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Bulk Materials Handling Fundamentals
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Bulk Materials Handling Fundamentals

2-Day Training Course: An Introduction to Bulk Solids Operations & Equipment. Attend this course to improve your knowledge & confidence in the technical aspects of the design, implementation & operation of bulk material handling system installations

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Key Learning Objectives

  • Review case studies for systems handling iron ore, coal, and other mining materials
  • Understand bulk material flow properties and their use in design and troubleshooting
  • Examine various bulk material feeders and discuss key selection criteria
  • Review bulk material handling systems needed for safe and environmentally sensitive areas
  • Learn about mining and mineral equipment for material processing, sizing, and conveying
  • Discuss options for bulk material stacking, reclaiming, ship/rail loading and unloading
  • Recognise common flow problems and how to prevent them from occurring
  • Learn about storage system discharge patterns in bins, hoppers, silos, and stockpiles
  • Examine system throughput requirements based on mass and volumetric flow rates

About the Course

This course provides participants with a thorough review of basic principles and practices for selection of bulk material equipment and handling systems.

The course starts with an overview of bulk material handling considerations, including the important discussion of key material properties required for effective equipment/system selection and design. An emphasis is made upon mining and mineral materials, such as coal, iron ore, bauxite, and ores that are routinely handled in Australia. A review of bulk material flow fundamentals will be presented, including common flow problems, types of flow patterns in storage equipment, including silos, bins, and stockpiles. Feeder selection is discussed, with an emphasis on applications involving high tonnage rates and abrasive bulk materials.

System selection criteria, such as site location, topography, environmental considerations, and fixed equipment vs mobile or semi-mobile requirements, are reviewed. Equipment sizing based on throughput needs, buffering and surge capacity, and material flow properties is also analysed. Equipment operational requirements for maintenance and strategies that can be utilised to avoid premature failure or reduced system performance are presented throughout the course.

The field of bulk material handling is often considered a “black art”; however, with the knowledge gained in this course, effective decisions can be made for selection of appropriate equipment for challenging bulk materials. The course notes are supplemented with many practical examples to illustrate important concepts.

Who will benefit

Course Level: Beginner/Intermediate
This course is geared towards arming the participant with knowledge of the basics of bulk material equipment selection and operation in a high throughput environment.

  • Engineers who work/have an interest in bulk material handling
  • New and graduate engineers
  • Operating and maintenance personnel
  • Project and operations managers for bulk material handling projects
  • Non-technical people who work with/consult to the industry
  • Those who make investment decisions on bulk handling systems

A CPD Course

Use this course to help fulfil your Continuing Professional Development (CPD) educational requirements to retain your professional/chartered status. Contact your relevant association to learn how


“Interesting course that does not go through details in-depth but gives us fundamentals of what we need. Knowledgeable presenter that places both emphasis on theory and practice. Good refresher course, well done!”
Mechanical Engineer, Ausenco Ltd.

Terms & Conditions

To read the training course terms and conditions read more here

Course Outline

Overview of bulk materials handling

Australian and different global operations

  • Typical materials
  • Ranges of capacities
  • Trends and production efficiencies

Bulk material flow properties and application to equipment design

  • Key properties of bulk solids needed for equipment design
  • Coefficient of sliding friction for hopper and chute design
  • Cohesive strength for selecting hopper outlet size and stockpiles
  • Bulk density and permeability for calculating hopper outlet size
  • Particle size and shape
  • Discussion of influences of moisture, fines content

Activity 1:
Workshop/quiz for flow properties measurement

Material throughput considerations and sizing of equipment

  • What does “nominal” throughput mean?
    • Annual vs instantaneous throughput rates
    • Throughput in tonnes compared to throughput in cubic meters
    • Minimum and maximum
    • Surge
  • How should we design to achieve this?
    • Interpreting equipment capacity
    • Current limitations on some technologies
    • Buffering flows

Layouts and designs

  • Typical design challenges
  • Safe and environmentally sensitive bulk materials handling systems
  • Topography
  • Climate
  • Real estate limitations

Bulk material sizing, screening, and conveying equipment

  • Review of main equipment types and key components
    • Crushers
    • Screeners
    • Conveying systems
    • Stackers/reclaimers
    • Loading/unloading systems for ships, rail cars
    • Mobile machines

Bulk material storage, feeding, and handling systems

  • Review of common flow problems
  • Types of storage
    • Silos, bins, hoppers and their flow patterns
    • Stockpiles
    • Stockyards
  • Feeders (eg. screws, belts, aprons, vibratory, rotary valve)
  • Transfer chutes

Activity 2:
Workshop/quiz for bulk storage systems

Managing equipment operational issues

  • Typical issues (eg plugging, wear, spillage, failure, high power consumption)
  • Methods to address and minimise maintenance costs

On-site & in-house training

Deliver this course how you want, where you want, when you want – and save up to 40%! 8+ employees seeking training on the same topic?

Talk to us about an on-site/in-house & customised solution.


Still have a question?

Sushil Kunwar
Training Consultant
+61 (0)2 9080 4395

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