The Flow and Segregation of Cement Clinker Particles in A Mill Feeding Hopper: Experiment and FEM Modelling

This thesis investigates particle flow and segregation in mill-feeding hoppers through scaled model experiments and Finite Element Method (FEM) simulations. The experiments successfully validate the FEM simulations and directly demonstrate flow and segregation phenomena. The results vividly illustrate distinct zones of fine and coarse particles, corresponding to hopper flow patterns and influenced by material parameters and hopper geometries. Additionally, an optimized hopper design method using FEM is presented, effectively mitigating segregation issues in the mill feeding hopper. Furthermore, these simulation results have been integrated into the control system and optimization processes, leading to a 5% increase in production and a 10% reduction in energy consumption at the cement plant.