Materials handling is one of the most asset- and energy-intensive segments in the mining space, which has led to companies turning their focus to the performance and reliability of bulk materials-handling and processing equipment, while adopting advanced technologies for equipment design, manufacturing processes and asset management to improve profitability.

“Owing to the tonnage of ore or coal involved, there are massive cost implications for mine site operations when equipment fails and there is unscheduled downtime. Conveyor transfer equipment is crucial to the transport and handling of thousands of tons an hour of mined materials, and the scale of operations means that equipment designs cannot be physically tested in advance of commissioning,” says software solutions provider Discrete Element Method (DEM) Solutions CEO Dr John Favier.

“Simulation of the flow of material through a transfer point enables engineers to virtually test and configure their designs to handle the range of anticipated operating conditions and substantially reduces the risk of malfunction during operation,” he notes.

Research firm Frost & Sullivan announced in April that DEM Solutions has been awarded the 2013 Global Entrepreneurial Company of the Year Award in the Engineering Simulation for Mining sector.

“At a time when simulation technologies were not well established in the mining industry, DEM Solutions introduced EDEM as a key engineering tool for production critical mining equipment,” the Frost & Sullivan announcement notes.

Based on Frost & Sullivan’s global best practices vision of the future of manufacturing and production (Visi-MAP 2.0) research findings, it has also named DEM Solutions as one of the top 50 game-changers in manufacturing hardware and software markets in 2013.

“This is a significant achievement for the company, recognising it as a software solutions game-changer that allows manufacturers to innovate, design and drive next-generation manufacturing best practices,” says Favier.
As part of this additional accolade, DEM Solutions is also featured in Frost & Sullivan’s upcoming thought leadership white paper, which profiles the top 50 game-changing winners and the findings of its Visi-MAP 2.0 research.

The Frost & Sullivan white paper was released in conjunction with the Manufacturing Leadership Summit that took place from May 14 to 15 in Palm Beach, Florida.
“The criteria used to benchmark DEM Solutions’ performance against key competitors comprised the degree of innovation demonstrated through products and technologies, leadership in customer value and the speed of response to market needs, as well as growth strategy and growth implementation,” explains Favier.

He notes that the company continues to grow by extending its global footprint through strategic partnerships with complementary software and computer hardware companies, and with engineering services companies with industry leading domain expertise.

“DEM Solutions also collaborates closely with academic researchers and a special focus on them brings significant innovation to the market,” Favier adds.

Frost & Sullivan concluded that DEM Solutions fills a gap in the mining industry with its EDEM BulkSim software solutions, which transform the design of bulk materials handling equipment, resulting in increased productivity and lower operating costs.

Working closely with leading engineering, procurement and construction management companies in the mining sector, DEM Solutions developed the EDEM BulkSim solution to provide an integrated package of software and services to deal with the bulk materials handling challenges of the global mining industry. The services include bulk materials model calibration that ensures simulation-based designs are grounded in physical tests. This new approach to deploying DEM software overcomes dependency on advanced software know-how and the risks associated with using uncalibrated models.

DEM Solutions partners with Bulk Materials Engineering Australia, which develops and provides bulk material flow testing services to the mining industry as well as engineering consulting services for the design of bulk materials handling equipment and dust mitigation technologies.

EDEM BulkSim software provides an unparalleled capability for transfer-point design engineers to virtually test and troubleshoot the performance of conveyor transfer equipment before it is commissioned.

“This capability not only reduces front-end design costs and shortens development time but it also results in better-performing and more reliable equipment, with less risk of unscheduled downtime,” Favier states.

It also allows mine operators to quantify the effect of changes in production capacity or orebody characteristics on the performance of and maintenance scheduling for transfer equipment, he explains.

Favier notes that these benefits are particularly important, as the mining industry increases its focus on optimising operational efficiencies to increase the production capabilities of existing mine operations, improving user safety and reducing environmental impact.

In addition to bulk materials handling, EDEM simulation is also being applied in the design of comminution equipment such as crushers and grinding mills in mineral processing operations.

“Experts from the mineral processing research community, in collaboration with mining companies and suppliers of comminution equipment, are applying EDEM software to generate new and valuable infor- mation for the design of comminution equipment.

Solutions combining EDEM simulation with complimentary numerical modelling and physical test methods are now able to predict the effects of ore characteristics, grinding mill geometry and dynamics, and wear of liners, on mill yield and power draw,” Favier states.

DEM Solutions partners with the Laboratório de Tecnologia Mineral, in Brazil, who are leaders in developing method- ologies for simulation of comminution equipment, and providers of material testing services for mineral comminution and engineering consulting services for the design of grinding mills, including ball, autogenous, semiautonegous and high pressure grinding roll mills.

Favier notes that the cyclical nature of the mining industry forces mine operators to respond quickly to ever-changing market conditions and opportunities. “In response to current market conditions, the mining industry is focused on improving the production capabilities of existing operations to meet market demand and increase margins.”

He adds that the mining industry has unique challenges in handling and processing its raw product at the scale that is now common in high-producing, high-output mines and is embracing the opportunity to deploy advanced simulation technology.

“EDEM simulation technology is used by mine operators, engi- neering companies and equip- ment suppliers throughout the production chain – from mine to mill to bulk terminal,” he says, adding that the information pro- vided is assisting the mining industry in realising the financial benefits of improved equipment performance and reduced pro- duction risks.