Materials Handling: Section 10

Source: HANDBOOK OF MECHANICAL ENGINEERING CALCULATIONS
SECTION 10
MATERIALS HANDLING
Choosing Conveyors and Elevators for Specic Materials Transported 10.1 Determining Equipment Design Parameters for Overhead Conveyors
10.4
Screw Conveyor Power Input and Capacity 10.13 Design and Layout of Pneumatic Conveying Systems 10.15
Bulk Material Elevator and Conveyor Selection 10.9
CHOOSING CONVEYORS AND ELEVATORS FOR SPECIFIC MATERIALS TRANSPORTED

Determine the maximum allowable product weight between supports that can be handled by a belt conveyor at any one time when it conveys 100,000 lb / h (4540 kg / h) of pulverized aluminum oxide in an abrasive state at a belt speed of 50 ft / min (15.2 m / min) with a center-to-center distance of 32 ft (9.75 m) between belt supports. Compare this capacity with that at belt speeds of 150, 250, and 350 fpm (45.7, 76.2, and 106.7 m / min). Choose the type of conveyor and elevator to handle this material under the conditions given.
Calculation Procedure:
1. Find the maximum allowable product weight at the given belt speed Use the relation, P KC / 60 S, where P maximum product weight on the belt at any one time, lb (kg) between belt supports; K load, lb / h (kg / h); C centerto-center distance between belt supports, ft (m); S belt speed, ft / min (m / min). Substituting, we have, P (100,000)(32) / 50 (60) 1066.7 lb (484.3 kg). 2. Determine the maximum allowable product weight at other belt speeds Typical conveyor belt speeds vary from a low of 150 ft / min (45.7 m / min) to a high 800 ft / min (243.8 m / min), depending on belt width, type of material conveyed, belt construction, etc. For this belt, using the data given earlier, P (100,000)(32) / 150(60) 355.6 lb (161.4 kg) when the speed is 150 ft / min (45.7 m / min). Likewise for the two higher speeds, respectively, P (100,000)(32) / 250(60) 213.3 lb (96.9 kg); P (100,000)(32) / (350(60) 152.4 lb (69.2 kg). 3. Verify the type of conveyor and elevator to use With such a wide variety of conveyors and elevators to choose from, it is wise to verify the choice before a nal decision is made. Table 1, presented by Harold V.
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TABLE 1 Preferred Types of Conveyors and Elevators for Bulk and Packaged Materials
Av wt / volume lb / ft Sticky b b b b Explosive Sticky Poisonous Dusty Corrosive Sometimes sticky Adheres Abrasive Abrasive Hygroscopic Adheres Heavy Abrasive Abrasive Abrasive Corrosive Adheres e e e
3
Material
Physical condition kg / m3 Reaction on conveyor Comment Preferred conveyors* Preferred elevators*
Fragile Packs Sluggish e e e e e e e e
b, c b b b b b b b b, c c c
MATERIALS HANDLING
10.2
May be abrasive Abrasive shell Sometimes sticky Abrasive Shell abrasive Abrasive Mild abrasive Abrasive Lubricant Abrasive May jam
Sluggish Fragile Sticky Sluggish c c c c c Corrosive Free-owing Free-owing Keep cool
b g, g g, g, g, b b g, g, g, g, g, g, g, g, g, b g, g, g, g, g, g, g, g, g, g, g, g, g, g, g, g, g, g b, b, b b b b, b b b, b b, b b, b, b b b
May be tough Poisonous
