In a time when the globalisation of markets forces companies to become more cost efficient, the design and development process of bulk material handling equipment is often characterized by a fast construction phase, which risks an improper design not fitting the requirements. Furthermore, the process of designing large conveyor plants can not be standardized. Therefore, the transport process can be optimized just under operating conditions. Due to these facts and the increasing computational power of standard PCs, the usage of numerical simulation methods, such as the Discrete Element Method, for the design process became increasingly popular.

The usage of Discrete Element Simulations in the field of bulk solids handling equipment provides possibilities for the optimization of the design and the operating conditions as well as a view of the wear characteristics.

The bulk solids properties of a Discrete Element Model should be adjusted by a calibration procedure comparing results form simulations and laboratory tests, namely the internal friction angle and the angle of repose.

The further improvement and enhancement of the Discrete Element Models requires measurements on large scale test rigs or industrial equipment. The observation of the general particle flow properties as well as the measurement of forces and moments acting on several components allows detailed and extensive possibilities for the comparison of simulations and experiments.

Transfer chutes and bucket elevators are two typical examples for bulk handling equipment, which can be optimized by Discrete Element Simulations. The paper will illustrate the optimization possibilities for these two components and will present the results of the simulations and the verification experiments. Furthermore it will give advises for the calibration of the used simulation model and an outlook into the verification of Discrete Element Simulations of other mechanical conveyors, such as screw conveyors.