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Minerals
Special Issues
Transfer Systems for Ores and Minerals
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Transfer Systems for Ores and Minerals

A special issue of Minerals (ISSN 2075-163X). This special issue belongs to the section "Mineral Processing and Extractive Metallurgy".

Deadline for manuscript submissions: closed (29 February 2024) | Viewed by 4577

Special Issue Editors

Dr. Dusan Ilic

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Guest Editor
Newcastle institute for Energy and Resources, University of Newcastle, University Drive, Callaghan 2308, Australia
Interests: modeling and simulation; engineering design; granular mechanics
Prof. Dr. Corné Coetzee

E-Mail Website
Guest Editor
Department of Mechanical and Mechatronic Engineering, Stellenbosch University, Joubert Street, Stellenbosch 7600, South Africa
Interests: granular materials; discrete element method; material point method
Prof. Dr. André Katterfeld

E-Mail Website
Guest Editor
Institute of Logistics and Material Handling Systems, Otto von Guericke University Magdeburg, Universitätsplatz 2, 39106 Magdeburg, Germany
Interests: material handling; conveyors; granular materials; discrete element methods (DEM)

Special Issue Information

Dear Colleagues,

Transfer chutes can be a barrier to productivity depending on mineralogy, fine content, and moisture. Productivity is a function of the effectiveness of the transfer system design and, with a high throughput, the adaptability of transfer systems for multiple products, characteristics, and operating conditions are of pronounced importance. With a growing need for sustainable ores and minerals, the application of transfer points for quality assurance and control that include sorting, sampling, blending, and de-watering are also increasing in prominence. The design of transfer systems influences the performance and wear life of both fixed plant consumables such as chute and skirt lining, idlers, and belt scrapers, as well as belt conveyors that can be exposed to problems such as belt mistracking. The simulation of ore and mineral flow through transfer chutes thus offers a state-of-the-art tool to the designer to assess functionality during product development and prior to manufacture and installation for troubleshooting in brownfield applications. It further provides a means of optimizing the location of sensors for monitoring and sorting. For the actual simulation, the Discrete Element Method (DEM) complements an analytical approach, with traditional continuum mechanics often a foundation of any design process; however, in more recent times, coupling with Computational Fluid Dynamics (CFD) has enabled the assessment of dust generation and, with Finite Element Analysis (FEA), assessing the forces and impacts on the supporting structure. In high-risk situations, physical scale modeling is used to validate designs. Despite these tools, the design process is typically a compromise between different and often contrasting criteria and a path to be treaded carefully. This Special Issue will collate research into the latest developments and relevant aspects of transfer system design to maximize productivity and functionality in practice, with a specific interest in ores and minerals that are critical for a sustainable global energy transition. The topics of interest are broad and include innovative approaches to calibrate and validate flow and performance, use of sensors, and IoT for sorting, quality assessment, quality control, dust emissions monitoring, water application, wear and build-up assessment, sampling, blending, de-watering, adoption of new approaches, technology, and calibration methods and tests in assessing wear, blockage and spillage, processes for the optimization of wear lining materials, maintenance considerations, innovative dust control approaches, and practical considerations. 

Dr. Dusan Ilic
Prof. Dr. Corné Coetzee
Prof. Dr. André Katterfeld
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Minerals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • transfer chute
  • transfer station
  • bulk solids
  • ores
  • minerals
  • flow
  • feeding
  • loading
  • discharge
  • blockage
  • build-up
  • spillage
  • wear
  • wall liner
  • abrasion
  • continuum mechanics
  • trajectory
  • sensing
  • visualization
  • sorting
  • de-watering
  • tracking
  • conveying
  • dust emissions
  • DEM
  • FEA
  • CFD
  • CFD-DEM
  • DEM-FEA
  • laser scanning
  • sampling
  • IoT
  • blending

Published Papers (4 papers)

