The dynamics of granular flow from a silo with two symmetric openings

The dynamics of granular flow in a rectangular silo with two symmetrically placed exit openings is investigated using particle image velocimetry (PIV), flow rate measurements and discrete element modelling (DEM). The flow of mustard seeds in a Perspex silo is recorded using a high-speed camera and the resulting image frames are analysed using PIV to obtain velocity, velocity divergence and shear rate plots. A change in flow structure is observed as the distance L between the two openings is varied. The mass flow rate is shown to be at a maximum at zero opening separation, decreasing as L is increased; it then reaches a minimum before rising to an equilibrium rate close to two times that of an isolated (non-interacting) opening. The flow rate experiment is repeated using amaranth and screened sand and similar behaviour is observed. Although this result is in contrast with some recent DEM and physical experiments in silo systems, this effect has been reported in an analogous system: the evacuation of pedestrians from a room through two doors. Our experimental results are replicated using DEM and we show that inter-particle friction controls the flow rate behaviour and explains the discrepancies in the literature results.

Granular size segregation in silos with and without inserts

The storage of granular materials is a critical process in industry, which has driven research into flow in silos. Varying material properties, such as particle size, can cause segregation of mixtures. This work seeks to elucidate the effects of size differences and determine how using a flow-correcting insert mitigates segregation during silo discharge. A rotating table was used to collect mustard seeds discharged from a three-dimensional (3D)-printed silo. This was loaded with bidisperse mixtures of varying proportions. A 3D-printed biconical insert was suspended near the hopper exit to assess its effect on the flow. Samples were analysed to determine the mass fractions of small particle species. The experiments without the insert resulted in patterns consistent with segregation. Introducing the insert into the silo eliminated the observed segregation during discharge. Discrete element method simulations of silo discharge were performed with and without the insert. These results mirrored the physical experiment and, when complimented with coarse graining analysis, explained the effect of the insert. Most of the segregation occurs at the grain-air free surface and is driven by large velocity gradients. In the silo with an insert, the velocity gradient at the free surface is greatly reduced, hence, so is the degree of segregation.

Modelling of Gyratory Crusher Liner Wear Using a Digital Wireless Sensor

A gyratory crusher is a key mineral processing asset in a comminution circuit. Monitoring and predicting the crusher liner wear is essential to ensure the throughput and product quality are maintained during production. This study developed a digital sensor and a discrete element modelling (DEM)-coupled methodology to monitor and reconstruct the gyratory crusher concave liner wear pattern. The developed digital sensor was able to track and report the live thickness of the specific installation point on a concave liner during operation. A wear reconstruction model was then developed based on the wear intensity obtained using the DEM and digital sensor results. The wear reconstruction model predictive results were subsequently compared with site measurements after 95 days of operation. The results indicated that the wear reconstruction model showed good agreement with measured results in terms of wear zone distribution as well as quantitative wear rate prediction. The outcome of this study can be potentially utilised in the mineral processing industry for plant monitoring and automation.

A Study on the Borehole Wall Stability Analysis and Slurry Ratio Optimization for Construction of Pile in Complex Marine Strata

In order to address the issue of hole collapse, which frequently arises when boring piles are being constructed in intricate marine strata, this paper discusses the influence of the slurry ratio on the slurry performance as well as the mechanism of slurry wall protection. It performs this by means of theoretical analysis, laboratory ratio testing, engineering analogies, numerical simulation, and field testing. Our findings demonstrate that adding sodium polyacrylate and sodium carboxymethyl cellulose can enhance mud's viscosity, contribute to flocculation, and improve the connection between mud and soil layers. Refering similar engineering cases, three optimization schemes are proposed for achieving a mud ratio that offers wall protection in complex marine strata. Furthermore, the particle flow model of slurry viscous fluid is established. The collapse of holes in the sand layer is reflected in the uneven radial displacement of hole walls and the invasion of mud particles. Increasing the viscosity of mud gradually transforms the uneven radial deformation of pore walls in the sand layer into a uniform radial deformation, whereas increasing the proportion of mud significantly decreases the radial displacement of hole walls. Additionally, when the mud pressure in the hole is 300 kPa and 600 kPa, the wall protection effect is better, and there is no particle penetration by substances such as sand. It is found that a high mud pressure can promote the diffusion of mud particles into the sand layer, while low mud pressure cannot balance the pressure on deep soil. The results of the field tests show that the ratio of water-clay-bentonite-CMC-Na-sodium carbonate = 700:110:90:1.5:0.5 used (where the mass percentage of each material is 77.8% water, 12.2% clay, 10% bentonite, 0.16% CMC-Na, and 0.05% sodium carbonate) can effectively prevent hole collapse and reduce the thickness of the sand layer at the bottom of the hole by 50%.