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90 6065 60 62 65 100 3540 4550 5560 5070 1620 55 40 90118 3560 5054 5060 5060 5060 7075 4045 40 515 45 3540 80100 45 100 3545 80 45 40 95135 60 100 1530 60150 5580 1,440 9601,040 960 990 1,040 1,600 560640 720800 880960 8001,120 260320 880 640 1,4401,890 560960 800860 800960 800960 800960 1,1201,200 640720 640 80240 720 560640 1,2801,600 720 1,600 560720 1,280 720 640 1,5202,160 960 1600 240480 9602,400 8801,280 a, e a, b, c, e a, e b, c, e c, e c, e d, f f a, b, c, d, a, b, c, d, a, b, c, d, c, e a, e a, c, d, e a, b, c, e a, b, c, e a, b, c, d, a, b, e a, b, c, d, a, b, c, d, a, c, e a, b, c, e a, b, c, d, a, c, e a, b, c, d, a, b, e a, b, c, d, b, d, e, f a, b, c, d, a, b, e a, c, e a, b, c, d, a, e, f a, b, c, e a, b, f a, b, d, e a, b, c, e a, b, c, e
Acid phosphate Alum Aluminum oxide Ammonium nitrate Ammonium nitrate Arsenic salts Ashes: dry wet Bone meal Borax Bran Brewers grains, hot Carbon black (pellets) Cement, dry Clays Coal: anthracite steam sizes bituminous, lump bituminous, slack Chalk Coffee beans Copra, ground Cork, ground Corn, shelled Cottonseed Cullet Flaxseed Flue dirt Fly ash, clean Glass batch Glue Graphite (our) Gravel Gypsum Heavy ores Hog fuel Lead salts Lime, pebble
Damp Granular Pulv. Pulv. Damp Pulv. Granular Sticky Pulv. Pulv. Granular Granular Granular Pulv. Pulv. Lumpy Granular Lumpy Granular Pulv. Granular Pulv. Pulv. Granular Granular Granular Granular Pulv. Pulv. Granular Granular Pulv. Granular Pulv. Lumpy Stringy Pulv. Granular
Pulv. Dry 1200 b b, c b b, c 163,200 Abrasive May be sticky a, i, j
8595 45
1,3601,520 720
Sluggish
a, b, e a, b, c, d, e
g, b
Boxed
e e e
Sometimes difcult Dusty Sticky Polisher Difcult Corrosive if wet
e e
Abrasive Free-owing Abrasive Mild abrasive Mild abrasive Very abrasive Sluggish Hygroscopic Flows freely Abrasive Sticky b b b b b b, c Sticky if wet Sluggish Fragile Flows freely Flows freely Sticky Sticky e e c c c c b b e c c Corrosive if wet Mild abrasive Sluggish Free-owing May arch May pack May pack e e
MATERIALS HANDLING
10.3
Abrasive Abrasive Sticky if hot Caustic Caustic Explosive dust Explosive dust Handle gently Explosion risk Adheres to metal Keep clean Corrosive if wet Avoid discoloration
15 5 50100 2030 110 42 45 110 50 50 7595 90110 90110 1520 60 80 1020 2535 5565 30 3040 5565 5055 55 5060 25 48 1820 2035 70 g, g, b g, g, g g, g, g, g, g, g, g g g g, g, g, g, g g g, g, g g, g, g g 240 80 8001,600 320480 1,760 670 720 1,760 800 800 1,2001,520 1,4401,760 1,4401,760 240320 960 1,280 160320 400560 8801,040 480 480640 8801,040 800880 880 800960 400 770 290320 320560 1,120 a, b, i, j i, j a, b, c, d, a, b, c, d, a, b, d a, b, c, e a, b, c, d, a, b, c, d a, b, e a, b, c, e a, b, c, d, a, e, f a, e, f a, b, c, d, a, b, e, f a, d, e a, c, e a, b, c, d, a, b, c, d, a, b, c, e a, b, c, e a, b, c, e a, b, c, e a, b, c, e a, b, c, d, a, b, d, e a, c, d, e a, c, d, e a, b, c, d, a, b, c, d,
Limestone dust Malt Manufactured products Merchandise: Packaged Garments Metallic dusts Mica, pulverized Molybdenum concts Petroleum coke Pumice Quartz (ground) Rubber scrap Salt: coarse cake Sand: dry damp Sawdust Sewage sludge Silica our Soap akes Soda ash: light heavy Soybean our Starch Sugar: raw rened Sulfur Talc Tobacco stems Wheat Wood chips Zinc oxide Zinc sulfate
Boxed Hanging Pulv. Pulv. Pulv. Lumpy Pulv. Pulv Stringy Granular Pulv. Granular Granular Granular Pulv. Pulv. Granular Pulv. Pulv. Pulv. Pulv. Granular Granular Pulv. Pulv. Stringy Granular Granular Pulv. Pulv.
*Explanation of letter symbols: abelt, bight, ccontinuous ow, dpneumatic, escrew, fdrag chain, gbelt and bucket, hchain and bucket, ioverhead straight power, joverhead power and free.
MATERIALS HANDLING 10.4

