ATCx DEM 2020 - DEM modeling of particulate processes – from conceptualization to industrial application

Altair® EDEM™ is a discrete element method solver that enables users to accurately simulate particulate processes. When coupled with Altair Computational Fluid Dynamics (AcuSolve), these two solutions enable the simulation and analysis of two-phase solid-fluid systems. These simulation tools are widely used in various industries and in academia to deepen the understanding of different unit operations, such as mixers, coaters, fluidized beds and pneumatic conveyors. The unique and novel solutions that Altair offers address the challenges when using DEM and coupled CFD-DEM methods.

Dust is a serious problem for industries that handle and process bulk materials, causing deteriorating ambient air quality, human health concerns, while increases housekeeping labor costs to meet safe levels for health and fire risks. Learn from Dr. Andrew Grima about the technologies employed to develop a successful solution to minimize dust by using calibrated discrete element modeling (DEM) and new dust extraction technology.

The Digital Twin concept is broadly applicable to all Altair customer base wanting to develop better products faster. We will explain how to maximize the value you can get from the Altair Platform for Digital Twins. We will illustrate how this solution helps diverse engineering teams develop better, more complex products faster by avoiding work in silos. This will include proven uses cases for the convergence of simulation and data.

This presentation provides an introduction to the Discrete Element Method (DEM) and its application to solve powder processing challenges. Use cases presented include the use of Altair EDEM to simulate a twin screw extruder as well as a proof of concept study using EDEM with CFD to investigate pneumatic conveying.

Presented at the 2nd Altair Academic Outreach Event in June 2021

Speaker: Dr. Akeem Olaleye, Research Fellow, University of Limerick
Duration: 17 minutes

For several years now, co-simulation between Multibody Dynamics (MBD) codes like MotionSolve and Discrete Element Method (DEM) software like EDEM has been used for many applications such as vehicles and material transportation. One missing link has been a realistic tire model that not only could interact with the soil material in a realistic way but also show the influence of varying tire pressure, change in contact area and pressure distribution over said contact area.

For very soft material such as deep mud with a high-pressure tire, using a rigid wheel is a decent approximation. But for tires on harder surface, this method has several short comings. For example, a rigid representation of the tire will have neglectable rolling resistance while the pressure distribution on a real tire has its peak well ahead of the centerline of the tire producing a resisting moment to the motion. The contact patch area will in reality not depend on sinkage, but the sinkage is dependent on the contact area that is dependent on load and internal pressure.

This presentation introduces the new PM-FlexTire model that is integrated in EDEM and will work with MotionSolve. Requirements for creating and correlating the tire model is presented together with several application examples on mud, clay and gravel beds.

Presented at the ATCx Heavy Equipment in May 2021.

Speaker: Jesper Slattengren, Technical Fellow, Pratt Miller

Duration: 20 minutes

Zoomlion Heavy Industry have been developing a simulation model of a threshing system of a combine harvester using the Discrete Element Method (DEM). Optimization of the performance parameters like grain recovery, grain damage and grain loss with an optimal use of power is the overall goal of the model. Dealing with small size multi-spheres with varying material properties and processing of large number of particles in a reasonable time were the real challenges which we successfully handled using Altair’s EDEM software. An important performance indicator of the agricultural crop processing and grain handling systems is the damage to the grain that occurs in the system.

Zoomlion are continuously discussing and working with Altair’s team to make it possible to study this important performance parameter. They are fully determined to address & solve the problems which are considered un-solvable in construction and agricultural industry of the world.

Presented at the ATCx Heavy Equipment in May 2021.

Speaker: Syed Hussain, Senior Mechanical Engineer Zoomlion Heavy Industry NA

Duration: 20 minutes

The production of agricultural commodities is a multi-billion dollar industry in Canada representing nearly 7% of the national GDP. While the food production system is complex and specific to each type of product grown, challenges in processing, handling, and storing agricultural commodities occur throughout the value chain.

Significant benefits and insights have been derived from the ability to model the interactions between granular particles in systems in the value chain. Two case studies from industry are presented where the effects of the geometry of bulk grain storage and processing equipment are considered. In one case, detailed insights were developed about the variation in bulk properties due to filling and storage details. In a second case, geometric design details were optimized virtually during the development of novel processing equipment. This resulted in improved performance and reduced physical prototyping costs.

Presented at the ATCx Heavy Equipment in May 2021.

Speaker: Ian Paulson, Technical Services Lead – Simulation and Numerical Modeling Prairie Agricultural Machinery Institute (PAMI)

Duration: 20 minutes

Coating of particulate solids by a thin film layer is of interest in many industrial applications such as seed and tablet coating. In seed processing, seeds are commonly coated with a protective coating layer consisting of fertilizers and crop protection products. Rotary drum batch coaters are typically used for this purpose.

