Rheological study of granular flows through a hopper: A comparative study

¹ R&D Tata Steel limited, Jamshedpur, Jharkhand, India
² Department of Chemical Engineering, Indian Institute of Technology Kanpur, Kanpur, Uttar Pradesh, India
³ Department of Chemical Engineering, Indian Institute of Technology Kanpur, Kanpur, Uttar Pradesh, India

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Published online: 1 December 2025

Abstract

The study of particle flow in bins and hoppers is critical for optimizing industrial processes parameters and system design. Discrete element method (DEM) simulations have been extensively used by researchers to study and understand particle flow behavior. In solids handling industries, non-spherical particles are ubiquitous, as spherical particles are rarely encountered in practical applications. However, spherical particles are often used in simulations due to their simplicity and ease of modeling. Accurately simulating non-spherical particles presents significant challenges, making it a focal point for advancing simulation techniques and improving industrial processes.

This study investigates hopper flow of non-spherical particles, specifically dumbbells is compared with that of spherical particles of equivalent diameter. We compare key flow properties such as velocity profile near the orifice, mass flow rate, and packing fraction. Our findings reveal distinct differences in flow behavior between dumbbell-shaped and spherical particles. These differences highlight the crucial role of particle shape in hopper flow dynamics. This research provides valuable insights for the design and optimization of hoppers and bins used to handle complex-shaped particles.