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Application of the discrete element method - Part 4: Bucket elevators and

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Design and Engineering

Application of the
Discrete Element Method – Part 4:

Bucket Elevators
and Scraper
Conveyors
A. Katterfeld and T. Gröger, Germany
This paper, the fourth and last of a series on DEM application, describes how this
new technology can be used to optimise the design of bucket elevators and scraper
conveyors at a very early stage of the engineering process. The verification of DEM-
simulations by means of experiments shows, that even with current restrictions,
DEM-simulations can beconsidered a valuable design tool.

C
harging and discharging processes have an important in-
fluence on the function of certain conveyors for bulk solid
handling. Computer simulations based on the Discrete
Element Method (DEM) offer a new approach for a qualitative
analysis of these processes. Therefore, the fourth and last part
of the article series about the DEM application in materials han-
dling presents the results of the qualitative verification of the
discharge behaviour of bucket elevators and of the charge be-
haviour of scraper conveyors.
The DEM can be characterised as the ideal tool for the analysis
of the charge and discharge processes due to the direct consid-
eration of each discrete particle. During the simulation the
computer calculates for each particle alternately the forces act-
ing upon it and the resulting acceleration by the application of
Newton’s second law. By integration over a very small time step
the particle velocity and hence the new particle positions are
calculated. The basics of the DEM are described in more detail
in [1].

Due to the high computation effort idealisations of the simula-

1 Introduction
The DEM-simulation of the discharge behaviour of bucket ele-
vators and of the filling process of the scraper conveyors prom-
ises new possibilities to control the function of the conveyors
before they are built as well as new possibilities for the optimi-
sation of the bucket geometry which heavily influences the
conveyor efficiency.
tion model are necessary to minimize the calculation time. The
particle number and the process time influence the computa-
tion time significantly and therefore determine the degree of
idealization. Hence, the real particle size distribution can only
be applied very seldom in the simulation. Idealised simulation
models force the calibration of simulation parameters by shear
tests and angle of repose tests. More information to the cali-
bration process is given in [1].

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Design and Engineering

a) b) c)

Fig. 1: Determination of the pole height for the three basic discharge behaviours: a) gravitational discharge, b) mixed discharge,
c) centrifugal discharge [3]; where: g = acceleration of gravity, m = particle mass, v = particle speed, r = distance between particle
and centre, rT = pulley radius, ra = distance between outer edge of the bucket and pulley centre, ri = distance between inner edge of
the bucket and pulley centre

From the necessary idealising of the simulation model follows
the question if the simulation provides realistic results. There-
fore, it is the aim of several research projects of the Institute of
Logistics and Material Handling (ILM) of the University of
Magdeburg to qualitatively and quantitatively verify the simu-
lation results by comparing them with the results of experi-
mental tests. The qualitative verification of the bucket elevator
and scraper conveyor is done by the comparison of the mate-
rial flow in simulation and reality.
fine the discharge process. The bulk solid is thrown over the
outer edge of the bucket only.
According to P et al. [2] the so called pole height and the
F number can be used for the characterisation of the dis-
charge process. The calculation of the pole height for the three
basic types of discharge behaviour can be visualised by Fig. 1. The
F number is given by the following equation:
v 2
Fr2 = ____
rT · g (1)

2 Bucket Elevator Table 1 relates the types of discharge behaviour to the pole
height and the F number [2].
2.1 Introduction
With the calculation of the pole height respectively the Froude
According to P et al. [2] basically three different discharge number only the basic discharge behaviour can be determined.
behaviour can be characterised: A complete analysis of the discharge process and a detailed char-
acterisation of the bulk material flow in the discharge area of the
1. Gravitational discharge: bucket elevator are not possible. Therefore, conventional ana-
The discharge is mainly influenced by the gravity and occurs lytical methods can not answer the question if the bulk material
over the inner edge of the bucket. leaves the bucket elevator completely or falls down in the return
strand of the elevator. An incomplete discharge process would
2. Mixed discharge: reduce the conveyor efficiency considerably.
Gravitational and centrifugal forces influence the discharge
of the bulk solid. The particles leave the bucket over the in- 2.2 Test Rig and Simulation Model
ner and outer edge.
The bucket elevator test rig at the ILM (Fig. 2) allows the obser-
3. Centrifugal discharge: vation of the discharge behaviour via a high speed camera. All
The bucket speed is so high that the centrifugal forces de- three basic types of discharge behaviour can be realised by the

