Upgrading a Coal Transfer Chute: Hatch Deploys Altair EDEM BulkSim Solution for Mining
Technology Category
- Infrastructure as a Service (IaaS) - Cloud Computing
- Sensors - Liquid Detection Sensors
Applicable Industries
- Life Sciences
- Mining
Applicable Functions
- Product Research & Development
- Quality Assurance
Use Cases
- Construction Management
- Experimentation Automation
Services
- Testing & Certification
About The Customer
Hatch Ltd. is a global supplier of engineering, project, and construction management services to the mining, metallurgical, energy, and infrastructure sectors. They were contracted to upgrade the conveyor transfer point at an existing coal preparation plant. The client required upgrades to accommodate a scheduled increase in production. The conveyor carried coarse product coal, topped by a layer of filter cake with a high moisture content. The existing chute was prone to material build-up of this “sticky” filter cake, often plugging during surges in flow rate and causing costly downtime.
The Challenge
Hatch Ltd., a global supplier of engineering, project, and construction management services to the mining, metallurgical, energy, and infrastructure sectors, was contracted to upgrade the conveyor transfer point at an existing coal preparation plant. The client required upgrades to accommodate a scheduled increase in production. The conveyor carried coarse product coal, topped by a layer of filter cake with a high moisture content. The existing chute was prone to material build-up of this “sticky” filter cake, often plugging during surges in flow rate and causing costly downtime. Despite being a relatively small conveyor, at 1,200 t/h, it was critical to ensuring constant product throughput to truck-loading bins.
The Solution
Hatch deployed the EDEM BulkSim Solution, including Material Testing and DEM Material Model Calibration services, to redesign the transfer chute. Dynamic flow testing was performed on actual samples of the product coal and filter cake that were representative of actual materials on-site. DEM Material Models were quickly calibrated by comparison of physical test results with simulations, using automated parameter sweeps on a cloud computing platform. Hatch’s new transfer point design included a flop gate, hinged at the top, to direct flow onto one of two flow paths. Virtual performance testing of design options was performed under a range of material flow conditions and included highly cohesive materials. This enabled Hatch to quickly select the optimal configuration for production of the detailed design.
Operational Impact
Quantitative Benefit
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