EDEM: A Solution for Particle Handling and Processing Problems

EDEM: A Solution for Particle Handling and Processing Problems

Chris Riley  DEM Solutions Ltd 

Summary 

The majority of industrial processes manipulate particles



Engineering simulation is proven to be effective in improving design, shortening development cycles and streamlining troubleshooting



Our company brings engineering simulation to particle processes

The Particle Problem…. Oer !"# of industrial $rocesses inole $articles %&T • The majority of particle handling and processing operations are empirically designed • Measurement and control is difficult and costly. • Simulation-based design no possible for particle systems

EDEM ' Soling $roblems in: "ul# Materials $andling

%ul( Handling E)ui$ment Design and operational challenges • Ma%imising throughput  & 'is# of spillage and bloc#age  & E%cessive ear of e(uipment leading to higher replacement costs and longer system dontime

• )ealing ith variation in design and operating re(uirements  & *sually bespo#e system designs  & "ul# material behaviour usually varies ith type, origin and environment

• Testing prototypes and troubleshooting problems  & +ostly to build and test designs and e%plore design options )ifficult to measure material-e(uipment interactions

*ase Study + *oneyor Transfer  *hallenge • To in a design contract, our customer needed to demonstrate that they ould meet their customers re(uirements to balance throughput, ear and operational cycle

Singing chute transfer to

*ase study + coneyor transfer  Design Objectives • +entre material on conveyor belts • Match belt speed and flo rate onto belt to minimise ear of the belt • revent e%cessive ear of the chute • Estimate safety limits for bloc#age due to change in material properties

/eft chute

*ase study ' *oneyor transfer  "elt ear 

+hute ear 

Outcomes •

+ontract on and E)EM softare then used to produce an optimised

EDEM + Soling $roblems in: "ul# Solids rocessing

%ul( solids $rocessing Design and operational challenges • $igher process efficiency 3often only 45-657 for particle processes8

 & )ifficult to understand particulate process fundamentals  & 9eed to reduce energy cost and aste

• 1mproving product (uality and consistency  & :ant better control, reduce product variability and defects  & +ontinuous production most profitable but highest ris#

• )ealing ith different ra materials and formulations  & +ostly to optimise process operating conditions Troubleshooting out-of-spec process costs time and money

*ase Study + Astec ,nc. Challenge To improve the reliability and robustness of  
Astecs Double %arrel HMA Drum Mi-er   
/i(uid asphalt cement in

Mi-ing $addles

Mi%ed asphalt out  
Simulation Objectives •

1dentify modes of poor mi%ing

•

1dentify potential si=e segregation

 1deal mi%ing means each roc# particle is fully coated ith li(uid asphalt cement Mi%ing is a function of residence time and uni(ue particle contacts

'esults Outcome "etter mi%ing at high throughput 9e system for virtually testing sensitivity to variations in feedstoc# "etter understanding of hy their design is effective  
*ase study + Tablet coater  Challenge To ma%imise the rate of coating of tablets in a Drum *oater  hile minimising the incidence of tablet brea#age )amage to tablets resulting in rejection of hole batches can be very costly. Optimising operating conditions in a batch coaters to better match the characteristics of a particular tablet type ill greatly reduce damage and improve

*ase study + Tablet coater  Simulation Objectives •To predict the location and fre(uency of impact forces on tablets. •residence time of tablets in the region of the spray.

?orce acting on tablets

Original design

9e design

More stable tablet circulation

Outcome •+oating process optimi=ed •9e tool for process design an improving coater mi%er design

E-$ertise in $article simulation )evelopment of ne techni(ues for industrial application of particle simulation using )EM ;22 @555

+ollaboration ith early industrial adopters of E)EM @55

)EM Solutions founded in @55@

/aunch of E)EM ;.5

/aunch of E)EM @.5 @550

@5;5

E)EM @.;

;5A years 'B) in )EM technology USA

UK Germany

      

Singapore

/eaders in particle simulation for industry roviding softare and support services for particle simulation :orldide channel partner netor#

Summary 

The majority of industrial processes manipulate particles



Engineering simulation is proven to be effective in improving design, shortening development cycles and streamlining troubleshooting



Our company brings engineering simulation to particle processes