Table 1: Discharge behaviour with the related pole height and F number [2]

Discharge behaviour Pole height Froude number

r
Gravitational discharge hp > ra Fr2 < __
T
ra
rT
__
Mixed discharge ra ≥ hp ≥ ri ra ≤ Fr ≤ 1
2

Centrifugal discharge hp < ri Fr2 > 1

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Fig. 2: Bucket elevator test rig at the ILM
variation of the bucket speed. Thus, the experiments allow a de-
tailed view on the bucket discharge and give an excellent possi-
bility for the comparison with the DEM-simulation results.
The technical data of the bucket elevator test rig can be sum-
marised as follows:
- driving drum diameter: 400 mm
- driving drum width: 130 mm
- rotational speed: 24 - 191 rpm
Fig. 3 shows the design of the bucket 125 × 106 C, which was
used for all experimental tests.
Almost every bucket and elevator design can be considered in
the DEM-simulation by the import of 3D-CAD data. All real geo-
metrical and operational parameters except the bucket fasten-
ing (two screw heads inside the bucket) are considered in the
DEM-model for the verification of the experimental tests. The
bucket speed allows the definition of the discharge behaviour in
reality as well in the simulation.
In opposition to the DEM-simulation of other bulk material han-
dling equipment, such as screw conveyors [4] and transfer sta-
tions of belt conveyors [5] etc. the idealisation of the simulation
model for bucket elevators is easier due to the limited particle
amount in one bucket. For the simulation of the discharge proc-
ess the consideration of one filled bucket in the simulation mod-
el is sufficient. Depend on the discharge behaviour (gravitational
and mixed discharge) an empty forerunner bucket has to be con-
sidered in the simulation model.
Due to the limited particle number in the simulated bucket it
was possible to consider the real particle size distribution of the
experimentally used bulk material mixed plastic granulate. Thus,
12 500 particles with a uniformly distributed diameter of 2.8 mm
to 5 mm were considered in each simulation.
Unlike the particle size distribution the particle shape had to be
idealised. Spherical particles were used instead of the real cylin-
drically shaped particles. Due to the influence of the cylindrical
230 bulk solids handling · Vol. 27 · 2007 · No. 4
BSH4_08_1_Katterfeld-Part4.indd 230
Fig. 3: Geometry of the bucket 125 × 106 - C [3]
shape on certain bulk material properties the simulation param-
eters had to be calibrated. With the help of the calibration proc-
ess the idealised bulk material in the simulation shows the same
angle of repose and the same angle of internal friction as the real
bulk material.
2.3 Results
Fig. 4 shows the comparison of the simulation and the experi-
ments. A good correlation between the pictures can be found.
The basic characteristic of the discharge process can be clearly
observed in the experiment as well as in the simulation.
Gravitational discharge occurs with a low bucket speed. As it can
be seen in Fig. 4 the bulk material flows only over the inner edge
of the bucket. The particles hit and rebounce from the forerun-
ner bucket and fall into the exit via hitting the chute. Due to the
hit of the forerunner bucket, a high amount of particles falls also
into the return strand of the elevator. The particles in the simula-
tion start to discharge earlier in comparison to the reality. Hence,
the particles impact the chute more to the right.
In mixed discharge conditions the bulk material flows over both,
the inner and outer edge out of the bucket. The bulk material
forms a very characteristic shape during the discharge. The simi-
larity between simulation and reality can be clearly recognised.
The simulated point of impact of the particles is nearly identical
to the real point of impact. In the simulation the particle dis-
charge starts too early what can be clearly seen on the character-
istic particle tail on the top of the elevator. The reason for this
unrealistic behaviour is the higher filling level of the bucket in the
simulation.
Fig. 4:
Comparison of the discharge behaviour of a bucket elevator in
the DEM-simulation (≈12,500 particles) and experiment. The
DEM-simulations were run with one filled bucket. The shown
simulation pictures are collages out of several pictures
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Design and Engineering

