Bridging Reality and Design: How 3D Scanning + 3D Modelling Supercharge Mining Process Plants

In mining and mineral processing environments, small mis-fits, outdated drawings, or inaccurate assumptions can translate into shutdowns, costly rework, or worse, safety incidents. For PMs, superintendents, engineering managers and plants operating under heavy uptime and safety constraints, combining 3D scanning and 3D modelling isn’t just “nice to have” — it’s becoming essential. At Hamilton By Design, we’ve leveraged this combination to deliver greater predictability, lower cost, and improved safety across multiple projects.

What are 3D Scanning and 3D Modelling?

3D Scanning (via LiDAR, laser, terrestrial/mobile scanners): captures the existing geometry of structures, equipment, piping, chutes, supports, tanks, etc., as a dense point cloud. Creates a digital “reality capture” of the plant in its current (often messy) state.
3D Modelling: turning that data (point clouds, mesh) into clean, usable engineering-geometry — CAD models, as-built / retrofit layouts, clash-detection, wear mapping, digital twins, etc.

The power comes when you integrate the two — when the reality captured in scan form feeds directly into your modelling/design workflows rather than being a separate survey activity that’s then “interpreted” or “assumed.”

Why Combine Scanning + Modelling? Key Benefits

Here are the main advantages you get when you deploy both in an integrated workflow:

Benefit	What it Means for PMs / Engineering / Plant Ops	Examples / Impacts
Accuracy & Reality Verification	Verify what’s actually in the plant vs what drawings say. Identify deformations, misalignments, wear, obstructions, or changes that weren’t captured in paper drawings.	Mill liner wear profiles; chute/hopper buildup; misaligned conveyors or supports discovered post-scan.
Reduced Risk, Safer Access	Scanning can be done with limited or no shutdown, and from safer vantage points. Less need for personnel to enter hazardous or confined spaces.	Scanning inside crushers, under conveyors, or at height without scaffolding.
Time & Cost Savings	Faster surveying; fewer repeat field trips; less rework; fewer surprises during shutdowns or retrofit work.	Scan once, model many; clashes found in model instead of in the field; pre-fabrication of replacement parts.
Better Shutdown / Retrofit Planning	Use accurate as-built models so new equipment fits, interferences are caught, installation time is optimized.	New pipelines routed without conflict; steelwork/supports prefabricated; shutdown windows shortened.
Maintenance & Asset Lifecycle Management	Scan history becomes a baseline for monitoring wear or deformation. Enables predictive maintenance rather than reactive.	Comparing scans over time to track wear; scheduling relining of chutes; monitoring structural integrity.
Improved Decision Making & Visualisation	Engineers, superintendents, planners can visualise the plant as it is — space constraints, access routes, clearances — before making decisions.	Clash-detection between new and existing frames; planning maintenance access; safety audits.
Digital Twin / Integration for Future-Ready Plant	Once you have accurate geometric models you can integrate with IoT, process data, simulation tools, condition monitoring etc.	Digital twins that simulate flow, energy use, wear; using scan data to feed CFD or FEA; feeding into operational dashboards.

Challenges & How to Overcome Them

Of course, there are pitfalls. Ensuring scanning + modelling delivers value requires attention to:

Planning the scanning campaign (scan positions, control points, resolution) to avoid shadow zones or missing data.
Choosing hardware and equipment that can operate under plant conditions (dust, vibration, temperature, restricted access).
Processing & registration of point clouds, managing the large data sets, and ensuring clean, usable models.
Ensuring modelling workflow aligns with engineering design tools (CAD systems, formats, tolerances) so that the scan data is usable without excessive cleanup.
Maintaining the model: when plant layouts or equipment change, keeping the scan or model up to date so your decisions are based on recent reality.

At Hamilton By Design we emphasise these aspects; our scan-to-CAD workflows are built to align with plant engineering needs, and we help clients plan and manage the full lifecycle.

Real World Applications in Mining & Process Plants

Here’s how combined scanning + modelling is applied (and what you might look for in your own facility):

Wear & Relining: scanning mill, crusher liners, chutes or hoppers to model wear profiles; predict failures; design replacement parts that fit exactly.
Retrofits & Expansions: mapping existing steel, pipe racks, conveyors, etc., creating accurate “as built” model, checking for clashes, optimizing layouts, prefabricating supports.
Stockpile / Volumetric Monitoring: using scans or LiDAR to measure stockpile volumes for planning and reporting; integrating with models to monitor material movement and flow.
Safety & Clearance Checking: verifying that walkways, egress paths, platforms have maintained their clearances; assess structural changes; check for deformation or damage.
Shutdown Planning: using accurate 3D models to plan the scope, access, scaffold/frame erection, pipe removal etc., so shutdown time is minimised.