PLANT AND FACILITIES ENGINEERING
Hawkins, Manager, Product Standards and Services, Columbus McKinnon Corporation, lists preferred types of conveyors and elevators for a variety of materials in both bulk and packaged forms. Entering this table at aluminum oxide in pulverized form shows that a belt or screw conveyor is preferred, while a ight elevator is recommended for vertical lifts of this material. While Table 1 gives general recommendations, the engineer should remember that a careful economic study is required to keep the capital investment to the minimum consistent with safe and dependable conveying of the material. Along with capital cost, the operating and maintenance costs must also be evaluated before a nal choice of the conveyor and elevator is made. Related Calculations. Choose the belt length to accommodate the maximum expected product capacity. Belt speed should be compatible with the process equipment served and with the other materials-handling equipment associated with the conveyor belt. Belt conveyors are suitable for bulk materials of many types. However, characteristics of the material conveyed must be considered before a nal choice of the belting material is made. Thus, as outlined by K. W. Tunnell Company: (a) Material stickiness may prevent materials handled from discharging completely from the conveyor belt, or may interfere with the belt drive components: motors, chains, etc. (b) Ambient temperatures exceeding 150F (83C) could cause deterioration or damage to the belt materials. (c) Chemical reactions between the conveyed product and the belt material can cause damage. Thus, oils, chemicals, fats, and acids can damage belts. (d) Excessively large lump size may require an oversize belt system to handle the conveyed product safely. One way around these problems is use of metal-belt conveyors. These are similar in design to conventional rubber and composite-material conveyor belts except that their surface is made of woven or solid metal. Popular materials include carbon steel, galvanized steel, stainless steel, and other metals and alloys. With todays emphasis on environmental and safety aspects of engineering decisions, it is wise for the design engineer to refer to the appropriate codes and specications governing the particular type of equipment being considered. Thus, in the materials handling eld, ANSI B 20.1 Conveyors, Cableways, and Related Equipment should be consulted before any nal design choices are made. Likewise, state and city codes should be checked before a rm equipment selection decision. In certain instances the local code may be more restrictive than the national code. OSHAOccupational Safety and Health Administration regulations are important where human safety is involved. Since these regulations vary so widely with material handled, type of equipment used, and location, no generalizations about them can be made other than to recommend strongly that the regulations be studied and followed.
DETERMINING EQUIPMENT DESIGN PARAMETERS FOR OVERHEAD CONVEYORS

