Weir(2)

Case Study

Weir Group + University of Strathclyde

Developing Capability in DEM Modelling for Vibrating Screens in Dry Conditions.

View from the top of a mine site at dusk

Weir Group

The Weir Group PLC is an engineering company headquartered in Glasgow over 150 years ago. We have evolved into a focused, high quality mining technology business, providing mission-critical solutions for smarter, more efficient, and
sustainable mining to a global customer base. Sustainable minerals extraction is a key sector in the drive to Net Zero as it provides a range base materials for technologies such as Li-Ion batteries and other energy storage systems. The Weir Group work in partnership to solve the toughest operating challenges safely, efficiently, and sustainably, helping to provide essential mineral resources, operating in over 70 countries, with circa 15,000 employees. It has been a global mining leader for over 60 years in specialist equipment targeting high wear mining applications from mill circuit, comminution, slurry transportation, mine dewatering and specialty pumps.

What was the need?

The Challenge

In the drive to Net Zero, mining technology will need to become more sustainable and efficient in order to meet increased demand for raw materials while also reducing emissions. These goals can only be met with new and innovative engineering designs. To support this level of rapid innovation, the design process must be supported by Digital Twins.

For vibrating screens, this takes the form of DEM, which can be used to iterate through design ideas and operating conditions in a way that is not feasible using current methods. However, before computational simulations can be used to influence design, the simulations must be validated so that there is confidence in the reliability of the results. Therefore it is necessary to develop a framework for the calibration and subsequent validation of DEM for vibrating screen modelling.

As part of the Digital Twin, live operational performance data is extremely valuable to customers and equipment suppliers alike. A reliable DEM model can in turn be used to validate the accuracy of machine learning equipment in achieving this goal.

What did we do?

The Solution

By developing a set of test scale experiments, this project created a method of experimentally validating a DEM model of a vibrating screen. Through this work, increased confidence can be gained in the reliability of the DEM simulation data.

With this increased confidence, outputs from the DEM model can be integrated into the current screen design cycle, rather than measurements taken from the field or historical assumptions. This will allow for more design iterations to be tested more time effectively than was possible previously, including more experimental and inventive design ideas that would not have been feasible if full prototyping was required. DEM can also allow the creation of designs better suited to specific operating conditions, rather than a one size fits all approach.

These improved designs, combined with the live screen performance data obtained from machine learning equipment, will lead to a decrease in energy usage and emissions, reduced wear and raw materials and less water wasted throughout the process. All of which will help drive towards the goal of sustainable mining and global Net Zero.

What changed?

The Impacts and Benefits

Impacts for the Company

By creating a capability in DEM modelling of vibrating screens, it allows Weir Group to implement smarter and more sustainable designs and processes, increasing their reputation and market share for separation products, as well as driving towards the company goal of Net Zero, sustainable mining.

With the development of a reliable validation process, it opens opportunities for further DEM orientated projects, which can help to establish the company at the forefront of innovation within the mining industry. The project also further strengthens the relationship with the University of Strathclyde, opening the door for future collaboration on projects in the mining and DEM space. The verification of machine learning equipment can also accelerate the transition to smart equipment and live performance monitoring, reducing energy consumption and emissions for Weir separation products.

Additionally, by applying various live performance monitoring equipment to Weir’s current testing equipment, the project helped to optimise both equipment and operations. These improvements can be carried forward into future projects to increase the reliability and value of in-house testing at Weir.

Overall, the project improved Weir’s design and testing processes, strengthened client relationships, and enhanced digital capabilities, positioning Weir as a leader in innovative screen design and validation.

Impacts for the Academic Team

The development of DEM capabilities for vibrating screens has had many positive impacts for the University of Strathclyde academic team. By validating the DEM models from the ground up it has built upon an existing knowledge base. This opens up the possibility for further projects that build upon the outcomes of this project, allowing the academic team to push the boundaries of innovation within the field.

This project has also increased the teams academic standing in the field as part of the cutting edge of research in the area, which will aid the acquisition of future funding for these exciting projects.

By working in partnership with the Weir Group, the KTP has further strengthened an established successful partnership, allowing the academic team to continue working with close ties to industry to carry out projects that produce the most valuable results for both academia and industry.

Overall, the project has lead to a deeper understanding of the field, exciting opportunities for future projects, and an increased reputation in both academic and industrial spaces.

Impacts for the KTP Associate

The project has offered the KTP Associate the opportunities to develop both professionally and personally at an accelerated rate over it’s course. The level of responsibility for managing many aspects of the project has provided valuable experience in delivering complex projects and balancing the needs of many stakeholders.

Due to the nature of the project, the project provided the opportunity to expand to a global network and to collaborate with groups internationally, which was insightful as well as challenging. The project also allowed the Associate to develop skills in complex computational simulation tools and applying problem solving techniques, helping the Associate become more effective at technical activities.

Additionally, through the development budget, the Associate was able to undertake specific courses to obtain career enhancing qualifications that benefit the project directly, and also courses outside the direct project scope to help build a wider skillset and explore different interests, all of which helps make the Associate a more effective professional in any career path that may follow the KTP project.

The People

Meet the Team

Jamie Roxburgh

KTP Associate

Professor David Nash

Knowledge Base Supervisor

Sofia Alves

Company Supervisor