Why Choose Hamilton By Design

To get full value from the scan + model combination, you need more than just “we’ll scan it” or “we’ll make a model” — you need a partner who understands both the field realities and the engineering rigour. Here’s where Hamilton By Design excels:

Strong engineering experience in mining & processing plant settings, so we know what level of detail, what tolerances, and what access constraints matter.
Proven tools & workflows: from LiDAR / laser scanner work that captures site conditions even under harsh conditions, to solid CAD modelling/reporting that aligns with your fabrication/installation requirements.
Scan-to-CAD workflows: not just raw point clouds, but models that feed directly into design, maintenance, procurement and operations.
Focus on accuracy, safety, and reduced downtime: ensuring that field work, design, installation etc., are as efficient and risk-averse as possible.
Use of modern digital techniques (digital twins, clash detection etc.) so that data isn’t just stored, but actively used to drive improvements.

Practical Steps to Get Started / Best Practice Tips

If you’re managing a plant or engineering project, here are some steps to adopt scanning + modelling optimally:

Define Clear Objectives: What do you want from this scan + model? Wear profiles, retrofit, layout changes, safety audit etc.
Survey Planning: Decide scan positions, control points, resolution (density) based on the objectives and site constraints. Consider access, safety, shutdown windows.
Use Appropriate Hardware: Choose scanners suited to environment (dust, heat), also ensure regulatory and IP protection etc.
Data Processing & Modelling Tools: Have the capacity/software to register, clean, mesh or extract CAD geometry.
Integrate into Existing Engineering Processes: Ensure the outputs are compatible with your CAD standards, procurement, installation etc.
Iterate & Maintain: Frequent scans over time to track changes; update models when plant changes; feed maintenance, design and operations with new data.

Conclusion

In mining process plants, time, safety, and certainty matter. By combining 3D scanning with sound 3D modelling you don’t just get a snapshot of your plant — you gain a powerful toolset to reduce downtime, avoid rework, improve safety, and enhance decision-making.

If you’re responsible for uptime, capital works, maintenance or process improvements, this integration can reshape how you plan, maintain, and operate. At Hamilton By Design, we’re helping clients in Australia harness this power — turning reality into design confidence, and giving stakeholders peace of mind that the layout, equipment, and safety are aligned not to yesterday’s drawings but to today’s reality.

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10 October 202514 January 2026

Engineering Confidence: Using FEA to Validate Real-World Designs

Mechanical engineering has always been a balance between creativity and certainty.
Every bracket, frame, chute, or structural support we design must perform under real loads, temperatures, and conditions — often in environments where failure simply isn’t an option.

That’s where Finite Element Analysis (FEA) earns its place as one of the most powerful tools in modern design. It allows engineers to move from assumption to verification — transforming the way we predict, test, and optimise mechanical systems.

What Is FEA — and Why It Matters

FEA divides complex geometry into a network of small, interconnected elements.
By solving the physical equations that govern stress, strain, and displacement across those elements, engineers can predict how a structure behaves under load, vibration, or temperature.

Instead of relying solely on hand calculations or over-built safety factors, FEA provides quantitative insight into performance — letting us see where structures flex, where stress concentrates, and how design choices affect real-world outcomes.

In mechanical engineering, that means fewer prototypes, lower material costs, and far greater design confidence.

1. Static Analysis — The Foundation of Structural Validation

Static linear analysis is the foundation of most FEA work.
It evaluates how a structure responds to steady, time-independent loads such as gravity, pressure, or fixed equipment weight.

Through static analysis, engineers can:

Visualise stress and displacement distribution across a part or assembly.
Evaluate safety factors under different loading conditions.
Check stiffness and material utilisation before fabrication.
Identify weak points or stress concentrations early in design.

This baseline validation is the difference between a design that “should” work and one that will.

2. Assembly-Level Simulation — Seeing the Whole System

Few machines fail because a single part breaks.
Most failures happen when components interact under load — bolts shear, brackets twist, or welds experience unplanned tension.

FEA allows engineers to simulate entire assemblies, including:

Contact between parts (bonded, sliding, or frictional).
Realistic boundary conditions such as bearings, springs, or pinned joints.
The influence of welds, fasteners, or gaskets on overall performance.

This system-level view helps mechanical engineers design not only for strength, but also for compatibility and reliability across the full structure.

3. Mesh Control — Accuracy Where It Counts

A simulation is only as good as its mesh.
By controlling element size and density, engineers can capture critical detail in stress-sensitive regions like fillets, bolt holes, and weld toes.

Modern FEA tools use adaptive meshing — refining the model automatically in areas of high stress until the solution converges.
That means precise, efficient results without excessive computation time.

