Introduction
When working with large grain processing equipment, even small operational changes can lead to significant structural considerations. We faced this recently when a client asked whether their existing vessel could safely handle a larger batch size than originally designed for. Rather than relying on assumptions and hand calcs, we carried out Finite Element Analysis (FEA) to properly understand how the kiln flooring would behave under the increased loading. This gave us a clear, reliable understanding of whether the structure could cope without risking deformation which, even if not structurally significant, could cause grain leaks.
To do this, we ran a static simulation using a mixed mesh, realistic boundary conditions and accurate material properties. Load conditions were based on the bulk density of the grain and its friction behaviour. This provided a detailed view of the system’s structural response and allowed us to give the client confidence in the feasibility of implementing the higher capacity.
Why FEA & Optimisation Matters
Kiln floors in malting applications experience complex loading conditions influenced by the bulk material, moving machinery, friction, support structure and thermal behaviour. FEA allows these factors to be analysed in a way that hand calculations cannot.
From identifying stress concentrations to validating safety margins and exploring “what-if” scenarios, simulation offers a deeply reliable method for confirming whether a structure can safely handle operational changes. In this project, it provided the clarity needed to increase capacity without unnecessary redesigns.
How We Did It
We created a SolidWorks model of the kiln flooring and applied loads that reflected the bulk behaviour of the grain. The setup included realistic constraints, material behaviour, and frictional effects. A mixed mesh helped capture stress patterns in critical regions. The model was then run under standard static conditions to assess how the floor would respond to the increased loading.
Results & Key Findings
The analysis showed that the kiln flooring stayed well within safe stress limits even with the higher load applied. The highest stresses appeared around the central structural areas, which was expected, but they remained comfortably below the material’s yield strength.
To build a deeper understanding of potential weak points, we ran a sensitivity study where we manually reduced the material yield strength. This highlighted where deformation would begin under extreme conditions, giving us insight into areas that might benefit from long-term optimisation. Overall, the structure was confirmed to be suitable for the increased capacity.
Conclusion & Future Work
The study confirmed that no structural modifications were needed; the flooring is safe for the increased grain load. The sensitivity work also highlighted the most critical areas of the design for future consideration.
Looking ahead, we plan to integrate Computational Fluid Dynamics (CFD) to better understand airflow within vessels, refine heat transfer predictions, and support improved heat exchanger selection across malting applications.