In the present study, Discrete Element Method (DEM) simulations are used to analyze the seed coating process, using corn seed as model material. The coating uniformity of the seeds is predicted by implementing two coating models. The distribution of mass of sprayed spheres on the corn seeds, their residence time in the coating zone and the coefficient of variation of coating mass and residence time of the seeds are evaluated for a range of process conditions, such as spinning disk rotational speed, droplet size, and baffle arrangement and designs.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Mehrdad Pasha, Powder Expert Scientist, UCB Pharma
Duration: 20 minutes

The development of novel active materials and compositions in lithium-ion battery electrodes is a main research focus due to the increasing demand for electric mobility. Calendering, as the final step in electrode production, is a critical process that significantly influences the mechanical and electrochemical properties of the electrode.

This presentation presents an approach using the Discrete Element Method (DEM) and Altair EDEM software to predict the influence of calendering on the electrode material, composition, thickness and the machine behavior. Additional investigations provide guidelines for optimizing the process. All in all, a deep understanding of how the calendering process effects the electrodes is presented and forms the basis for further investigations.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: David Schreiner, Research Associate, Technical University of Munich
Duration: 24 minutes

When building simulation models of military vehicles for mobility analysis over deformable terrain, the powertrain details are often ignored. This is of particular interest for electric and hybrid-electric vehicles where the maximum torque is produced at low speeds. It is easy to end up with the drive wheels spinning and reducing traction and eventually the vehicle digging itself down in the soil.

The presentation discusses the reason why simplified terramechanics models (ST) such as the Bekker-Wong models are not suitable for dynamic traction control studies and shows how Altair EDEM's complex terramechanics models (CT) can be co-simulated with multi-body dynamics software Adams using the ASCI interface.

The presentation focuses around an 8x8 transport vehicle with and without TCS. To model the traction control system a PD controller is used to limit the slip velocity at low speed and wheel slip at higher velocity. A soil model has been correlated to the Pratt & Miller sandbox and a 35% hill climb was used to tune the TCS parameters in the co-simulation.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Jesper Slattengren, Technical Fellow, Pratt Miller Engineering
Duration: 20 minutes

Pneumatic conveying pipelines undergo series of direction changes due to space restrictions, site location, or position of receiving silos and hoppers. When dairy powder and air flows around pipe bends or experiences any change in flow direction during pneumatic conveying, the particles form a rope-like structure due to inertial, gravitational and centrifugal effects. The formation of such particle ropes can lead to particle stratification, re-agglomeration, deposition, and pipe blockages especially when handling cohesive powders.

This research focuses on the design and optimization of novel flow-aided pipe bends that prevents powder deposition, pipe clogging, and improves throughput. Several conceptual designs of such flow-aids are investigated for various bend orientation by coupling Altair EDEM with Computational Fluid Dynamics (CFD) supported with targeted experimentation. The optimum flow-aided design integrated into a pilot-scale conveying test rig results in higher rope dispersion after the than similar test rig with conventional bends.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker:Akeem Olaleye, University of Limerick
Duration: 24 minutes

Desired or not, particle breakage can occur when dealing with particulate materials in industry. For cases in which breakage severely influences the flow of the material, the only viable option is to describe it within the DEM environment. Several powerful approaches have been proposed over the years, but only very few are suitable to be used in large-scale simulations.

The presentation shows one such model that has been implemented in Altair EDEM to describe body breakage of brittle materials. It is based on a novel stochastic particle replacement approach involving spheres. It accounts for variability and size-dependence of fracture energies, besides weakening when particles do not break and fragment size distribution dependent on stressing energy. Results from model verification and validation in EDEM are presented, which demonstrate its high fidelity, besides examples of application to predict breakage in selected crushers.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Prof. Marcelo Tavares, University Federal de Rio de Janeiro
Duration: 25 minutes

Particle processing is one of the core activity of pharmaceutical products and processes development, manufacturing, and also drug delivery. The powder behavior and processing performance have direct impacts on process robustness, yield, and final product performance (drug delivery). 

Product and process development efforts are normally time consuming and expensive by experimental trial-and-error approach. Discrete Element Method (DEM) modeling, and other mechanistic methods, are enabling tools for creating a digital sandbox. Engineering can utilize these tools for equipment characterization, process parameter optimization, target performance tuning, rapid process development and cost saving, and eventually delivering product faster to the market (patients benefits). The applications are diverse, from batch or continuous blending, micronization, tablet making, coating, or using CFD-DEM methods for dry powder inhalers and drug delivery. 