4. Thermal-Structural Interaction — When Heat Becomes a Load

Many mechanical systems face thermal as well as mechanical challenges.
Whether it’s ducting in a process plant or hoppers near heat sources, temperature gradients can cause expansion, distortion, or thermal stress.

FEA allows engineers to:

Model steady-state or transient heat transfer through solids.
Apply convection, radiation, or temperature boundary conditions.
Combine thermal and structural analyses to study thermal expansion and thermal fatigue.

Understanding how heat and load combine helps ensure equipment remains stable, safe, and accurate throughout its lifecycle.

5. Modal and Buckling Analysis — Designing Against Instability

Some risks are invisible until they’re simulated.
Vibration and buckling are two of the most overlooked — yet most common — causes of structural failure.

Modal Analysis

Determines a structure’s natural frequencies and mode shapes, helping designers avoid resonance with operating machinery, fans, or conveyors.

Buckling Analysis

Predicts the critical load at which slender members or thin-walled panels lose stability — allowing engineers to reinforce and optimise designs early.

By identifying these limits before fabrication, engineers can prevent problems that are expensive and dangerous to discover on site.

Design Optimisation — Smarter, Lighter, Stronger

Good design is rarely about adding material; it’s about using it wisely.
FEA supports parametric and goal-based optimisation, enabling engineers to vary geometry, thickness, or material and automatically test multiple configurations.

You can set objectives such as:

Minimising weight while maintaining strength.
Reducing deflection under fixed loads.
Optimising gusset or flange size for stiffness.

This process of “digital lightweighting” drives better performance and cost efficiency — especially valuable in industries where both material and downtime are expensive.

7. Communication and Confidence

FEA isn’t only a calculation tool — it’s a communication tool.
Colour-coded plots, animations, and automated reports make it easier to explain complex mechanical behaviour to project managers, clients, or certifying bodies.

Clear visuals turn stress distributions and displacement fields into a shared language — helping stakeholders understand why certain design choices are made.

Real-World Applications Across Mechanical Engineering

Application	Type of Analysis	Key Benefit
Chutes & Hoppers	Static + Buckling	Confirm wall thickness and frame design for structural load and vibration
Conveyor Frames	Modal + Static	Avoid resonance and ensure adequate stiffness
Pressure Equipment	Thermal + Static	Evaluate thermal stress and hoop stress under load
Machine Brackets	Static + Optimisation	Reduce weight while maintaining rigidity
Platforms & Guarding	Buckling	Validate stability under safety loading
Welded Frames & Supports	Static	Check deformation, stress, and weld performance

These examples show how FEA becomes an everyday design partner — embedded in the workflow of mechanical engineers across manufacturing, resources, and infrastructure.

The Engineer’s Advantage: Data Over Assumption

In traditional design, engineers often relied on prototypes and conservative safety factors.
Today, simulation delivers the same assurance — without the waste.

By applying FEA early in the design cycle, mechanical engineers can:

Predict failure modes before they occur.
Shorten development time.
Reduce material usage.
Justify design decisions with quantitative proof.

FEA enables engineers to focus less on guesswork and more on innovation — designing structures that are both efficient and dependable.

Engineering Integrity in Practice

At Hamilton By Design, we integrate FEA into every stage of mechanical design and development.
It’s how we ensure that every frame, chute, and mechanical system we deliver performs as intended — safely, efficiently, and reliably.

We use FEA not just to find the limits of materials, but to push the boundaries of design quality — delivering engineering solutions that last in the toughest industrial environments.

Design backed by data isn’t a slogan — it’s how we engineer confidence.

Building a Culture of Verified Design

When FEA becomes part of everyday engineering culture, it changes how teams think.
Designers begin to see structures not just as drawings, but as living systems under real forces.

That shift builds trust — between engineer and client, between concept and reality.
It’s what defines the future of mechanical design: informed, optimised, and proven before the first bolt is tightened.

3 October 202514 January 2026

Coal Chute Design

Coal handling and processing facility with multiple conveyors, stockpiles of coal, and stacking-reclaiming machinery operating under a blue sky

A Systems Engineering Approach for Reliable Coal Handling

In coal mining operations, transfer chutes play a deceptively small role with disproportionately large impacts. They sit quietly between conveyors, crushers, and stockpiles, directing tonnes of coal every hour. Yet when a chute is poorly designed or not maintained, the whole coal handling system suffers: blockages stop production, dust creates safety and environmental hazards, and worn liners demand costly maintenance shutdowns.

At Hamilton by Design, we believe coal chute design should be treated not as a piece of steelwork, but as a systems engineering challenge. By applying systems thinking, we connect stakeholder requirements, material behaviour, environmental factors, and lifecycle performance into a holistic design approach that delivers long-term value for mining operations in the Hunter Valley and beyond.

