Craig Wheeler

• University of Newcastle Australia

Dust pollution related to the discharge of hoppers has drawn the attention from industries dealing with bulk solids handling. This paper presents an experimental setup to measure the dust concentration of dust suppression hoppers (DSHs) with various geometries and investigate the dust influencing factors. To understand the interactions of the bulk...

The throughput of a belt conveyor system is the primary design parameter when considering a new installation, determined by the cross-section of the material on the belt, coupled with the belt speed. Optimizing this area not only improves efficiency, but also minimizes capital costs through the optimal selection of equipment. Whilst speed-related o...

In this chapter, the fundamentals of design of conveying and construction machinery will be presented. Machines that fulfill transportation tasks in limited operating areas such as mines, ports, work and storage yards, as well as construction sites are most common and can be found in any type of industry. Hence, the diversity of conveying and const...

Pouch conveyors commonly employ point-contact drive systems, indenting a rigid drive wheel into the viscoelastic running surface of the conveyor. Rigid indentation of a viscoelastic surface exhibits regions of stick and slip, reducing the tractive limits of the contact. By modelling the conveyor cover as both an elastic material, and using a 3-para...

During marine transport of coal commodities, cargo slip or liquefaction failure scenarios within the hold may occur under cyclic ship motions. The resulting cargo shift affects the vessel stability, and subsequently endangers goods and crews on board the vessel. This study aims to investigate the coal cargo stability under marine transport conditio...

Increasing demands have been required to accurately determine the gate loads of storage bins for the optimised design of the supports and operation efficiency. The Australian Standard - AS3774 considers that gate loads are highly dependent on the degrees of bulk solids compressibility and gate structure rigidity and calculates gate loads in an empi...

The energy consumption of modern belt conveying systems has reduced considerably over the past few decades. Although extensive research has been conducted into the production of energy-efficient belt conveyors, significant scope remains to further reduce the energy consumption, especially when heavily loaded or long overland belt conveyors are cons...

This study addressed the issues of high working temperatures and poor throw that are commonly associated with Ship Loaders (SLs) used at export terminals. High temperatures can degrade the properties of liners and reduce life, while poor throw may lower efficiency and lead to equipment operating in close proximity to ships. The temperatures of the...

Slurry in wet grinding mills is critical for transporting fine progenies out of the system to downstream floatation process. It is commonly modelled as Newtonian fluids when simulating grinding mills with numerical tools. However, rheology of the slurry exhibits shear thinning non-Newtonian behaviours. This study aims to investigate the non-Newtoni...

Belt deflection due to the belt weight and bulk solid loads is essential not only for reducing the flexure resistance but also for extending the service life of belt conveyors. Current theoretical analysis and numerical modelling have failed to fully consider the interaction between a belt and bulk solid and therefore are not suitable to investigat...

The continuum method is an approach to model transfer chutes characterised by accelerated flow conditions, with origins stemming from free flowing materials. Physical bulk solid properties obtained through laboratory tests are incorporated and the focus is to maintain a rapidly moving stream, with minimum variation in velocity across the burden dep...

The adhesive tensile stress between moist bulk iron ore solids and wall surfaces are critical to control and avoid blockage in large throughput material handling plants. In this study, an experimental system was designed to investigate the adhesive tensile contact between a range of iron ore materials and wall lining specimens. The contact mechanis...

The University of Newcastle has designed and built a large test facility to measure the combined indentation rolling resistance and belt flexure resistance. This test facility allows tests to be conducted on a full-sized conveyor belt over a range of tensions and belt velocities and is designed in accordance with an Australian standard [1]. The tes...

Due to the reduction of the energy consumption of belt conveyors over the past few decades, longer installations of overland conveyors are now more feasible. Installations of single flight belt conveyors up to 30km in length have been successfully commissioned with longer systems already planned. To further push the boundaries of long overland conv...

The determination of the wall liner properties and more importantly the flow properties of a bulk material is critical for the design of any bulk materials handling system. The design of such materials handling systems will be most effective when handling bulk materials at the physical properties they were designed to handle. Due to the fast-paced...

Rubber stress relaxation models are the main material input data for numerical and analytical conveyor belt indentation rolling resistance calculations. Stress relaxation data for rubbers, such as those used in the construction of conveyor belts, are difficult to measure directly due to their fast relaxation times and, as such, they are usually der...

In the field of handling, storage and transportation, chutes are used to transfer bulk solids between conveyors. In these systems, traditional analysis methods based on the principle of continuum mechanics approximate an accelerated stream that incorporates physical bulk solid properties obtained from standardised tests. Due to difficulties in phys...

HyLogger profile scanning is commonly utilised for drill-core logging but the limited scanning area may not detect all important geological features. The study presented in this paper aims to develop a mineral mapping solution for this core-logging process by leveraging the colour image captured during the scanning process. A machine learning-based...

