conducted using EDEM software at the specified operating parameters (3.4 m/s belt speed, 1,400 TPH belt capacity, coal bulk material).
Key findings confirm: (1) stable, uniform material transport on the BC-12A approach belt; (2) significant particle acceleration through the near-vertical drop chute, reaching peak velocities of 5.0–6.0 m/s; (3) a concentrated high-impact wear zone at the lower chute wall requiring abrasion-resistant liner protection; and (4) controlled, centralized discharge onto Conveyor 13B at near-belt-speed conditions. The overall performance rating of 8.0 / 10 confirms Transfer Point TP-13 is operationally stable and capable of sustaining the rated 1,400 TPH capacity.