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Fig. 5: Work principle of a scraper conveyor shown by example of a
portal scraper conveyor [8]
A high bucket speed causes centrifugal discharge where the par-
ticles flow only over the outer bucket edge. The simulated shape
of the bulk material during discharge is similar to the real shape.
Also the real and the simulated impact points are identical.
Despite the good correlation small difference can be found be-
tween the simulated and real discharge behaviour. These differ-
ences can be traced back to the too high bucket filling level of
the simulated bucket and to the idealisation of the simulation
model. Parameter studies show a high influence of the particle
stiffness on the whole discharge process.
2.4 Conclusion and Outlook
In summary the results of the verification could be called very
promising. A good correlation between simulation and experi-
ment was achieved. A similar precise and detailed prediction of
the particle flow during the discharge process can not be ob-
tained by analytical methods. The costs and the time effort for
undertaking the experiments were much higher in comparison
to the simulation. Therefore the DEM-simulation can be named
as very suitable and effective for the analysis of the discharge
process in bucket elevators.
Current research projects are focused on the bucket filling proc-
ess of chain elevators. Due to the application of a new DEM-soft-
ware not only the particles can be modelled as discrete elements
but also the buckets and chain links. Therefore it will be possible
232 bulk solids handling · Vol. 27 · 2007 · No. 4
BSH4_08_1_Katterfeld-Part4.indd 232
to analyse the dynamical behaviour of the buckets and the chain
during the filling process. The aim is the analysis of the dynamical
forces in the bucket fastening.
In future also the scoop process in the L-shaped base of bucket
elevators used for ship unloading will be simulated to optimise
the design and the operational parameters of these high-per-
formance conveyors.
3 Scraper Conveyors
3.1 Introduction
The reasons for the build of stockpiles in the field of bulk mate-
rial handling are manifold. The main function of a stockpile is the
creation of a buffer between the bulk material delivery and con-
sumption. Often different delivery and the consumption proc-
esses with continuous or discontinuous operation have to be
combined by the stockpile buffer. Indoor and outdoor stockpiles
are usually created by a stacker belt conveyor. The continuous
reclaiming of the bulk material is often realised by the use of a
scraper conveyor (Fig. 5) [7].
The transport process of a scraper conveyor combines the linear
movement of the buckets and the feed movement of the whole
conveyor (see Fig. 5) with the scrape off process, the bucket fill-
ing process, the acceleration and the discharge of the bulk mate-
rial. During the transport process, the bulk material is filled into
the buckets and is carried along the pile bank.
Due to the complex bulk solid motion, which is dependent on
the bucket design and on operational parameters, the determi-
nation of the average bucket filling level is not fully understood.
However, it is known that the filling level influences the efficiency
of a scraper strongly. Therefore the ILM undertook extensive ex-
perimental tests on a scraper conveyor test rig (Fig. 6) as well as
DEM-simulations utilising two different bucket designs.
The test rig and the experimental tests offered an excellent pos-
sibility for the qualitative verification of the DEM-simulation and
were performed in close cooperation with the Magdeburger
Förderanlagen und Baumaschinen GmbH (FAM).
3.2 Test Rig and Simulation Model
Due to the general difficulties of undertaking experimental tests
on conveyors during real operation conditions, a test
rig was build to allow an easy variation of the design
parameters at realistic operating conditions. The work
principle of the scraper conveyor was simplified by
two moving buckets and a bulk solid bed which could
be inclined.
The so called span geometry was defined by the prep-
aration and inclination of the bulk solid bed. The first
Fig. 6:
3D-CAD model of the scraper conveyor test rig; the close-
to-reality transport process can be observed using a 6 m
long bulk solids bed and two industrial sized buckets
22.06.2007 15:48:25
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Design and Engineering

of the two installed buckets prepares real scraping conditions for

the second bucket. Due to the bed length of 6 m it was possible
to use industrial sized buckets for the experiments.