The Discrete Element Method (DEM) requires input parameters to be calibrated and validated in order to accurately model the physical process being simulated. This is typically achieved through experiments that examine the macroscopic behavior of particles, however, it is often difficult to efficiently and accurately obtain a representative paramete...

In a belt conveyor system the belt and conveyed bulk material experience cyclic movement due to the presence of the belt sag during operation. This dynamic belt deflection results in the trampling resistance of the belt conveyor. Dynamic belt deflection is complicated as it depends on the properties of the belt and bulk material, belt and material...

The accuracy of analytical models used to predict the indentation rolling resistance of belt conveying systems depends on the method of testing the material properties. Due to the limitations and inconsistency of obtaining material properties using mechanical methods, it is becoming more common for viscoelastic behaviour to be represented by non-me...

The safe maritime transport of bulk commodities, such as iron ore, by large bulk carriers is vitally dependent on the stability of the cargo. During transport there is a propensity that cargo shift may be triggered under the vessel's rolling motion. The study presented in this paper aims to model the critical stress conditions within iron ore bulk...

The inherent moisture in a coal cargo constantly migrates under the dynamic ship motion during maritime transport. The moisture often builds up at the bottom of the cargo. The accumulated water, if not removed sufficiently by the bilge well, can cause safety concerns during a voyage and difficulties during cargo unloading. The study presented in th...

This article describes a new continuous conveying technology for the transportation of bulk materials. The new technology merges the benefits of both belt conveyor technology and railway to produce a highly energy-efficient and cost-effective bulk material transportation system known as the Rail Conveyor. An overview of the development of the Rail...

Guidelines for the calculation of bulk solid material cross sectional dimensions and the influence of the belt conveyor transition length on the inclination of the trajectory at discharge are well established. However, not a great deal of research has been conducted on the influence of bulk solid material properties and conveyor belt transition geo...

This article presents findings from a research program to investigate the interaction between bulk solids and a conveyor belt during transportation. The research involved measuring and simulating the loads acting on a conveyor belt during transportation for a number of bulk solid materials and belt sag ratios. Laboratory experiments and simulations...

The indentation rolling resistance of conveyor belts is an important design consideration for long belt conveyors and can also be important for heavily loaded belt conveyors. Indentation rolling resistance is dependent on the properties of the conveyor belt, including the carcass and bottom cover as well as properties of the belt conveyor including...

The energy loss due to indentation rolling resistance in a conveyor belt system can account for up to 60% of the total power usage. It arises due to an asymmetric pressure distribution as a viscoelastic belt cover is indented by a rigid idler roll. This causes a retarding moment on the idler roll, dependent on the load, speed, idler diameter and th...

The primary function of idler rolls in a belt conveyor system is to support the conveyor belt along its length. Predicting the cumulative resistance of idler rolls is vitally important in calculating the belt tension and therefore power requirements of a system, particularly on long overland conveyors where there are typically more than one thousan...

The study is to quantify the pressure distribution caused by bulk material on a loaded conveyor belt using a tactile pressure sensor. The pressure distribution is important for the engineering design of conveyor belts, and the verification of theoretical models. Tactile pressure sensors have been proven to produce acceptable measurements of the pre...

The objective of this study is to assess the applicability of the tactile pressure sensors for the measurement of the dynamic pressure on a loaded conveyor belt. Theoretical models have been developed to predict the dynamic pressure caused by the bulk material on the belt. However, there has been no satisfactory sensors or procedures for the direct...

The bulk material on a belt conveyor deforms itself due to the run through idler stations. The deformation results in energy losses which are summarised in the bulk solid flexure resistance. The right understanding of the interaction between bulk material and idler stations is important for the prediction of this resistance and the idler loads. For...

In many industries across the world, the topic of dust control is a major concern. Within the bulk material handling process the action of material free fall is generally unavoidable. In this case, the adjacent air surrounding the free falling stream is induced into the stream of bulk material as the particles naturally dilate, which results in gen...

The University of Newcastle has undertaken a systematic research program to identify, model and measure key design elements to reduce the energy consumption of belt conveyors. Research outcomes include the development of theoretical models to accurately predict the main resistances of belt conveyors, in parallel with developing extensive test facil...

The bulk material on a belt conveyor deforms itself due to the run through idler stations. The deformation results in energy losses which are summarised in the bulk solid flexure resistance. The right understanding of the interaction between bulk material and idler stations is important for the prediction of this resistance and the idler loads. For...

The Two Fluid Model can be used to simulate the large particle-gas flow in transfer chutes.•The granular viscosity model has a strong influence on both particle and air flow due to the large particle size.•The influence of the drag model is not as significant as the viscosity model in transfer chute simulation.•Based on the study, the SST k-ω model...

