Simulation of Mechanical Fractionation of Chopped Whole-Plant Corn (WPC) Using Discrete Element Method (DEM)

Highlights Mechanical separation whole-plant corn (WPC) was simulated with DEM flexible fibers model. Mass percent WPC was sensitive to DEM particle shape distribution. DEM predicted mass fraction within 10% error compared with ASABE sieving test data. Abstract. Fractionating whole-plant corn (WPC) in a single-pass harvesting system requires studies on the WPC-to-equipment interaction for improved property control, as well as mechanical and air-driven separation processes compared to the traditional multi-pass grain and stover harvesting system. The discrete element method (DEM) technique has the potential to simulate WPC mechanical fractionation and support simulation-based design of WPC separation processes. In this study, methods to develop DEM particle models of WPC (kernel, cob, stalk, and husk) and their material properties for simulating mass fractionation using the ASABE standard mechanical shaker were proposed. Measurement was done on the axial dimensions (major, intermediate, and minor) and mass of each WPC type (mean sample size is 56), sampled from single-pass harvesting. Applying gaussian multivariate regression and bootstrapping re-sampling techniques, a DEM particle approximate to each WPC was developed. Sensitivity analysis of the DEM Young’s modulus, Poisson’s ratio, and interaction parameters of coefficient of restitution, coefficient of rolling friction, and coefficient of static friction on mass fraction was performed after 156 ASABE sieve-shaking DEM simulation runs, generated using Latin Hypercube Design (LHD) design of experiment (DOE) from 19 DEM material parameters. DEM simulation using Hertz-Mindlin with flexible bond contact laws and DOE optimized material properties successfully reproduced the mass fractions retained in ASABE sieves at 9.8% mean relative error and a coefficient of determination of R2 = 0.87. The DEM methodology developed for mechanical WPC mass fractionation could be deployed to perform virtual design of feedstock handling equipment and performance analysis of mechanical fraction systems. Keywords: Chopped whole-plant corn (WPC), Corn cob, Corn husk, Corn kernel, Corn stalk, Discrete element method (DEM), Flexible-bonded particle.