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Research

18 pages, 8437 KiB  
Article
Trends in the Growth of Damage Extents in a Steel Conveyor Belt’s Core
by Leszek Jurdziak, Ryszard Błażej, Agata Kirjanów-Błażej and Aleksandra Rzeszowska
Minerals 2024, 14(2), 174; https://doi.org/10.3390/min14020174 - 6 Feb 2024
Viewed by 794
Abstract
The initial set of four measurements (scans) captures the failures occurring in the core of steel cable conveyor belt segments used in a lignite coal mine in Poland. These measurements utilize the DiagBelt+ magnetic system, enabling the analysis of averaged damage sizes. The [...] Read more.
The initial set of four measurements (scans) captures the failures occurring in the core of steel cable conveyor belt segments used in a lignite coal mine in Poland. These measurements utilize the DiagBelt+ magnetic system, enabling the analysis of averaged damage sizes. The scanning results allowed the analysis of complete changes in the failure sizes to a maximum of six different time intervals from 1 to 19 months. The cumulative increase in the length and width of the failure (their total extent in both directions) is a linear function of time. However, the inclination of the selected lines (growth speed) depends on the age of the belt segment at the time of its first scan. It is possible to find the best regression function of slope coefficients for the age of the belt segment. The obtained results are crucial for rational belt management, including reliable short-term forecasts of belt needs with the flow of time, indications of the best moments for belt segment replacements, and estimating the budget of the belting department. Full article
(This article belongs to the Special Issue Transfer Systems for Ores and Minerals)
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18 pages, 17438 KiB  
Article
Transverse Profiles of Belt Core Damage in the Analysis of the Correct Loading and Operation of Conveyors
by Leszek Jurdziak, Ryszard Błażej, Agata Kirjanów-Błażej and Aleksandra Rzeszowska
Minerals 2023, 13(12), 1520; https://doi.org/10.3390/min13121520 - 5 Dec 2023
Viewed by 993
Abstract
This article presents an analysis of the transverse profile of belt damage in the context of the proper loading and operation of conveyors. The aim of this study was to identify and understand the characteristic features of damage and their placement that may [...] Read more.
This article presents an analysis of the transverse profile of belt damage in the context of the proper loading and operation of conveyors. The aim of this study was to identify and understand the characteristic features of damage and their placement that may occur in conveyor belts during operation and indicate abnormalities in any of the components of the conveyor system, especially during loading at chutes. A total of seven different conveyors were examined, and the obtained results allowed for a thorough comparison and investigation of the distribution of belt damage on their cross-sectional profiles. This article discusses factors that may contribute to the occurrence of unevenly distributed belt damage. The conclusions from the conducted research can be of significant importance for conveyor owners and operators as they enable an effective assessment of the conveyor belt’s condition, the correctness of the conveyors, and the chutes’ designs as well as the implementation of necessary design changes, correct actions, and repairs. Through proper belt monitoring and maintenance, the risk of failure can be minimized, extending the belts’ lifespan and ensuring the efficiency of the transportation process. The article presents practical approaches to the analysis of the cross-sectional profile of damage, serving as a valuable source of information for individuals interested in optimizing the transportation process and maintaining efficient and safe conveyor operation. Full article
(This article belongs to the Special Issue Transfer Systems for Ores and Minerals)
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19 pages, 21619 KiB  
Article
Discrete Element Modelling of a Bulk Cohesive Material Discharging from a Conveyor Belt onto an Impact Plate
by Otto C. Scheffler and Corné J. Coetzee
Minerals 2023, 13(12), 1501; https://doi.org/10.3390/min13121501 - 29 Nov 2023
Cited by 1 | Viewed by 990
Abstract
The discrete element method (DEM) has become the numerical method of choice for analysing and predicting the behaviour of granular materials in bulk handling systems. Wet-and-sticky materials (WSM) are especially problematic, resulting in build-up and blockages. Furthermore, due to the large number of [...] Read more.
The discrete element method (DEM) has become the numerical method of choice for analysing and predicting the behaviour of granular materials in bulk handling systems. Wet-and-sticky materials (WSM) are especially problematic, resulting in build-up and blockages. Furthermore, due to the large number of particles in industrial-scale applications, it is essential to decrease the number of particles in the model by increasing their size (upscaling or coarse graining). In this study, the accuracy with which upscaled DEM particles can model the discharge of a cohesive material from a belt conveyor onto an inclined impact plate was investigated. Experimentally, three sand grades (particle size distributions, PSDs) were used, each in a dry (non-cohesive) state and with three levels of moisture-induced cohesion. The effects of the modelled PSDs on the material flow, build-up on the plate, the peak impact force and the residual weight were investigated. Although a linear cohesion contact model was mostly used, the results were also compared to that of the Johnson–Kendall–Roberts (JKR) and simplified JKR (SJKR) models. It was found that the general profile of the pile (build-up) could be accurately modelled, but using a more accurate (but still upscaled) PSD improved the results. The impact force and the residual weight on the plate could be accurately modelled (error <15%) if the particle size was not excessively scaled. The maximum acceptable scaling factor was found to be a geometric factor of the bulk measure of interest, and not a factor of the physical particle size. Furthermore, with an increase in cohesion, the bulk measures such as the thickness of the discharge stream and the height of the material build-up increased, which meant that the maximum acceptable scale factor also increased. The results are valuable for future accurate and efficient modelling of large industrial scale applications of WSMs. Full article
(This article belongs to the Special Issue Transfer Systems for Ores and Minerals)
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16 pages, 5230 KiB  
Article
The Use of DEM for Optimising an Industrial Vezin Sampler Operation
by Marcus Félix Magalhães, Ana Carolina Chieregati, Dusan Ilic, Isabella Targino Borges de Carvalho, Mariana Gazire Lemos, José Gregório da Mata Filho and Homero Delboni, Jr.
Minerals 2023, 13(11), 1460; https://doi.org/10.3390/min13111460 - 20 Nov 2023
Viewed by 937
Abstract
Rotary dividers, also known as “vezin samplers”, are widely used in the mining industry to obtain representative samples of particulate streams, and they are used as primary, secondary, or tertiary samplers. Based on Pierre Gy’s theory of sampling (TOS), the correct extraction of [...] Read more.
Rotary dividers, also known as “vezin samplers”, are widely used in the mining industry to obtain representative samples of particulate streams, and they are used as primary, secondary, or tertiary samplers. Based on Pierre Gy’s theory of sampling (TOS), the correct extraction of an increment when composing a sample must give all particles the same chance of being selected. Aiming to comply with the theory of sampling, sampler construction parameters must be considered to avoid increment delimitation and extraction errors (IDE and IEE). In this way, a detailed study of the ore physical properties is necessary before designing sampling systems, which are customised for each application and ore type. Based on ore characterisation studies and combined with Discrete Element Method (DEM) simulations, it is possible to evaluate samplers’ dimensions as proposed by the theory of sampling and determine the best design and operational parameters. The present study investigated and optimised the performance of a secondary vezin sampler installed in the feed sampling system of a gold plant in Brazil using DEM. Full article
(This article belongs to the Special Issue Transfer Systems for Ores and Minerals)
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