Design of Chutes & Hoppers
DEM, Wear Protection, Lining Solutions & Dust Control
Bulk materials handling systems such as chutes and hoppers are critical interfaces within mining, processing, and industrial plants. Poorly designed transfer points can lead to excessive wear, blockages, dust generation, structural damage, and unplanned downtime.
At Hamilton By Design, we deliver engineering-led chute and hopper design that integrates accurate site data, advanced modelling, DEM analysis, and compliance-driven detailing to improve reliability, safety, and asset life.
Engineering-Grade Understanding Starts With Accurate Geometry
Effective chute and hopper design begins with understanding the true as-built condition of the asset and its surrounding structure. We use
Engineering-grade 3D LiDAR scanning
https://www.hamiltonbydesign.com.au/3d-laser-scanning-mechanical-design-australia/
to capture high-accuracy geometry of existing transfer stations, bins, feeders, conveyors, and support steelwork. This ensures all downstream modelling and analysis reflects real site constraints, not assumptions.
Captured scan data is converted into engineering-ready 3D models, forming the foundation for DEM, wear analysis, and structural verification.
DEM-Informed Chute & Hopper Design
Discrete Element Modelling (DEM) is used to simulate bulk material flow behaviour through chutes and hoppers, allowing engineers to assess:
- Flow patterns and material trajectories
- Impact zones and wear hot-spots
- Velocity, segregation, and material buildup risks
- Choking, ratholing, or flooding potential
DEM outputs are used to inform geometry optimisation, liner placement, and dust-control strategies before physical modifications are made.
This approach significantly reduces trial-and-error, retrofit costs, and premature liner failure.
Wear Protection & Lining Solutions
Based on DEM results and operational requirements, we engineer wear-protection strategies that may include:
- Ceramic, rubber, or composite liners
- Replaceable impact and deflector plates
- Geometry changes to reduce direct impact energy
- Structural reinforcement where required
Wear designs are developed in accordance with AS 3774 – Loads on Bulk Solids Containers, ensuring bulk material loads are correctly understood and applied.
https://www.hamiltonbydesign.com.au/as-3774-loads-on-bulk-solids-containers/
Structural Verification & Support Steelwork
Chute and hopper modifications often introduce new load paths into supporting steelwork. We use finite element analysis (FEA) to verify:
- Chute bodies and liner attachment systems
- Support frames and head chute connections
- Load transfer into existing structures
Our FEA capabilities ensure wear solutions and DEM-driven geometry changes are structurally sound and compliant.
https://www.hamiltonbydesign.com.au/home/engineering-services/fea-capabilities/
Dust Control & Operational Improvements
Dust generation is often a symptom of poor flow control and excessive material velocity. By combining DEM analysis, geometry optimisation, and enclosure design, we support:
- Reduced free-fall distances
- Improved material stream control
- Integration of skirts, sealing, and enclosures
- Safer and cleaner operating environments
Designs consider access, inspection, and maintainability from the outset.
Digital Engineering & Fabrication-Ready Outputs
All chute and hopper designs are delivered as fabrication-ready engineering packages, developed using SolidWorks-based modelling and detailing.
https://www.hamiltonbydesign.com.au/home/engineering-services/solidworks/
Deliverables can include:
- 3D models and GA drawings
- Liner layouts and replacement strategies
- Structural drawings and connection details
- Integration with broader transfer station detailing workflows
https://www.hamiltonbydesign.com.au/detailing-transfer-stations-in-the-age-of-digital-engineering/
Mining & Heavy Industry Focus
Our chute and hopper engineering services are commonly applied across:
- Mining and mineral processing plants
- Coal handling and CHPP facilities
- Ports, ship loaders, and stockyard systems
- Industrial bulk materials operations
These services align closely with our broader mining engineering services in Australia.
https://www.hamiltonbydesign.com.au/home/engineering-services/mining-engineering-services-australia/
A Connected, Engineering-Led Approach
By combining:
- 3D LiDAR scanning
- DEM flow analysis
- Wear and liner engineering
- FEA structural verification
- Digital engineering and detailing
Hamilton By Design delivers chute and hopper solutions that are fit-for-purpose, compliant, and operationally robust — reducing risk before steel is cut or liners are installed.
Our clients:
Advanced Bulk Materials Handling Solutions
At Hamilton By Design, we specialize in delivering cutting-edge engineering solutions for bulk materials handling across industries such as mining, minerals processing, agriculture, and heavy industry. Our services are designed to optimize material flow, enhance equipment longevity, and ensure operational efficiency.
Our Expertise
- Advanced Chute and Hopper Design: Utilizing state-of-the-art CAD tools and Discrete Element Method (DEM) simulations, we design transfer chutes, diverter chutes, and trouser legs that ensure precise material flow and minimize wear.
- DEM Simulation and Flow Modeling: Our team employs DEM simulations to analyze particle behavior within chutes, allowing us to predict and mitigate issues such as blockages, spillage, and uneven wear.
- Wear Protection and Lining Solutions: We offer customized wear-resistant linings and impact protection systems to extend the lifespan of your equipment and reduce maintenance downtime.
- Dust and Spillage Control: Our designs incorporate features that minimize dust generation and material spillage, promoting a safer and cleaner work environment.
- Surge Control and Flow Regulation: We engineer systems that effectively manage surge loads and regulate mass flow rates, ensuring consistent and reliable material handling.
Why Choose Hamilton By Design?
- Tailored Solutions: We understand that each project has unique requirements. Our team works closely with clients to develop customized solutions that meet specific operational needs.
- Innovative Technology: By integrating advanced modeling techniques and simulation tools, we stay at the forefront of engineering innovation in bulk materials handling.
- Proven Track Record: Our portfolio includes successful projects across various industries, demonstrating our capability to deliver efficient and reliable handling systems.
- Commitment to Quality: We adhere to the highest standards of engineering excellence, ensuring that our designs not only meet but exceed industry expectations.
Let’s Collaborate
Whether you’re looking to design a new materials handling system or upgrade an existing one, Hamilton By Design is here to assist. Contact us today to discuss how we can contribute to the success of your project.