Numerical Simulation of Conveying Fine Powders in a Screw Conveyor Using the Discrete Element Method

Due to their high efficiency and spatial utilization, screw conveyors are widely used in pharmacy, agriculture, and industry. Recently, this has made it a popular research subject in the numerical modelling of the transport of bulk solids. Modelling of granular systems at the level of individual particles is mainly possible due to the use of discrete numerical methods. The most common is the use of the Discrete Element Method (DEM), which is still limited from the point of view of simulations on an industrial scale, as increasing the size of the system also increases the cost of simulation. Certain powders with low density, large angles of repose, poor fluidity, and bad flowability can accumulate during transportation, causing inaccurate and non-uniform movement. Additionally, the friction and impact between the particles can cause wear. To address these issues, the present study utilizes the discrete element method to simulate and analyse powder transportation in an inclined screw conveyor using the commercial software ANSYS-ROCKY. Numerous phenomena that arise while transporting and feeding small-sized or irregularly shaped particles, often present in industrial processes, remain insufficiently investigated. This paper aims to analyse the transportation process of adhesive powders in a screw conveyor, with a focus on evaluating the impact of different screw blade speeds on transport. Multiple simulations were conducted, along with the implementation of an additional wear model, to better understand the transport phenomena and wear. An example was used to demonstrate the impact of screw speed on the wear of the transporter due to the interaction between the material and the structure of the conveyor, power consumption, and performance.