Advances in granular flow modeling: GPU-based multi-sphere DEM approach and tumbling mill dynamics

Modeling irregular-shaped particulate flow systems poses challenges, especially in mineral processing where accurate representation of particle shape is crucial for capturing macroscopic behavior. The multi-sphere approach, employing DEM, addresses this by approximating particles as overlapping spheres within GPU computing. This study validates particle flow dynamics using literature-based data, showcasing the model’s fidelity and GPU advantages. However, calibration and shape approximation limitations require careful consideration. A quaternion-based orientation method enhances DEM and validates experimental data from packing, hoppers, and tumbling mills. Simulations reveal how particle shape influences granular dynamics, affecting lift-off tendencies, responses to lifter face angles, and power draw trends with mill speed changes. Cubical and spherical particles exhibit orderly packing behavior, contrasting with irregular shapes. This investigation underscores the significant role of particle shape in granular dynamics and its implications for industrial processes. [Display omitted] •GPU computing accelerates granular simulations, enhancing complexity.•Efficient GPU utilization with parallel processing, memory optimization, and adaptive granularity.•Quaternion-based orientation enhances DEM with robust rotational representations.•Particle shape influences tumbling mills’ lift-off, dynamics, and power draw.•Cubical & spherical particles exhibit orderly packing behavior over irregular shapes.