In conveyor transport systems, different solutions to the transfer points constructions are used. Choosing the right solution requires conditions analysis of the cooperation between two conveyors. For years, the analytical methods have been used to evaluate the discharge trajectory of the transported material. Increasingly, to evaluate the movement of grains in the transfer space to analyze the behavior of the bulk material in contact with transfer chute elements, researchers successfully use simulations performed in the discrete element method (DEM). Well-constructed chute allows the material stream to be uniformly fed onto the receiving conveyor with a desired stable tangential speed. Proper design reduces motion resistances and belt wear. In the paper, the analysis of selected construction solutions of transfer points and the possibilities of their usage in copper ore transport systems were performed. The research was conducted using the DEM simulations of the ore flow. For specifying the best conditions of the cooperation of the feeding and receiving conveyors, a series of simulations were generated. The criteria for the comparative evaluation of the analyzed solutions were the values of acceleration zone length and abrasive wear of the belt.
A transfer point is an element of a belt conveyor prone to increased energy losses and to the risk of failure. It is also a location in which the receiving belt is particularly susceptible to damage. Except failure-free operation, a transfer point should offer minimal belt resistances to motion by ensuring that the transported material is placed centrally on the receiving belt, both spillage of the material and blockages are prevented, the process of particle defragmentation is limited, and also that noise and dust emissions to the environment are reduced. Ensuring that the above requirements are met requires inter alia the use of advanced simulation tests. The article analyzes the flow of ore particles stream through a longitudinal transfer point used in an underground copper ore mine. Discrete Element Method was used to identify the phenomena which occur while transferring ore onto the receiving conveyor. The research allowed key variables affecting the transfer point performance to be identified. It also resulted in a proposal of actions which can improve the performance of the transfer point and which are focused on saving energy and on minimizing the damage and wear of the receiving belt.
The paper shows the preparation of the numerical models necessary for the simulation mapping of industrial-scale crushers of problematic material, such as copper ore with complex lithology. The crushers investigated in this work are located in the KGHM Polska Miedz S.A. copper ore processing plant. The complex ore consisting of sandstone, dolomite and shale is modeled using the Discrete Element Method (DEM) with Particle Replacement Model (PRM) that was chosen to simulate the crushing process. The article discusses the tests and calibration of material parameters and proceeds to test a breakage model in a laboratory-scale jaw crusher. The results are finally validated with the data from actual industrial-scale crushers and compared with the simulations. As an optimization option, the new shape of hammers is proposed and tested in a numerical environment. The performance of the newly designed hammers was examined using numerical methods. The numerical tests showed that the new design performed worse than the current solution. As a result, time and money were saved by avoiding industrial tests. In conclusion, the work shows how complex processes can be characterized in the numerical environment and used for further analysis.
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