Virtual particles: Simulation as the key to modern bulk solids technology

Bulk solids technology faces the challenge of designing complex material flows efficiently and reliably. Modern simulation techniques, in particular the discrete element method (DEM), make it possible to precisely predict the behavior of bulk materials under different conditions. This leads to improved planning and optimization of plants, reduces costs and minimizes risks.

The DEM, which is particularly relevant for modeling the behaviour of bulk solids, is a numerical simulation method for calculating the behaviour of bulk solids and other granular materials. Each particle is modeled as an individual element that interacts with neighboring particles and environmental boundaries via physical contact laws. The method takes into account forces such as friction, impact and gravity in order to realistically represent movements and interactions. DEM thus allows complex phenomena such as flow behavior, clogging or material separation to be analyzed in detail.

From experiment to simulation

Traditionally, the design of bulk solids systems was based on empirical data and extensive experiments. With the advent of powerful digital technology and advanced simulation software, this approach has changed. Simulations are increasingly making it possible to test different scenarios virtually, saving time and resources while increasing accuracy.

Hurdles in the use of simulation

Despite the advantages, there are still challenges at present:

• Calibrating the models: The accuracy of simulations depends heavily on the quality of the input data. The determination of material and process-specific parameters requires careful calibration.
• Computing effort: Complex simulations, especially with large numbers of particles, can require considerable computing resources.
• Integration into existing processes: The integration of simulations into existing development and production processes requires adaptations and trained employees.

Three examples of simulation in use

What sounds good in theory must also work in practice. In fact, there are numerous examples of applications in which simulation optimizes the handling of bulk materials.

Simulation of spiral conveyors with DEM

At the Institute of Materials Handling and Bulk Solids Logistics (IFSL), DEM was used to analyze the behavior of bulk materials in spiral conveyors. The simulations enabled a detailed investigation of the particle movements and led to an improved design of the conveyors.

Coupling DEM and multi-body simulation for bucket elevators

A method was developed at Otto von Guericke University Magdeburg that combines DEM with multi-body simulation (MBS). This enabled a more precise analysis of the scooping resistance in bucket elevators and led to optimized designs.

Classification processes in sieving and countercurrent screening

Researchers at TU Berlin used DEM to simulate separation curves in screening and sifting processes. The results helped to increase the efficiency of these processes and improve product quality.

Outlook: The future of simulation in bulk solids technology

As digitalization progresses and artificial intelligence is developed, new possibilities for simulation in bulk solids technology will continue to emerge in the future. Some are already within reach today:

• Real-time simulations: By using AI, simulations can be carried out in real time, allowing processes to be adjusted immediately.
• Automated optimization: AI algorithms can be used to automatically determine optimal process parameters.
• Integration into digital twins: Simulations are increasingly becoming part of digital twins that enable comprehensive monitoring and control of plants.

These developments not only promise further increases in efficiency and flexibility in bulk solids technology - they also open up new possibilities for predictive plant planning and control. Simulations will foreseeably become an integral part of digitally networked processes and enable continuous optimization during operation.

The combination with artificial intelligence in particular can help to uncover previously unrecognized correlations in material behaviour. This makes simulation not only a planning tool, but also a driver of innovation and competitiveness in the increasingly data-driven bulk solids industry.