Analysis and Optimization of Material Flow inside the System of Rotary Coolers and Intake Pipeline via Discrete Element Method Modelling

There is hardly any industry that does not use transport, storage, and processing of particulate solids in its production process. In the past, all device designs were based on empirical relationships or the designer’s experience. In the field of particulate solids, however, the discrete element method (DEM) has been increasingly used in recent years. This study shows how this simulation tool can be used in practice. More specifically, in dealing with operating problems with a rotary cooler which ensures the transport and cooling of the hot fly ash generated by combustion in fluidized bed boilers. For the given operating conditions, an analysis of the current cooling design was carried out, consisting of a non-standard intake pipeline, which divides and supplies the material to two rotary coolers. The study revealed shortcomings in both the pipeline design and the cooler design. The material was unevenly dispensed between the two coolers, which combined with the limited transport capacity of the coolers, led to overflowing and congestion of the whole system. Therefore, after visualization of the material flow and export of the necessary data using DEM design measures to mitigate these unwanted phenomena were carried out.