In the first step the experimental tests were used for the qualita-
tive analysis of the influence of the bucket geometry on the
bucket filling level during the operation. For this the bulk solid
bed was built from Limestone.

Because of the large size of the test rig in comparison to the aver-
age particle diameter a reduced simulation model had to be
used. Therefore, only the particles in vicinity of scraper bucket
were considered. The bulk material under the span is modelled
as a particle grid with a thickness of one particle diameter. The
particles in the grid are fixed. The particle shape and the coeffi-
cient of friction form a realistic friction basis with a compara-
tively low amount of particles.

A further reduction of the particle number can be achieved by

continuously generating and deleting particles depend on their
position. A particle range with a specific span shape is generated
in front of the buckets after these have covered a certain dis-
tance. Particles behind the buckets are deleted at the same
time.
With the help of these idealisations a particle size distribution
closer to the real conditions could be considered in the simula-
tion model. Nevertheless only the coarse fraction (with diame-
ters ranging from 14 mm to 16 mm) of the limestone could be
simulated.
The calibration of the simulation parameters allowed real angle
of repose and angle of internal friction of the simulated bulk
solid. The simulation models considered two buckets with a usu-
al flat and a new round design.
3.3 Results
For an initial qualitative verification the observed material flow
in experiments and DEM simulations were compared, as is
shown in figures 10 and 11. The characteristic filling behaviour
can be observed on the second bucket for both experiment
and simulation.
Fig. 7: Qualitative verification of the DEM-simulation of the trans-
port process in a scraper conveyor with flat buckets
solid ends inside respectively with the front edge of the bucket.
Therefore the round bucket geometry shows many advantages
in comparison to the flat geometry.
3.4 Conclusion and Outlook
In summary a good qualitative correlation between simulation
and experiment was observed, although the DEM-simulation
model does not consider the bulk solids fine fraction, uses spher-
ical shaped particles which also have a lower stiffness than the
real bulk material. Since the DEM-simulation allows to vary near-
ly every geometrical and operational parameter it is a very suit-
able method to optimise the bucket design.
The promising results of the qualitative verification indicate also
good results for the ongoing quantitative verification of the mo-
tion resistances due the scraping and breaking of the bulk solid.
Fig. 8: Qualitative verification of the DEM-simulation of the trans-
port process in a scraper conveyor with round buckets

The comparison between experiment and simulation for both

bucket geometries shows the same qualitative behaviour of the
bulk solid in the bucket.

With a usual flat geometry (Fig. 7) the bucket is not filled com-
pletely. Also, a lower filling level can be observed in both simu-
lation and experiment in the right hand side of the second
bucket.

Although the bucket is not completely filled, the bulk solid be-
gins to flow around the right edge of the bucket. This behaviour
reduces the efficiency of the conveyor. Furthermore it can be
recognized that the bank of the bulk solid in the bucket ends far
outside of the bucket.

With the new developed round bucket geometry (Fig. 8) the

bulk solid fills a larger space in comparison to the usual flat buck-
et. Also, the bulk solid does not flow around the right edge, but
flows more likely over the top of the bucket. The bank of the bulk

