Characterisation of discharge and flow rate predictions for asymmetric wedge-shaped hoppers

It is important to understand the flow behaviour inside wedge-shaped hoppers and accurately predict the discharge rate for the processing and handling of granular materials, regardless of whether the wedge hopper is symmetric or asymmetric. In this paper, the discrete element method (DEM) was used to reveal the flow behaviour of pellet feed in an asymmetric wedge-shaped hopper from the discharge rate, flow pattern, velocity distribution, normal contact force between particles and free-fall arch. The results showed that, with the hopper angle decreasing, the area of the active region of the particles increased, the stagnation zone decreased, and the free-fall arch became unstable. When the unilateral hopper angle was less than 45°, the discharge rate of the wedge-shaped hopper increased, and the average discharge rate reached the maximum value of 1.070 kg s⁻¹ when the left and right hopper angles were equal to 15°. In addition, using the discharging mass proportion coefficient to represent the size of the region in which the unilateral hopper angle affected the flow of particles in the hopper, the hopper angle term in the Brown and Sellers model was corrected. The predictive errors of the corrected discharge rate model were less than 7.6% and 3.3% in the simulated and actual discharging tests respectively, which was better than that of the Brown and Sellers model. The results of the study could provide a theoretical basis for the intelligent upgrading of feed accurate handling equipment, and provide a reference basis for the design of asymmetric wedge-shaped hopper.