Select suitable equipment for the overhead conveyor shown in Fig. 1. Determine the total chain pull and horsepower required if the conveyor is 700 ft (213 m) long, the coefcient of friction is 0.03, the total chin pull is 60 lb / ft (89.4 kg / m) comprised of the components detailed below. Use the design method presented the K. W. Tunnell Company.
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10.5
SI values 150' 45.7 m 3' 0.91 m 130' 39.6 m 5' 1.5 m 3' 0.91 m 8' 2.4 m 10' 3.0 m 4' 1.2 m 30' 9.1 m 280' 85.3 m 20' 6.1 m 40' 12.2 m 60' 18.3 m FIGURE 1 (a) Plan of conveyor layout. (b) Elevation of conveyor layout.
1. From the process ow charts, determine all the operations to be serviced by the conveyor The process ow charts will be provided by the manufacturing enginner or the process engineer, depending on the type of installation the conveyor is serving. To assist in the conveyor layout and design a listing of each process served by the conveyor should be prepared. 2. Determine the path of the conveyor on a scaled plant layout Draw a plan and elevation of the conveyor, Fig. 1, on a scaled layout of the plant. Show all obstructions the conveyor will encounter, such as columns, walls, ma-

chinery, and work aisles. Indicate the loading and unloading zones, probable drive location, and passage through walls. 3. Develop a vertical elevation to determine incline and decline dimensions Show the inclines and declines, and their dimensions, Fig. 1b. A three-dimensional view of the installation can be prepared at this point to help people better visualize the nal installation and the various routes of the conveyor. 4. Determine the material movement rate, unit load size, spacing, and carrier design for the conveyor Information for these variables can be obtained from the ow chart and the personnel in charge of the process being served by the conveyor. It is important that the conveyor be designed for the maximum anticipated load and material size. 5. Modify turn radii to provide adequate clearances Prepare drawings showing needed load spacing on turns, Fig. 2. Without adequate clearnaces, the conveyor may not provide the desired transportation capability needed to serve properly the process for which the conveyor is being designed. 6. Design the load spacing for clearances on inclines and declines As inclines and declines get steeper, Fig. 2 load spacing has to be increased to provide a constant clearance or separation between loads. Table 2 gives selected clearances on inclined track for overhead conveyors for a given separation at various incline angles. 7. Redraw the conveyor path and vertical elevation views using newly determined radii and incline information Show the new radii and incline information as determined by the redesign of the system layout, Figs. 1 and 2. 8. Compute the chain pull in the conveyor The chain pull is the total weight of the chain, trolleys, Fig. 3, and other components, plus the weight of the carriers and load. Thus, for the given system, the tenative chain pull can be found from Cp L PL , where Cp tentative
FIGURE 2 Clearance design for overhead conveyor turns and rises.
MATERIALS HANDLING
MATERIALS HANDLING
10.7
TABLE 2 Selected Load Clearance on Inclined Track for Overhead Conveyors
Incline angle, deg Load spacing, in 12 16 18 24 cm 30.5 40.6 45.7 60.9 29.9 40.0 45.1 60.0 28.6 38.7 43.2 57.5 10 11 8 1534 1734 2358
7
20 11 4 1518 17 2258
1
30 1038 1378 1558 2078 26.4 35.2 39.7 53.0
40 914 1214 1378 1838 23.5 31.1 35.2 46.7
50 734 1038 1138 1512 19.7 26.4 28.9 39.4
60 6 8 9 12 15.2 20.3 22.9 30.5
Horizontal centers, in
Horizontal centers, cm
chain pull, lb (kg); L conveyor length, ft (m); PL chain load, lb / ft (kg / m); coefcient of friction 0.03 for this installation. The given chain load of 60 lb / ft (89.4 kg / m) is comprised of 10.0 lb / ft (14.9 kg / m) for the chain and trolleys, 12.5 lb / ft (18.6 kg / m) for the carriers, and 37.5 lb / ft (55.9 kg / m) for the line load. Substituting, Cp 700(60.0)(0.03) 1260 lb (572 kg). For this initial calculation, inclines and declines are assumed to be level sections if the number of declines balances out the number of inclines. However, for each additional incline, the total line load rise has to be added to determine the total chain pull. If, for example, a vertical incline in this installation raises the line load 8 ft ((2.4 m), then the additional chain pull 37.5 lb line load 8 ft 300 lb (136.2 kg). The total chain pull then becomes 1260 300 1560 lb (708.2 kg). 9. Select the tenative conveyor size based on the trolley load and chain pull Use the manufacturers data to choose the tenative conveyor size. In making your choice, try to comform to standard conveyor sizes and layouts because this will reduce the capital cost of the installation. Further, the installation will probably be made faster because there will be less customizing required. 10. Select vertical curve radii Again, work with the standard radii available from the manufacturer, if possible. This will reduce installation costs and time. 11. Determine the conveyor power requirements and drive locations Make point-to-point calculations of the chain pull around the complete path of the conveyor, Fig. 1. Use the following equations to compute point-to-point chain pull: (a) Pull for each horizontal run, lb (kg), PH XWL, where X 0.02 for standard ball-bearing trolleys; W total moving weight, lb / ft (kg / m), empty or loaded as the case may be; L length of straight run, ft (m). (b) Pull for each traction wheel or roller turn, lb (kg), PT YP, where Y 0.02 for traction wheel or roller turn; P pull at turn, lb (kg). (c) Pull for each vertical curve, lb (kg), PV XWS ZP HW(1 Z), where X 0.02 for standard ballbearing trolleys; W total moving weight, lb / ft (kg / m); S horizontal span of

FIGURE 3 Power- and free-trolley overhead conveyors.
vertical curve, ft (m); H total change of level of conveyor, ft (m) (plus, when conveyor is traveling up the curve; minus when conveyor is traveling down the curve); Z 0.03 for 30 incline; 0.045 for 45 incline; 0.06 for 60 incline; 0.09 for 90 incline; P pull at start of curve, lb (kg). Drive horsepower (kW) can be calculated from: Drive hp (drive capacity, lb)(maximum speed, ft / min) / 0.6(33,000). Thus, if the drive capacity required is 6000 lb, the maximum speed is 50 ft / min, the horsepower required (6000)(50) / 0.6(33,000) 15.2 hp (11.3 kW). 12. Design the conveyor supports and superstructures Refer to the manufacturers data for suitable supports and superstructures. It is best, if possible, to use standard supports and superstructures. This will save money and time for the rm owning the plant being tted with the conveyor. 13. Design guards required by laws and codes Federal, state, and applicable codes require guards of various types under high trolley runs, particularly over aisles and work areas. Guard panels are normally
MATERIALS HANDLING
MATERIALS HANDLING
10.9
made from woven or welded wire mesh with structural angles and channels to suit the size and weight of the material being handled. Related Calculations. The general procedure presented here is valid for overhead conveyors handling a variety of materials: manufactured goods, parts for assembly, raw materials, etc., in plants in many different industries. Since conveyor layout, sizing, and safety design are a specialized skill, the engineer should consult carefully with the conveyor manufacturer. The manufacturers wide experience will be most helpful to the engineer in achieving an economical and safe design for the installation being considered. The steps, illustrations, and table in this procedure are the work of the K. W. Tunnell Company. SI values were added by the handbook editor.
BULK MATERIAL ELEVATOR AND CONVEYOR SELECTION