Coal Chutes in the Mining Value Chain

Coal chutes form the links in a chain of bulk material handling equipment:

ROM bins and crushers feed coal into the system.
Conveyors carry coal across site, often over long distances.
Transfer chutes guide coal between conveyors or onto stockpiles.
Load-out stations deliver coal to trains or ports for export.

Although they are small compared to conveyors or crushers, coal chutes are often where problems first appear. A well-designed chute keeps coal flowing consistently; a poorly designed one causes buildup, spillage, dust emissions, and accelerated wear. That’s why leading operators now see chute design as a critical system integration problem rather than just a fabrication task.

Flow diagram of a coal chute system showing upstream and downstream conveyors, the transfer chute, stakeholder interactions, and main issues such as blockages, dust, wear, maintenance safety, and cost versus performance

Systems Engineering in Coal Chute Design

Systems engineering is the discipline of managing complexity in engineering projects. It recognises that every component is part of a bigger system, with interdependencies and trade-offs. Applying this mindset to coal chute design ensures that each chute is considered not in isolation, but as part of the broader coal handling plant.

1. Requirements Analysis

The first step is gathering and analysing stakeholder and system requirements:

Throughput capacity: e.g. handling 4,000 tonnes per hour of coal.
Material properties: coal size distribution, moisture content, abrasiveness, stickiness.
Safety requirements: compliance with AS/NZS 4024 conveyor safety standards, confined space entry protocols, guarding, and interlocks.
Environmental compliance: dust, noise, and spillage limits.
Maintenance objectives: target liner life (e.g. 6 months), maximum downtime per liner change (e.g. 30 minutes with two workers).

A structured requirements phase reduces the risk of costly redesign later in the project.

2. System Design and Integration

Once requirements are defined, the design process considers how the chute integrates into the coal handling system:

Flow optimisation using DEM: Discrete Element Modelling allows engineers to simulate coal particle behaviour, test different geometries, and reduce blockages before steel is ever cut.
Dust control strategies: designing chutes with enclosures, sprays, and extraction ports to minimise airborne dust.
Wear management: predicting wear zones, selecting suitable liner materials (ceramic, Bisplate, rubber composites), and ensuring easy access for replacement.
Structural and safety design: ensuring the chute can withstand dynamic loads, vibration, and impact, while providing safe access platforms and guarding.
Interfaces with conveyors and crushers: alignment, skirt seals, trip circuits, and integration with PLC/SCADA control systems.

By treating the chute as a subsystem with multiple interfaces, designers avoid the “bolt-on” mentality that often leads to operational headaches.

3. Verification and Validation

The systems engineering V-model reminds us that every requirement must be verified and validated:

Component verification: weld inspections, liner hardness testing, nozzle spray checks.
Subsystem verification: chute section fit-up, guard gap measurements, coating checks.
Integration testing: conveyor-chute alignment, PLC spray interlocks, trip circuits.
System validation: commissioning with live coal flow, dust monitoring against limits, maintainability time trials for liner change.

By linking requirements directly to tests in a traceability matrix, operators can be confident that the chute is not only built to spec, but proven in operation.

Lifecycle Engineering: Beyond Installation

Good chute design doesn’t stop at commissioning. A lifecycle engineering mindset ensures the chute continues to deliver performance over years of operation.

Maintainability: modular liners, captive fasteners, hinged access doors, and clear procedures reduce downtime and improve worker safety.
Reliability: DEM-informed designs and wear-resistant materials reduce the frequency of blockages and rebuilds.
Sustainability: dust suppression and enclosure strategies reduce environmental impact and support community and regulatory compliance.
Continuous improvement: feedback loops from operators and maintenance teams feed into the next design iteration, closing the systems engineering cycle.

A Rich Picture of Coal Chute Complexity

Visualising the coal chute system as a rich picture reveals its complexity:

Operators monitoring flow from control rooms.
Maintenance crews working in confined spaces, replacing liners.
Design engineers using DEM simulations to model coal flow.
Fabricators welding heavy plate sections on site.
Environmental officers measuring dust levels near transfer points.
Regulators and community monitoring compliance.

This web of relationships shows why coal chute design benefits from systems thinking. No single stakeholder sees the whole picture—but systems engineering does.

Benefits of a Systems Engineering Approach

When coal chute design is guided by systems engineering principles, operators gain:

Higher reliability: smoother coal flow with fewer blockages.
Lower maintenance costs: liners that last longer and can be swapped quickly.
Improved compliance: dust, spillage, and safety issues designed out, not patched later.
Lifecycle value: less unplanned downtime and a lower total cost of ownership.

In short, systems engineering transforms coal chutes from weak links into strong connectors in the mining value chain.