In this presentation the applications of DEM and CFD-DEM modeling in pharmaceutical manufacturing will be discussed. Critical aspects of the model development, validation, and implementation in compliance with regulatory criteria will be explained. A new hybrid machine learning-DEM approach will be introduced for extended DEM runs for rapid DEM modeling to a realistic process time (hours) in reduced computational expenses and time.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Dr. Nima Yazdanpanah, Principal, Procegence
Duration: 24 minutes

Discrete Element Method has drawn an increasing attention in both academia and in industry. While there are tremendous successes reported in open source, many practical challenges exist when applying DEM modelling to pharmaceutical processes development. In this talk, experience of DEM applications in pharmaceutical development will be shared with discussion on benefits. A case study on scale-up of tablet coating processes will be given in greater detail. And an outlook for future path forward will be open for discussion.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Dr. Liang Li, Process Engineering Scientist, The Janssen Pharmaceutical Companies of Johnson & Johnson
Duration: 18 minutes

Material model calibration is an integral part of the Discrete Element Method modelling methodology, but the commonly adopted trial and error calibration approach is time and resource intensive. Recently developed workflow automation tools and coupling methods with Altair’s suite of machine learning solutions have improved the efficiency and accuracy of the calibration process in Altair EDEM software. This talk explores the ways users can leverage the power of these tools when conducting EDEM material model calibration.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Stefan Pantaleev, EDEM Engineer, Altair
Duration: 26 minutes

Many industries and applications involve bulk and granular materials interacting with machines and fluids. The use of Multiphysics and Altair EDEM software can play a major role when trying to understand, predict and optimize bulk material handling equipment and processes.

This presentation provides an introduction to the Multiphysics capabilities and options available with Altair EDEM. It includes an overview of the benefits obtained from combining EDEM with other solvers and software from Altair, including couplings to finite element method (FEA), computational fluid dynamics (CFD) and multi-body dynamics (MBD).

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Ignacio Diez Alonso, EDEM Engineer, Altair
Duration: 18 minutes

The mechanical behavior of granular materials can be usefully described in terms of continuum fields such as stress, strain, porosity, and mass density. These fields and their derivatives are often of interest when modelling granular systems with Altair EDEM. An example is the calculation of the kinetic stress field in a powder mixer, which is used to analyze the convective flow patterns in the system. The EDEMpy library of python functions enables the calculation of such continuum fields from discrete particle data in EDEM and this talk gives an overview of continuum analysis with EDEMpy using a powder mixing process as a case study.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Stefan Pantaleev, EDEM Engineer, Altair
Duration: 19 minutes

Most users know Discrete Element Method modelling for the need of defining material properties, particle shapes, equipment working conditions and contact physics. In this talk, key features of Altair EDEM that expand beyond the usual DEM settings will be showcased. From easy ways to create complex particle shapes and configurations to ad-hoc post processing, attendees will discover unique features and capabilities of EDEM they might not know about and will find out why EDEM has been leading the DEM market for years.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Carles Bosch Padros, EDEM Engineering Services Team Lead, Altair
Duration: 19 minutes

The presentation discusses the problems of designing screw conveyors with regard to the determination of the exploitation parameters (mass efficiency and power demand) when current calculation methods are in use. To improve the designing process and provide more reliable results, a DEM method was introduced to everyday usage in FMK company. The presentation shows the innovative results of the experimental and simulation studies concerning the determination of the exploitation parameters of the screw conveyor. Our studies indicated great agreement of the DEM results with reality in the aspect of mass efficiency and power demand calculation. Moreover, exemplary simulations of bulk material transport in a screw conveyor are be presented.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Piotr Rubacha, Simulation Engineer, FMK Poland
Duration: 18 minutes

In chemical process industries, process equipment were designed and optimized based on the designer’s experience, available empirical correlations and experimental studies in the past. However, in recent years, Discrete Element Method (DEM) has been widely used in many process industries for large-scale simulations of particulate handling and processing operations for better understanding of material flow and design optimization.

