- Increase in throughput from 500 TPH to 600 TPH. (ton per hour)
- Maximum aggregate size increased from 101 mm to 152 mm.
- Eliminate belt damage caused by material trapped between conveyor belt and feeder discharge box.
- Reduce shear wear in the feeder area of conveyor belts.
- Increase the mean time to failure (MTTF) of conveyor belt skirt wear plates.
To test and validate our design modifications, we relied on Rocky DEM software to quickly and accurately simulate the likely behavior of the material inside the drop hopper. We began our analysis in Rocky by calibrating the software to ensure that the aggregate was representative of the reality in the field.
We then created a simulation using this calibrated material and the original hopper geometry. After comparing the results of the simulation with existing conditions and making sure that they matched, we used the results as a design basis for testing our future solutions.
After analyzing the basic results, we decided to completely resize the feeder discharge box. The final design includes:
- Conveyor belt width increased from 1219 to 1320 mm
- Increase in conveyor belt linear speed from 0.49 to 1 m/s
- Reduction in the length of the unloading area and addition of a corner on the rear of the box
- Unloading area narrowed from rear to front
- Feeder top opening reduced from 1500 to 800 mm
- Added opening angle on feeder sides
As further Rocky simulations have shown, this new optimized design has exceeded targets, producing a calculated throughput of 670 TPH. What's more, conveyor skirts become superfluous thanks to the optimized shape of the hopper, facilitating material swathing.
The more natural flow of material through the distributor, combined with the reduced loading area on the belt, has resulted in a drastic reduction in shear wear. In addition, it has been demonstrated that the material is no longer trapped between the distributor's discharge box and the belt, considerably reducing wear and damage to the conveyor belt.
With the help of Rocky DEM software, it was possible to redesign the pebble feeder, then test it virtually to ensure that all design objectives were met before installation.
