Objective Bulk material transport in emergency rescue scenarios and coal transportation poses stringent demands for the structural performance of transfer chutes. Given this, from the perspective of the energy dissipation mechanisms of particles, this study proposed structural optimization methods for transfer chutes based on the regulation of particle energy dissipation.

Methods An experiment–simulation integrated analysis framework was established. Using this framework, this study systematically simulated the impact process of particles between two-stage walls I and Ⅱ using the discrete element method (DEM), highlighting the coupling mechanisms among velocity fluctuations, stress distribution, and energy transformation pathways. Based on the results, this study defined an energy loss ratio coefficient (α) related to particle-particle interactions and constructed mathematical expressions for the relationships of the total energy dissipation of particles with the installation heights and angles of the walls. Additionally, it developed a control model of energy dissipation equilibrium and quantitatively analyzed the relationships of particle energy dissipation with wall geometry.

Results and Conclusions  The results indicate that the wall installation angle governed the relative proportions of the particle-particle and particle-wall energy dissipation pathways, with three representative energy dissipation mechanisms identified: local instability, stress continuity, and impact-dominated behavior. In combination with the particle velocity contour maps and stress distributions, this study further analyzed the synergistic evolution between the macroscopic flow behavior of particles and microscopic energy dissipation pathways. Accordingly, two structural optimization strategies were proposed: (1) A guiding structure was arranged to reduce the initial impact intensity, and (2) A stepped surface was introduced into the chute walls to enhance local shear and convert energy dissipation pathways. Both approaches significantly increased energy dissipation induced by particle-particle interactions while avoiding reverse flow and the local overloading of the walls. These methods proved effective through engineering applications. The results of this study provide theoretical and engineering bases for the energy management and structural design of chute systems under complex constraints.