Two case studies here showcase the effective use of DEM for design and process optimization of rotary equipment. In the first case study, DEM was used successfully to test various concepts of the lifter designs for drying fragile material in rotary dryer for achieving higher throughput and drying rate at reduced specific energy consumption. Another case study highlights evaluation of different grinding media configurations in ball mill through DEM simulations for predictions of power and collision energy spectra impacting the material grinding pattern and overall specific energy consumption.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Dr. Manoj T. Kandakure, Lead Scientist, Aditya Birla Science & Technology
Duration: 25 minutes

The production of hot mix asphalt (HMA) involves drying and heating aggregates and mixing and coating the aggregates with liquid asphalt bitumen. This process presents many simulation challenges.  As an equipment manufacturer Astec uses simulation to improve equipment design and performance, but the changing characteristics of the HMA mixture during the production process has meant the development of a range of custom DEM models to account for different stages of the process.  In this presentation, Astec's head of simulation and modeling reviews successes and where there are gaps in the process of simulating HMA production from rock to road.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Andrew Hobbs, Head of Simulation and Modeling, Astec Industries
Duration: 18 minutes

A default in the Blast Furnace burden permeability is an important issue in the Blast Furnace process. Particle segregation can lead to a preferential flow and disturb the gas distribution. Material charging is one of the few levers on which a Blast Furnace operator can act to control segregation.

The deep Discrete Element Method (DEM) simulations coupled with a FIFO evaluation allowed Paul Wurth to increase their knowledge of the important factors influencing the segregation and helped to improve the design of the complete material handling. Learn more in this presentation.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speakers: Stefan Rühl, Project Engineer & Christian de Gruiter, Head of Calculation Tools, Paul Wurth
Duration: 22 minutes

In this talk, two examples of how ArcelorMittal uses Altair EDEM software for steelmaking applications are discussed. In each considered granular flow configuration, simulation results are validated with experimental data and observations. 

The first application is about the DEM modelling of segregation issue from a charging system of a sinter cooler. The DEM model is set up, with a calibration step, validated with a segregation measurement from the plant and used to analyze the granular flows in the charging chute, better understand the material behavior and optimize the sinter cooling efficiency. 

After, the DEM numerical study of a high-stress particles impact test on steel plate. Calibrated simulations with EDEM show a good agreement with experimental observations regarding abrasion location and magnitude. Particles flow in the test is better understood and local measurements in the simulation of abrasion energy locations and contact forces distribution are numerically assessed with the EDEM software which is impossible to realize in the experiment.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Dr. Edouard Izard, Research Engineer, ArcelorMittal
Duration: 22 minutes

Tools used in soil cultivation are subject to heavy wear. Simulation methods, such as the Discrete Element Method (DEM), show a good suitability to analyze these processes. In materials science, many investigations of wear are based on the scratch test, in which a diamond tip is moved along a material surface and the volume removed provides information about the abrasion behavior. With the DEM it is possible to simulate this scratch test virtually.

During the simulation of the stress, no geometric deformation according to the expected wear takes place so far. For this purpose, a program has been developed which changes the geometry of the tool to be examined at defined intervals as a CAD model and returns it to the simulation. The interaction is automated, so that no manual adjustments are necessary and the wear process can be displayed in any detail.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Florian Schramm, M.Sc, Technical University of Braunschweig
Duration: 21 minutes

Many industries involving bulk solids require a fundamental understanding of powder bed packing structure and stress distribution in order to effectively design process equipment, optimize powder processes, and enhance product quality. Using Discrete Element Method simulations, a simple container filling and uniaxial compression process is modelled for a system of 70,000 glass bead particles with varying particle-particle cohesion and particle-wall friction and adhesion. Watch the presentation to find out more about the results of this study.

Presented as part of the virtual ATCx Discrete Element Method in November 2020.

Speaker: Nicholas Monroe, University of Delaware
Duration: 29 minutes

The world is full of bulk and granular materials. From ores being mined, soil being excavated, rocks being conveyed, or powders being processed - over 70% of all industrial processes involve the handling or processing of these challenging materials.

This presentation illustrates how Altair’s latest simulation product updates can facilitate and accelerate customers’ product design cycles by addressing specific tasks for both designers and engineers, from part to system level structural design, spanning from concept- to detailed development stages.

Within the context of an excavation scenario, we will show a range of solutions with a focus on the following:
- optimization of an excavator arm with regards to structural performance and fatigue life assessment under realistic loading conditions,
- rapid, early loadcase evaluation and improvement of structural robustness by performing detailed design exploration of a truck trailer assembly,
- improvement of Roll-Over-Protective Structure test results of an excavator cabin by applying Altair’s innovative C123 optimization,

A technical overview of aforementioned solutions is followed by relevant software demonstrations of updated model build & exploration workflows within the new HyperWorks user interface, integrated Inspire solutions for Motion & Structural analysis, along with automatic CAD redesign & CAD parametric optimization processes.

Presented at the ATCx Heavy Equipment in May 2021.

Speaker: Alexander Gnech, Technical Manager, Altair

Duration: 20 minutes