Case Study: Hunter Valley Context

In the Hunter Valley, coal mines have long struggled with transfer chute problems. Companies like T.W. Woods, Chute Technology, HIC Services, and TUNRA Bulk Solids have all demonstrated the value of combining local fabrication expertise with advanced design tools. Hamilton by Design builds on this ecosystem by applying structured systems engineering methods, ensuring each chute project balances performance, safety, cost, and sustainability.

Conclusion

Coal chute design might seem like a small detail, but in mining, details matter. When transfer chutes fail, production stops. By applying systems engineering principles—from requirements analysis and DEM modelling to verification, lifecycle planning, and continuous improvement—we can design coal chutes that are reliable, maintainable, and compliant.

At Hamilton by Design, we believe in tackling these challenges with a systems mindset, delivering solutions that stand up to the realities of coal mining.

Are you struggling with coal chute blockages, dust, or costly downtime in your coal handling system?

Contact Hamilton by Design today and discover how our systems engineering expertise in coal chute design can optimise your mining operations for performance, safety, and sustainability.

Mechanical Engineering | Structural Engineering

Mechanical Drafting | Structural Drafting

3D CAD Modelling | 3D Scanning

Chute Design

SolidWorks Contractors in Australia

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24 September 202515 January 2026

The Future of Smelting & Steelmaking:

Trends Shaping a Greener, Smarter Industry

Steel has been the backbone of industrial progress for over 150 years. It is the invisible framework behind our skyscrapers, bridges, transport systems, and modern cities. But the industry that gave us the Industrial Revolution is now facing one of the greatest transitions in its history. The combined pressures of climate change, regulatory scrutiny, fluctuating energy costs, and global trade realignments are forcing steelmakers to rethink how steel is made, used, and traded.

Recent news reports show a fascinating picture: a sector in the middle of transformation, experimenting with new technologies like hydrogen-based direct reduction, while still relying on traditional blast furnace smelting to meet soaring demand. In this article, we explore the future direction of the smelting and steelmaking industry, what challenges lie ahead, and where the biggest opportunities are likely to emerge.

The Push for Green Steel

Hydrogen & Direct Reduced Iron (DRI): A Pathway to Decarbonization

Hydrogen-based steel production remains the single most promising pathway for deep decarbonization in the steel sector. Instead of using metallurgical coal and coke to chemically reduce iron ore, hydrogen can be used to produce direct reduced iron (DRI) that can then be melted in an electric arc furnace (EAF). This dramatically cuts CO₂ emissions, especially if the hydrogen is produced using renewable energy.

Projects like Salzgitter’s Salcos program in Germany are leading the way. Salzgitter has been developing one of the most ambitious hydrogen-based steel transformation roadmaps in Europe, gradually phasing in hydrogen reduction units and retiring carbon-intensive blast furnaces. Similarly, Australia’s NeoSmelt initiative, backed by Rio Tinto and ARENA, is exploring a combination of DRI and electric smelting furnaces to create a pathway that works for Australian ore quality and energy markets.

But this transition is anything but smooth. Salzgitter has recently delayed later stages of its program, citing economic and regulatory headwinds, such as the high cost of hydrogen, uncertain carbon pricing, and the slow rollout of renewable energy infrastructure. This highlights a hard truth: the green transition will not be instant or cheap. The next decade will likely be defined by pilot projects, incremental scale-ups, and careful balancing between economic viability and climate commitments.

The Coal Paradox

Even as green steel makes headlines, metallurgical coal is seeing a surprising resurgence. Demand for coal-based blast furnace production remains robust, especially in China and India, where domestic infrastructure spending continues to grow. In fact, recent research from the Global Energy Monitor shows that coal-based capacity is still expanding, even as global climate targets call for steep reductions in emissions.

This paradox points to the transitional nature of the current era. For the foreseeable future, the world will be living in a dual-track steel economy: one track relying on traditional blast furnaces and coke ovens to meet near-term demand, and another experimenting with hydrogen, electric smelting, and alternative reduction technologies.

For businesses, this means they cannot simply abandon existing capacity overnight. Instead, expect to see retrofit investments to improve the efficiency of blast furnaces, capture more waste heat, and install carbon capture and storage (CCS) where feasible. This “cleaner coal” approach will act as a bridge until low-carbon technologies can compete at scale on cost and availability.

Regional Shifts & Strategic Investments

Australia’s Green Steel Ambitions

Australia is emerging as a key player in the global conversation on sustainable steelmaking. The country has vast high-grade iron ore resources, growing renewable energy capacity, and a strategic interest in maintaining domestic steelmaking capability.