This article discusses how determining the viscoelastic properties of the cover material of a conveyor belt, using different rheological test modes, can result in significant differences in properties for the same material and testing conditions. The viscoelastic properties are applied to two mathematical models used to predict and compare the inde...

A microcontroller-based conveyance system using a hybrid electromagnetic suspension (EMS) system and a linear synchronous motor (LSM) is proposed. Unique placements of the hybrid EMS and LSM integrated with an array of infrared sensors, embedded microcontroller, and electronics switching circuits are designed to maintain the air gaps and the propul...

Transfer chutes are essential components in almost all bulk material handling plants. Belt conveyors utilize transfer chutes to load and redirect bulk materials from one conveyor to another, with their reliability and performance being critical to the overall operation of the plant. While reliability and operational performance is typically measure...

This article presents the outcomes from a series of physical experiments to measure the air entrainment rates encountered within a stream of freefalling particles. The experimental work presented spans a range of particle parameters and hopper geometries. From these results a new theory for the prediction of air entrainment is developed and present...

There are many analytical and numerical models that are designed to predict the indentation rolling resistance of conveyor belts that have as their main input the relaxation properties of the physical rubber that is being modelled. Relaxation data for rubbers such as those used in the construction of conveyor belts are difficult to obtain directly...

A technique to simulate airflow around transfer chutes that involves linking Discrete Element Method (DEM) commercial package Rocky and Computational Fluid Dynamics (CFD) commercial package ANSYS Fluent is proposed. The flow of particles is first calculated in the DEM domain; after that continuum parameters of this flow (porosity, mean particle siz...

This paper describes a pilot plant investigation of Bayswater fly ash slurries where the flow behavior of the slurries was investigated in respect to the effect of solid concentration, pipe size and flow velocity. A re-circulation pipe loop configuration with instrumented pipes of nominal bore of 80 mm and 53 mm was used for measuring the slurry fl...

This paper presents findings from a research program aimed at investigating the interaction between the bulk solid and the conveyor belt during transportation. The outcomes will improve the methods used to calculate the loads on conveyor idler rolls and predict the energy loss due to the flexure of the bulk solid. The research involved simulated la...

This paper presents an investigation of loads exerted by bulk solid materials on a conveyor belt during transportation. Experimental measurements were performed on a re-circulating belt conveyor test facility including a 3D laser scan of the belt. Ge-ometry obtained from the scan was implemented to model the opening and closing of the troughed belt...

This paper presents an investigation of wall load profiles in troughed belt conveying systems from active and passive stress states induced in bulk solid materials due to the opening and closing of the conveyor belt. Measurements were conducted on an experimental belt conveyor simulation test rig incorporating a TekScan pressure pad measuring syste...

This paper focuses on a study concerned with reducing dust emissions from belt conveyor transfer chutes in bulk material handling plants. Several transfer chute configurations were investigated with the aim of analysing the system performance. Scale model laboratory testing was undertaken to determine the effectiveness of each design in reducing du...

Energy loss due to indentation rolling resistance is a major factor in belt conveyor design. The determination of the indentation rolling resistance of a conveyor belt over the idler system depends on the properties of the rubber compound of the backing the method of calculation of the resistance value and, of course the conveyor system parameters...

Dust control is a widespread problem affecting the mining industry in Australia and most parts of the world where the mining of natural resources is taking place. Due to the ever increasing focus on the health and safety of personnel, as well as environmental concerns, the problem of dust control is certainly an important one that needs total atten...

This paper presents work undertaken to model dust emissions from belt conveyor transfer chutes. Several transfer chute configurations were investigated during the course of the project with the aim of analysing the performance of each usingscale model laboratory testing. The experimental work involved measuring the quantity of fugitive dust, in add...

This paper provides details of the development and application of a viscoelastic finite element analysis of the indentation rolling resistance problem of a conveyor belt moving over an idler roll. The finite element analysis (FEA) is performed using the commercial FEA software Strand7. The analysis presented models the viscoelastic rolling contact...

The application of numerical analysis and simulation methods is a main part of the design process of today’s bulk solids handling facilities. The Finite Element Method (FEM) is mainly used for static and dynamic structural analysis when designing and optimising components. Meanwhile the Discrete Element Method (DEM) is used to simulate and optimise...

A novel magnetic levitation conveyor system consists of a linear synchronous motor and a hybrid electromagnetic levitation system was designed and built. The linear synchronous motor for propulsion was constructed using non-contact digital commutation while the hybrid electromagnetic levitation system was implemented using two permanent magnets and...

