Optimal numerical design of bucket elevators using discontinuous deformation analysis

Abstract

Bucket elevators are efficient machines to transport granular materials in industrial and civil engineering applications. These materials are composed of hundreds, thousands or even more particles, the global behavior of which is defined by contact interactions. The first attempts to analyze the transportation of granular materials were treated by very simple continuum methods that do not take into account these interactions, producing simulations that do not fit the experimental results accurately. Given the internal discontinuity nature of granular media, it is reasonable to use numerical methods to model their behavior, such as discontinuous deformation analysis (DDA)-a member of the discrete element method family that started to be used in the 90s to analyze similar problems. The version of DDA used in the current work treats grains as rigid circular particles with friction, damping and eventually cohesion with the objective of simulating and analyzing in detail the discharge of granular materials with bucket elevators. A deterministic computer code has been implemented and validated against simplified analytical formulae and experimental results taken from the literature. This computer code is then used to obtain optimum two-dimensional bucket geometries under specific working conditions. The optimization aims to maximize transport distance and to minimize remaining material, taking into account bucket velocity and the properties of the grains. The resulting geometries are discussed and compared against standard designs.