EDEM BulkSim 1.2 Addresses Engineering Challenges of Conveyor Transfer Equipment Design

Latest Release of EDEM BulkSim® Software Streamlines Engineering Workflow with Enhanced Visualization and Analysis Tools to Support Critical Design Decisions

DEM Solutions is pleased to announce the release of EDEM BulkSim 1.2, which includes the latest updates to EDEM BulkSim® software.

“Ensuring that equipment performance meets operational needs is essential as mine operators look to reduce operating costs, improve production capabilities and improve worker safety,” stated Dr. John Favier, CEO and Founder of DEM Solutions. “EDEM BulkSim provides designers of bulk materials handling equipment in mine and mineral processing operations with key design information to ensure that proposed designs meet performance requirements.”

EDEM BulkSim is high-performance bulk material flow simulation software for use by engineers designing bulk materials handling equipment in mine operations and minerals processing plant, such as conveyor transfer points, stockpile reclaimers, and material feed and discharge chutes in comminution circuits.

EDEM BulkSim simulation and analysis predicts bulk material flow and interaction with equipment components, enabling design engineers to identify and remedy potential problems in a design, such as material build-up and blockage, flow dispersion, spillage, size segregation, and excessive belt and chute wear — before commissioning.

Developed for use by design engineers, rather than DEM experts, EDEM BulkSim significantly enhances the productivity of bulk materials handling engineering teams, while reducing the risk of equipment underperformance and malfunction and increasing operational efficiencies for clients.

mass flow entering transfer point

mass flow discharge


A virtual “bulk sensor” measures the mass flow of bulk material entering
and exiting a transfer point. (material is colored by velocity)

Employing the most powerful DEM simulation technology on the market, EDEM BulkSim provides information on bulk material flow behavior critical to engineering of conveyor transfer equipment, such as flow alignment, dispersion and holdup, surface wear and delivery to receiving belts and comminution process equipment. This enables engineering design teams to virtually test the performance of prototypes designs under varying conditions and material characteristics, more quickly and easily than with traditional methods — enabling informed decisions during the design cycle and ensuring delivery of more reliable and better-performing equipment.


wear on deflector hood
Iron Ore transfer point showing wear


Examples of surface wear in transfer points predicted by EDEM BulkSim.
Red areas are those experiencing the highest wear due to impact
and/or abrasion by the bulk material. (Image on left courtesy of Benetech, Inc;
image on right courtesy of Calibre Global)

EDEM BulkSim does not require users to have knowledge of DEM, enabling enterprise-wide deployment by simplifying the process of setting up a DEM simulation, and allowing less experienced engineers to tackle more challenging design problems by reducing dependence on inadequate traditional design methods. The software gives users the ability to investigate the suitability of transfer point designs prior to fabrication and commissioning, enabling delivery of better performing equipment for ‘right first time’ installations.

Engineering teams with in-house DEM expertise can also make use of the EDEM Material Modeler add-on module which provides the tools needed to define all components of a Bulk Material Model.


Enhanced Visualization and Analysis Tools Support Critical Design Decisions

EDEM BulkSim 1.2 includes a number of enhancements to the analysis and visualization of bulk material flow and interaction with equipment. EDEM BulkSim Analyst makes use of virtual “bulk sensors” to implement several of the Analyst tools. These sensors can be set up as a single bin (calculation volume) or a grid of bins (“grid bins”). Bins provide a mechanism for users to place virtual sensors that monitor and extract data from a particular volume of the simulation domain.

The range of virtual bulk flow sensors, such as mass flow rate, velocity and size segregation has been expanded and further integrated with CAD design workflow, making it easier to interactively translate and rotate bulk analysis sensors.


velocity profile using grid bins

A series of flow sensors is used to measure the change in velocity
of a bulk material as it flows onto a receiving belt

mass distribution during belt loading

Graph shows the mass distribution of material across a receiving belt.
A symmetrical loading of material prevents conveyor damage
and damage to equipment downstream

The analysis of bulk flow behavior has also been enhanced with more bulk flow sensors and clipping planes, enabling visualization of internal flow behavior within cross-sections of the bulk material.

simulation image showing clipping plane in place
simulation image showing how clipping plane reveals internal flow behavior


Flow behavior of a bulk material inside the bulk or in regions
not visible in a physical system can be examined using clipping planes.

EDEM BulkSim Block and EDEM Material Modeler diagrams with lables

EDEM BulkSim software and the EDEM Material Modeler are available off-the-shelf,
or as part of the complete EDEM BulkSim Solution

DEM Solutions offers EDEM BulkSim software and the EDEM Material Modeler add-on separately, or as part of an integrated deployment solution. This provides a complete approach to simulation-based design of conveyor transfer points in Mining and Mineral Processing operations that includes material model calibration services, worldwide support for deployment, and training in simulation-based design of conveyor transfer equipment.

Visit the software pages for more information on the EDEM Software Platform. Visit our extensive video library, the EDEM Video Gallery, to view examples of conveyor transfer equipment simulated using EDEM BulkSim, bulk particle physics modeled using EDEM, and industrial applications of EDEM simulation.