On accurate prediction of transfer chute wear using a digital wear sensor and discrete element modelling

Transfer chutes are critical material handling assets in mining operations. Monitoring and predicting the transfer chute liner wear are essential to ensure safety and efficiency of the mineral process circuit. This study aims to develop a digital wear sensor to monitor transfer chute liner wear and to predict its wear distribution by coupling to a numerical modelling framework. The digital sensor is designed to track, and report live point-wise thickness on a chute liner while in operation. An expanded wear prediction model was then developed by integrating wear sensor readings and wear intensity results obtained through numerical modelling. Discrete element modelling was performed to obtain the stress conditions as well as wear intensity distribution. Liner wear prediction results were subsequently compared with manual measurements after operating for 123 days. Results suggested that the expanded wear prediction showed good agreements with measured results in terms of the high wear zone as well as quantitative thickness loss. Outcome of this study can be utilised in mining industry for safer operation as well as automated plant monitoring.