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H
atch, a global engineering,
Table 1: moisture content for product coal and filter cake
construction and project
management (EPCM) company is Moisture
Sample Comment
working with developers of simulation content (%wb)
software to provide intuitive and Filter cake – HBF A 24.68 As received
integrated tools that will increase mine Filter cake – HBF B 23.05 As received
performance at the operational level. Filter cake – HBF A & B 23.92 As received, 50% HBF A/50% HBP B
A team of Hatch engineers specialising
Saturation moisture content,
in bulk materials handling and processing Filter cake – HBF A & B 28.96
50% HBF A / 50% HBP B
has been working with DEM Solutions,
and its partner, Bulk Materials Engineering Product coal 6.73 As received, bulk measurement
dealing with highly cohesive materials and worst-case situations to be investigated build-up and wear.
at surge in-flow rates, with lower wear and operational robustness ensured. Troublesome issues such as spillage
rates indicated. The updated design improved the and material build-up in the conveyor
The design flow and verification of functionality of the transfer chute and load zone were also examined in the DEM
process equipment involves an iterative reliability of material flow by optimising simulations in order to reduce future
process of preliminary, internal and client the geometry of the equipment. maintenance costs and downtime.
review sessions. Modifying the shape of the flop-gate Based on these results, Hatch was able
The availability of both 3D images and and loading chute allowed the angles of to verify the performance of the new
dynamic video streams as a part of the incidence between the coal stream and chute design and select the configuration
transfer chute design has proved to be an equipment to be decreased in order to for production of it.
effective review element. Further, the reduce the deceleration of the material The mining company client benefitted
ability to explore ‘what if’ scenarios allows upon impact and minimise material from Hatch’s understanding of the
reliability improvement required for
The benefits of BulkSim increasing conveyor performance.
The EDEM BulkSim Solution provides the essential components needed to deploy DEM ENGINEERING WITH CONFIDENCE
technology throughout an organisation. Hatch has a long history of including
With easy-to-use EDEM software, customised for the mining industry, outsourced innovative technologies that enable
materials-testing services and the highly-optimised material calibration provided by clients to improve their equipment
simulation experts, DEM Solutions and its partner, BMEA, provide an enterprise- performance and raise production levels.
wide, scalable engineering solution, which enables engineers to deliver superior Over the past several years, Hatch has
designs. been integrating EDEM simulation
Hatch can now test a higher percentage of designs virtually before installation, and technology and services into design
disseminate simulation analysis and investigations throughout the organisation, thus projects, and has achieved a high level of
offering simulation expertise to the majority of its clients around the globe. Additional confidence in materials-handling
benefits include: equipment designs.
• The security features of the Calibrated Material Model. Here, the material parameters This results in substantial benefits
cannot be modified, except by authorised users, reducing the design risk of around design robustness, equipment
unsubstantiated DEM simulations; and reliability in plant start-up and commis-
• Designers engaged in 3D surface modelling of transfer points can deploy DEM sioning, and boosting plant quality, yield
simulation confidently, to deliver a robust design, by combining 3D CAD and EDEM and performance.
BulkSim simulation and analysis within their design environment. Deployment of the EDEM BulkSim
Solution allows Hatch to integrate DEM
Fig 7: simulated
Fig 5a material flow for
the new design,
running at design
rate (1,200t/h)
with extra-
cohesive material,
showing velocity
profile. Reliable
flow is maintained
Fig 5b
Fig 9b
Fig 9a
Dr Brian Moore is lead engineer, bulk materials handling, South East Australian Hub, with more than 30 years’ experience, specialising in bulk materials-handling systems
and equipment. James Fuata is a graduate engineer. His experience includes belt-conveyor analysis and transfer-chute design utilising EDEM. Dr Richard LaRoche is vice-
president of engineering and US general manager of DEM Solutions. He has over 25 years’ experience as an expert consultant in engineering simulation, and the manage-
ment of technical support and engineering consulting teams. Stephen Cole is a senior consulting engineer at DEM Solutions who focuses on DEM project management
for the mining industry. Dr Andrew Grima is a principal design engineer at BMEA. He is an expert on the deployment of EDEM for the design and troubleshooting of
equipment for handling ores in overland and in-plant conveying. Dr Peter Wypych is general manager of BMEA and an associate professor of mechanical, materials &
mechatronic engineering at the University of Wollongong. For more information: www.dem-solutions.com; www.hatch.ca; www.uow.edu.au/eng/research/bmea