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 Design and Engineering
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Therefore the simulation of the consolidated bulk solid proper-
ties is necessary. So far the bulk solid in the simulation was as-
sumed to be unconsolidated. Consolidated bulk solid can be
considered by the use of bonded particles which requires not
only the calibration of the simulated particle properties but also
the calibration of the bond properties.
Acknowledgements
The authors thank the German Ministry of Economics and Tech-
nology and the companies Aumund-Fördererbau GmbH & Co.
KG, Bühler AG, Emde Industrie-Technik GmbH, Magdeburger
Förderanlagen und Baumaschinen FAM GmbH, ITASCA Con-
sultants GmbH, Koch Transporttechnik GmbH, MAN Takraf
GmbH, PHOENIX Conveyor Belt Systems GmbH, RUD Gruppe,
RWE Power AG and ThyssenKrupp-Fördertechnik GmbH for the
given financial and technical support.
References
[1] G, T. and K, A.: Application of the Discrete
Element Method in Materials Handling - Part 1: Basics and
Calibration. bulk solids handling Vol. 27. (2007) No. 1, pp.
17-23.
About the Author
Dr. André Katterfeld
Dr. André Katterfeld currently works
as a Scientific Assistant and Project
Manager at the Institute for Conveying-
and Construction Machinery Technol-
ogy, Steel Construction and Logistics at the Otto-von-Guericke
University, Magdeburg, Germany. After receiving his Ph.D. with
his work on the Functional Analysis of Pipe Chain Conveyors
(Funtionsanalyse von Rohrkettenförderern), he took part in nu-
merous research projects about the application of computer
simulations on basis of the Discrete Element Method in the ar-
ea of bulk material conveying technology. Dr. Katterfeld is co-
founder of the CeParTec GmbH.
Contact:
Otto-von-Guericke Universität Magdeburg
Dr.-Ing. André Katterfeld
Institut für Logistik und
Materialflusstechnik
Universitätsplatz 2,
39106 Magdeburg, Germany
Tel.: ++49 (0) 391 67 12245
Fax: ++49 (0) 391 67 12518
E-Mail:
andre.katterfeld@mb.uni-magdeburg.de
234 bulk solids handling · Vol. 27 · 2007 · No. 4
BSH4_08_1_Katterfeld-Part4.indd 234
View publication stats
[2] P, G., K, H. and K, F.: Stetigförderer. 5. Aus-
gabe, Verlag Technik, Berlin 1988.
[3] H, T.: Einfluß des Entleerungsverhaltens auf Becher-
form und Becherteilung zur Erhöhung der Leistungsfähig-
keit von Becherförderern. Dissertation, Otto-von-Guer-
icke-Universität Magdeburg 1993.
[4] M, A., K, A. and G, T.: Application of
the Discrete Element Method in Materials Handling - Part
2: Screw and Shaftless Screw Conveyors. bulk solids han-
dling Vol. 27 (2007) No. 2, pp. 84-93.
[5] G, T. and K, A.: Application of the Discrete
Element Method in Materials Handling - Part 3: Transfer
Stations. bulk solids handling Vol. 27 (2007) No. 3, pp.
158-166.
[6] D, M.: Zum Schöpfverhalten von Becherförderern.
Dissertation, Otto-von-Guericke-Universität Magdeburg,
1993.
[7] S, A.: Untersuchungen des Grabwiderstandes an
Entspeicherungskratzern. Dissertation, Technische Uni-
versität Magdeburg 1977.
[8] Website of FAM (Magdeburger Förderanlagen und Bau-
maschinen GmbH): www.fam.de, Mai 2007. ■
About the Author
Dr. Torsten Gröger
Dr. Torsten Gröger studied Mechanical Engi-
neering at the Otto-von-Guericke University,
Magdeburg, Germany, and specialised in
continuous conveying of bulk materials un-
der guidance of Prof. Friedrich Krause. He received his Ph.D. with
his work on DEM simulations of vertical pipe conveying (Dis-
crtete-Elemente Simulationen zur senkrechten Schlauchgurt-
förderung). For one year, Dr. Gröger worked as a Post-Doc with
Prof. Jürgen Tomas (Institute for Mechanical Processing, Magde-
burg) and for three years with Prof. U. Tüzün (Institute for Chem-
ical and Process Engineering, University of Surrey, United King-
dom). During his work for Itasca Consultants GmbH he gained
imporant experience in the execution of industry projects on
basis of DEM simulations. Dr. Gröger is the Managing Director
and co-founder of CeParTec GmbH.
Contact:
CeParTec GmbH
Dr.-Ing. Torsten Gröger
Uhlandstrasse 4,
39108 Magdeburg, Germany
Tel.: ++49 (0) 2327 96 56 48
Fax: ++49 (0) 2327 96 56 49
E-Mail: groger@cepartec.de
22.06.2007 15:49:11