BlueScope’s $1.15B blast furnace reline at Port Kembla is one of the largest industrial projects in the nation’s history, designed to keep steel production secure for another 20 years. This investment shows that Australia is taking a pragmatic approach — continuing to support blast furnace technology while planning for a green future.
The NeoSmelt project, which just secured nearly $20M in government funding, is a potential game-changer. It will explore how to combine renewable-powered hydrogen and electric furnaces to make a commercial-scale green steel process that works with Australian ore.
The potential takeover of Whyalla Steelworks by a consortium led by BlueScope could turn the plant into a testbed for low-emissions ironmaking, providing a national blueprint for decarbonizing heavy industry.

Global Trade & Policy Realignment

Meanwhile, trade policy is also shaping the future. The EU and U.S. have resumed talks to revisit steel and aluminium tariffs, with a focus on creating carbon-based trade measures. If implemented, this could reward producers who adopt low-carbon technologies while penalizing those that rely on high-emission processes. For global producers, this will accelerate investment in low-emissions capacity to stay competitive in export markets.

Innovation Beyond Furnaces

The transformation of steelmaking is not just about switching fuels — it’s about reimagining the entire production system.

Modular, low-emission smelting plants like those being developed in Western Australia by Metal Logic allow companies to build capacity closer to demand centers, reduce transport emissions, and scale production up or down as needed.
Digital twins and AI-driven process control are making smelting more efficient. By modeling every step of the steelmaking process, producers can optimize energy use, reduce material losses, and increase yield — all of which improve profitability and lower emissions simultaneously.
Circular economy practices, such as increased use of scrap steel in EAFs, are becoming a central strategy. Recycling steel uses a fraction of the energy required to make virgin steel and fits neatly into the industry’s sustainability narrative.

This convergence of physical and digital innovation will likely create a new generation of steel plants that are smaller, smarter, and cleaner than their 20th-century predecessors.

Where the Industry is Headed

Looking ahead, the future of smelting and steelmaking will be defined by hybridization, regulation, and resilience:

Hybrid production systems will dominate for at least the next decade. Expect blast furnaces to operate alongside hydrogen-based DRI units and electric smelters as companies transition gradually.
Stricter carbon regulations will push companies to adopt low-carbon pathways faster than market forces alone would dictate. Carbon border adjustment mechanisms (CBAMs) will effectively tax “dirty steel” in major economies, making investment in green capacity a competitive necessity.
Domestic capability building will remain critical. The COVID-era supply chain crises reminded governments why domestic production matters. Expect to see policies that support keeping steelmaking onshore, even if that requires subsidies or preferential procurement.
Collaborative innovation will become the norm. Mining giants, energy producers, and technology firms are already forming alliances to solve the “green steel puzzle.” This cross-industry collaboration will unlock new efficiencies and accelerate commercialization.

Final Thoughts

The smelting and steelmaking industry is standing at the crossroads of history. The coming years will test its ability to balance sustainability with profitability, scale with flexibility, and tradition with innovation.

Companies that embrace this challenge — investing in low-carbon technology, digital transformation, and strategic partnerships — will not just survive the coming disruption but thrive as leaders in a new, greener industrial age. Steel may be one of the oldest materials in human civilization, but its future is being forged right now, and it has never been more exciting.

References

Salzgitter Salcos Project

Global Energy Monitor – Steel Sector Reports

ARENA NeoSmelt Funding Announcement

Challenges in the Australian Smelting Industry

24 September 202528 January 2026

Unlocking the Future of Design

Illustration of an engineering workspace where a tripod-mounted 3D LiDAR scanner captures a green point-cloud of an industrial pump assembly. Two engineers review scan data on a tablet beside technical drawings, while two others model components on computer workstations. A digital map of Australia is displayed in the background, highlighting Hamilton By Design’s service locations including Perth, Brisbane, Sydney, and Melbourne. The scene emphasises advanced 3D scanning, digital engineering, and nationwide support.

3D Laser Scanning & Mechanical Engineering Solutions

In today’s fast-paced engineering and construction industries, precision and efficiency are everything. Whether you’re managing a large-scale infrastructure project in Brisbane, creating a mechanical prototype in Perth, or needing accurate as-built data for a site in the Hunter Valley, 3D laser scanning and expert mechanical design services are game changers.

At Hamilton By Design, we specialise in connecting cutting-edge scanning technology with skilled mechanical designers and structural drafting services to deliver seamless, accurate solutions for every stage of your project.

The Power of 3D Laser Scanning

3D laser scanning is transforming the way engineers, architects, and manufacturers work. By capturing millions of data points with millimetre accuracy, laser scanning creates a highly detailed 3D representation of your asset, site, or structure.