In the field of bulk solid materials handling, belt conveying systems including transfer chute configurations such as rock box, dead box, bifurcations, hoods and spoons, slewing/luffing stacker reclaimers and ship loaders are extremely important components of mines, ports and processing plants.. Up to date, the ongoing analysis techniques used to a...

This paper presents an investigation of active and passive stress states induced in bulk solid materials due to the transverse opening and closing of the conveyor belt. The relationship between active and passive stress states to the subsequent load profile exerted by the bulk solid material on the belt was modeled and examined using Discrete Eleme...

“Passive” dust control systems for belt conveyor transfer stations have become increasingly popular in recent years. Effective design relies on a fundamental understanding of the flow of granular material and air throughout the transfer chute. This paper presents an investigation into the flow properties of the air and particles in the enclosure fo...

The enhancement of load assumptions for the calculation of bulk material handling equipment is one of the research projects currently undertaken by the University of Magdeburg and the University of Newcastle. This research topic also includes the detailed analysis of the conveyor belt deflection under realistic load conditions. The aim of the proje...

A co-operation among Universities of Newcastle, Australia, and Magdeburg, and Germany, is established to develop and apply the new analysis methods such as Discrete Element Method (DEM) and Computational Fluid Dynamics (CFD), for prediction of diffuse dust emission from dust exhaustion plants. The combined analysis of DEM and CFD includes two CFD s...

Dust emission is one of the main problems associated with the operation of transfer chutes. The design of the transfer chute influences dust generation to a large degree. Due to the very specific design of transfer chutes, sophisticated simulation methods such as the Discrete Element Method (DEM) and Computational Fluid Dynamics (CFD) are necessary...

Two computer based modelling approaches are presented in this paper which focus on the flow of dust in bulk solids handling operations. Granular flow through a constant radius chute is modelled using computational fluid dynamics (CFD) in which a multiphase simulation is considered. This approach provides valuable information about the flow of dust...

This paper presents an investigation of active and passive stress states induced in bulk solid materials due to the transverse opening and closing of the conveyor belt. Measurements were conducted on an experimental belt conveyor simulation test rig incorporating a TekScan pressure pad measuring system. The process was modeled and examined with Dis...

The introduction of more stringent environmental and occupational health and safety regulations have instigated efforts to reduce the amount of dust generated during loading of ships with dusty bulk materials. An initial study was undertaken to investigate possible methods to reduce dust emissions from wheat loading operations at the Port of Newcas...

AI Aggregates International ISSN 1861-9126

In belt conveying systems, bulk solid material immediately prior to discharge moves from a troughed profile on the last idler set to a flat profile at the head pulley. How the bulk solid material behaves in this zone is a function of the material properties of the bulk solid and the transition time, which in turn depends on the transition length an...

This article presents an industrial case study to reduce dust emissions from a grain handling ship loader. The primary objective of the study was to reduce dust emissions to within acceptable environmental levels during ship loading. Several constraints were imposed on the solution as the result of time and budgetary restrictions, and the inability...

Based on an industrial case study, the performance of a rotary dryer employed in a mineral processing plant was investigated. The loads on the rotating elements of the dryer are analyzed with a view to ascertaining possible causes of failure. The particular type of dryer comprises a steam-heated drying unit composed of a central hollow drum and a n...

This paper describes an experimental test rig which simulates the motion of bulk solid material on the conveyor belt during transportation. An investigation of active and passive slip surfaces of bulk solid materials formed due to the opening and closing of the conveyor belt is presented. In particular, the influence of the angle of internal fricti...

This paper presents an industrial case study to reduce dust emissions from a grain handling ship loader. The primary objective of the study was to reduce dust emissions to within acceptable environmental levels during ship loading. Several constraints were imposed on the solution due to time and budgetary restrictions, and the inability to add a du...

A linear viscoelastic finite element analysis used to calculate the indentation rolling resistance of belt conveyor systems using experimentally measured viscoelastic properties was presented. It was found that the indentation rolling resistance occurs due to the formation of an asymmetric pressure distribution within the contact area. The finite e...

Belt conveyors are used extensively in the mining and mineral processing industries to transport bulk solid. As industry demands arise and conveying technology improves, belt conveyor installations are becoming progressively longer and belt speeds significantly faster. With longer conveying distances it becomes increasingly important to accurately...

Dust control in belt conveying operations is becoming increasingly important due to a number of reasons, most notably the increasing emphasis on health and safety and also the conservation of the environment. The primary objective is to reduce dust emissions by passive means without the need for external energy as associated with dust extraction sy...

The effective design of transfer chutes is of utmost importance in the materials handling chain to ensure reliable flow of the product being transported. In addition to this, the control of fugitive dust is needed to meet occupational health and safety standards as well as environmental concerns. In the design of transfer chutes classical continuum...