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OPTIMIZATION OF RAW MATERIAL

TRANSPORT IN A TRANSFER CHUTE


USING EDEM
Magno A. Calil Resende Silveira, Usiminas
Gustavo Lucas Rocha de Oliveira, Usiminas
Brulio Viegas da Silva, Usiminas
Daniel Schiochet Nasato, ESSS

SUMMARY
Overview - Usiminas
Introduction
Objectives
Chute optimization step by step

Conclusion

Overview - Usiminas
Usiminas acts in different segments in the steel chain,
delivering high quality products and services, integrating
solutions and adding value to the customer;
Usiminas works in four business units: mining and logistics,
steel works, steel transformation and capital assets;
With a modern steel processing infra-structure, Usiminas is
prepared to attend, in a tailored way, the demands of the
automobile, auto parts, civil construction, electro-electronic,
capital assets, domestic devices, among other segments

Introduction
Raw material transport using conveyor transfer and chutes
may become critical due to details not covered in the design
phase or the low maintenance frequency in the process.
Problems such as material spillage, belt misalignment,
breakage and premature wear of peripherals associated with
the system can cause damage to the process.
Currently, part of the raw material is lost in transportation in
the Ipatinga ironmaking plant (Usiminas)

Objectives
Use EDEM to reproduce material flow conditions through a
transfer chute and material misalignment in a conveyor;
Validate EDEM with experimental data;
Propose modifications to solve misalignment problems.

Step 1 Data calibration


Sequence of fast and well established experiments allows
the user to easily capture the parameters;
Free fall test, static friction, critical rolling angle and repose
angle were mesured;
Simulations were performed on EDEM to calibrate data

Material data and initial conditions


Material data
Posisson's Ratio
Shear modulus
Density (Kg/m3)

Interaction data
Coeff. of restitution
Coeff. Os static friction
Coeff. Of rolling friction

Pellet

Rubber

Steel

0.25
0.25
0.25
1.00E+06 1.00E+07 1.00E+10
3900

1500

7800

pellet/pellet

pellet/rubber

pellet/steel

0.2
0.55
0.28

0.5
0.5
0.2

0.09
0.3
0.15

Particle factory form reproduce particle dynamic angle


Particle size: 12 mm diameter
Mass flow: 278 kg/s
4 hours to simulate 10s in a quad core machine

Step 2 Experimental validation


Real case was video recorded and compared to the
simulated case;
Simulation showed good agreement with real case;
Flow through the chute and conveyor misalignment could be
accurately reproduced.

Real Case

Step 3 Modification Initial idea


Initially was proposed to insert a internal deflector to adjust
material flow;
The idea was rejected because the accumulation changed
side, but the misalignment remained;
Expensive solution high wear on deflector.

Modification Initial idea

Step 4 Final solution


It was proposed to move the right guide from bottom chute
40 mm to the left;
Solution showed good alignment in the conveyor;
Cheaper solution.

Proposed modification on detail

Final solution

Conclusions
EDEM captured real case phenomena to identify the causes
of the problem;
Proposed solution (internal deflector) would be expensive
and would not align conveyor misalignment:
Discarded before implemented.

Validated changes:
Changes were implemented on Usiminas and solved the problem.

Final solution cheap to implement!


Saved costs of trial and error!