Our team provides 3D laser scanning services in Perth, Brisbane, and Melbourne, as well as laser scanning in the Hunter Valley, helping clients save time and avoid costly rework. This technology is ideal for:

Capturing as-built conditions before design or construction.
Supporting plant upgrades and facility expansions.
Documenting heritage structures and complex geometries.
Reducing site visits with accurate digital models.

Reverse Engineering & Mechanical Design

In addition to scanning, we offer reverse engineering services in Perth and beyond. By combining point cloud data with CAD modelling, we can recreate components, optimise designs, and prepare manufacturing-ready files.

Our mechanical engineers and mechanical designers bring years of experience in 3D mechanical engineering, design and manufacturing mechanical engineering, and problem-solving for a wide range of industries. From bespoke machinery to process equipment, we deliver solutions that work.

Structural Drafting & Project Support

No project is complete without clear, accurate documentation. Our skilled drafters at Hamilton By Design provide high-quality structural drafting services that integrate seamlessly with your workflows.

Whether you need shop drawings, fabrication details, or BIM-ready models, our team ensures every line and dimension is correct — saving you time and cost on-site.

Why Choose Hamilton By Design?

Nationwide Reach: Serving clients with 3D scanning services in Perth, Brisbane, and Melbourne, and supporting projects in the Hunter Valley.
Complete Solutions: From scanning to modelling to mechanical engineering design.
Accuracy & Efficiency: Reduce project risk and improve decision-making with reliable data.
Experienced Team: Skilled mechanical engineers and drafters who understand your industry.

Ready to Get Started?

If you’re looking for mechanical engineering companies that deliver precision, innovation, and reliability, Hamilton By Design is ready to help. Whether you need laser scanning in Perth or Brisbane, structural drafting, or full mechanical design services, our team can support your next project from concept to completion.

Contact us today to discuss your project requirements and find out how our 3D laser scanning and mechanical engineering design solutions can save you time and money.

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20 September 202514 January 2026

Chute Design in the Mining Industry

Infographic showing Hamilton By Design’s engineering workflow, including millimetre-accurate LiDAR reality capture, material-flow simulation, optimised chute designs, and safer, more efficient production outcomes. Two workers in PPE highlight reliable design and longer liner life, with icons representing time, cost and quality benefits.

Getting Coal, Hard Rock, and ROM Material Flow Right

Chute design is one of the most critical yet challenging aspects of mining and mineral processing. Whether you are handling coal, hard rock ore, or raw ROM material, chutes and transfer stations are the unsung workhorses of every operation. When designed well, they guide material smoothly, minimise wear, and keep conveyors running. When designed poorly, they cause blockages, spillage, excessive dust, and expensive downtime.

Modern chute design has moved far beyond rules of thumb and back-of-the-envelope sketches. Today, successful projects rely on accurate as-built data, particle trajectory analysis, and advanced Discrete Element Method (DEM) simulation to predict, visualise, and optimise material flow before steel is cut. In this article, we explore why these tools have become essential, how they work together, and where software can — and cannot — replace engineering judgement.

Illustration showing common problems with poorly designed material-handling chutes. A chute discharges material onto a conveyor while issues are highlighted around it: unpredictable material flow, material spillage, maintenance challenges, high wear, blockages, and dust and noise. Warning icons for downtime and cost appear on the conveyor, and workers are shown dealing with the resulting hazards and maintenance tasks.

The Challenge of Chute Design

Coal and hard rock have very different flow behaviours. Coal tends to be softer, generate more dust, and be prone to degradation, while hard rock is more abrasive and can damage chutes if impact angles are not controlled. ROM material adds another level of complexity — oversize lumps, fines, and moisture variation can cause hang-ups or uneven flow.

Chute design must balance several competing objectives:

Control the trajectory of incoming material to reduce impact and wear
Prevent blockages by maintaining flowability, even with wet or sticky ore
Manage dust and noise to meet environmental and workplace health requirements
Fit within existing plant space with minimal modification to conveyors and structures
Be maintainable — liners must be accessible and replaceable without excessive downtime

Meeting all these goals without accurate data and simulation is like trying to design in the dark.

Illustrated graphic showing a tripod-mounted 3D laser scanner capturing millimetre-accurate as-built data in an industrial plant with conveyors and walkways. Speech bubbles highlight issues such as “Outdated drawings don’t tell the full story” and “Modifications rarely get documented.” The scan data is shown being visualised on a laptop, with notes describing full coverage of conveyors, walkways, and services. Benefits listed along the bottom include faster data collection, fewer site revisits, safer shutdowns, accurate starting point for design simulation, and safer outcomes that ensure designs fit first time.

Capturing the Truth with 3D Scanning

The first step in any successful chute project is to understand the as-built environment. In many operations, drawings are outdated, modifications have been made over the years, and the real plant geometry may differ from what is on paper. Manual measurement is slow, risky, and often incomplete.

This is where 3D laser scanning changes the game. Using tripod-mounted or mobile LiDAR scanners, engineers can capture the entire transfer station, conveyors, surrounding steelwork, and services in a matter of hours. The result is a dense point cloud with millimetre accuracy that reflects the true state of the plant.

From here, the point cloud is cleaned and converted into a 3D model. This ensures the new chute design will not clash with existing structures, and that all clearances are known. It also allows maintenance teams to plan safe access for liner change-outs and other work, as the scanned model can be navigated virtually to check reach and access envelopes.

Understanding Particle Trajectory

Once the physical environment is known, the next challenge is to understand the particle trajectory — the path that material takes as it leaves the head pulley or previous transfer point.

Trajectory depends on belt speed, material characteristics, and discharge angle. For coal, fine particles may spread wider than the coarse fraction, while for ROM ore, large lumps may follow a ballistic path that needs to be controlled to prevent impact damage.

Accurately modelling trajectory ensures that the material enters the chute in the right location and direction. This minimises impact forces, reducing wear on liners and avoiding the “splash” that creates spillage and dust. It also prevents the material from hitting obstructions or dead zones that could lead to build-up and blockages.

Modern software can plot the trajectory curve for different loading conditions, providing a starting point for chute geometry. This is a critical step — if the trajectory is wrong, the chute design will be fighting against the natural path of the material.

The Power of DEM Simulation

While trajectory gives a first approximation, real-world flow is far more complex. This is where Discrete Element Method (DEM) simulation comes into play. DEM models represent bulk material as thousands (or millions) of individual particles, each following the laws of motion and interacting with one another.

When a DEM simulation is run on a chute design:

You can visualise material flow in 3D, watching how particles accelerate, collide, and settle
Impact zones become clear, showing where liners will wear fastest
Areas of turbulence, dust generation, or segregation are identified
Build-up points and potential blockages are predicted

This allows engineers to experiment with chute geometry before fabrication. Angles can be changed, ledges removed, and flow-aiding features like hood and spoon profiles or rock-boxes optimised to achieve smooth, controlled flow.

For coal, DEM can help ensure material lands gently on the receiving belt, reducing degradation and dust. For hard rock, it can ensure that the energy of impact is directed onto replaceable wear liners rather than structural plate. For ROM ore, it can help prevent oversize lumps from wedging in critical locations.

Illustration of an optimised chute design showing material flow represented by green particles, with check marks and gear icons indicating improved efficiency and engineered performance.

🖥 Strengths and Limitations of Software

Modern DEM packages are powerful, but they are not magic. Software such as EDEM, Rocky DEM, or Altair’s tools can simulate a wide range of materials and geometries, but they rely on good input data and skilled interpretation.

Key strengths include:

Ability to model complex, 3D geometries and particle interactions
High visualisation power for communicating designs to stakeholders
Capability to run multiple scenarios (different feed rates, moisture contents, ore types) quickly

However, there are limitations:

Material calibration is critical. If the particle shape, friction, and cohesion parameters are wrong, the results will not match reality.
Computational cost can be high — detailed simulations of large chutes with millions of particles may take hours or days to run.
Engineering judgement is still needed. Software will not tell you the “best” design — it will only show how a proposed design behaves under given conditions.

That’s why DEM is best used as part of a holistic workflow that includes field data, trajectory analysis, and experienced design review.

From Model to Real-World Results

When the simulation results are validated and optimised, the design can be finalised. The point cloud model ensures the chute will fit in the available space, and the DEM results give confidence that it will perform as intended.

This means fabrication can proceed with fewer changes and less risk. During shutdown, installation goes smoothly, because clashes have already been resolved in the digital model. Once commissioned, the chute delivers predictable flow, less spillage, and longer liner life.

Why It Matters More Than Ever

Today’s mining operations face tighter production schedules, stricter environmental compliance, and increasing cost pressures. Downtime is expensive, and the margin for error is shrinking.

By combining 3D scanning, trajectory modelling, and DEM simulation, operations can move from reactive problem-solving to proactive improvement. Instead of waiting for blockages or failures, they can design out the problems before they occur, saving both time and money.

Partnering for Success

At Hamilton by Design, we specialise in turning raw site data into actionable insights. Our team uses advanced 3D scanning to capture your transfer stations with precision, builds accurate point clouds and CAD models, and runs calibrated DEM simulations to ensure your new chute design performs from day one.

Whether you’re working with coal, hard rock, or ROM ore, we help you deliver designs that fit first time, reduce maintenance headaches, and keep production running.

Contact us today to see how our integrated scanning and simulation workflow can make your next chute project safer, faster, and more reliable.

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