Choose a bucket elevator to handle 150 tons / h (136.1 t / h) of abrasive material weighing 50 lb / ft3 (800.5 kg / m3) through a vertical distance of 75 ft (22.9 m) at a speed of 100 ft / min (30.5 m / min). What hp input is required to drive the elevator? The bucket elevator discharges onto a horizontal conveyor which must transport the material 1400 ft (426.7 m). Choose the type of conveyor to use, and determine the required power input needed to drive it.
1. Select the type of elevator to use Table 3 summarizes the various characteristics of bucket elevators used to transport bulk materials vertically. This table shows that a continuous bucket elevator would be a good choice, because it is a recommended type for abrasive materials. The second choice would be a pivoted bucket elevator. However, the continuous bucket type is popular and will be chosen for this application. 2. Compute the elevator height To allow for satisfactory loading of the bulk material, the elevator length is usually increased by about 5 ft (1.5 m) more than the vertical lift. Hence, the elevator height 75 5 80 ft (24.4 m). Related Calculations. The procedure given here is valid for conveyors using rubber belts reinforced with cotton duck, open-mesh fabric, cords, or steel wires. It is also valid for stitched-canvas belts, balata belts, and at-steel belts. The required horsepower input includes any power absorbed by idler pulleys. Table 6 shows the minimum recommended belt widths for lumpy materials of various sizes. Maximum recommended belt speeds for various materials are shown in Table 5. 3. Compute the required power input to the elevator Use the relation hp 2CH / 1000, where C elevator capacity, tons / h; H elevator height, ft. Thus, for this elevator, hp 2(150)(80) / 1000 24.0 hp (17.9 kW). The power input relation given above is valid for continuous-bucket, centrifugaldischarge, perfect-discharge, and super-capacity elevators. A 25-hp (18.7-kW) motor would probably be chosen for this elevator.

TABLE 3 Bucket Elevators
4. Select the type of conveyor to use Since the elevator discharges onto the conveyor, the capacity of the conveyor should be the same, per unit time, as the elevator. Table 4 lists the characteristics of various types of conveyors. Study of the tabulation shows that a belt conveyor would probably be best for this application, based on the speed, capacity, and type of material it can handle. Hence, it will be chosen for this installation. 5. Compute the required power input to the conveyor The power input to a conveyor is composed of two portions: the power required to move the empty belt conveyor and the power required to move the load horizontally. Determine from Fig. 4 the power required to move the empty belt conveyor, after choosing the required belt width. Determine the belt width from Table 5. Thus, for this conveyor, Table 5 shows that a belt width of 42 in (106.7 cm) is required to transport up to 150 tons / h (136.1 t / h) at a belt speed of 100 ft / min (30.5 m / min). [Note that the next larger capacity, 162 tons / h (146.9 t / h), is used when the exact capacity required is not tabulated.] Find the horsepower required to drive the empty belt by entering Fig. 4 at the belt distance between centers, 1400 ft (426.7 m), and projecting vertically upward to the belt width, 42 in (106.7 cm). At the left, read the required power input as 7.2 hp (5.4 kW). Compute the power required to move the load horizontally from hp (C / 100)(0.4 0.00345L), where L distance between conveyor centers, ft; other symbols as before. For this conveyor, hp (150 / 100)(0.4 0.00325 1400) 6.83 hp (5.1 kW). Hence, the total horsepower to drive this horizontal conveyor is 7.2 6.83 14.03 hp (10.5 kW). The total horsepower input to this conveyor installation is the sum of the elevator and conveyor belt horsepowers, or 14.03 24.0 38.03 hp (28.4 kW).
MATERIALS HANDLING
TABLE 4 Conveyor Characteristics

TABLE 5 Capacities of Troughed Rest [tons / h (t / h) with Belt Speed of 100 ft / min (30.5 m / min)]
TABLE 6 Minimum Belt Width for Lumps
FIGURE 4 Horsepower (kilowatts) required to move an empty conveyor belt at 100 ft / min (30.5 m / min).
MATERIALS HANDLING
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10.13
Related Calculations: The procedure given here is valid for conveyors using rubber belts reinforced with cotton duck, open-mesh fabric, cords, or steel wires. It is also valid for stitched-canvas belts, balata belts, and at-steel belts. The required horsepower input includes any power adsorbed by idler pulleys. Table 5 shows the minimum recommended belt widths for lumpy materials of various sizes. Maximum recommended belt speeds for various materials are shown in Table 6. When a conveyor belt is equipped with a tripper, the belt must rise about 5 ft (1.5 m) above its horizontal plane of travel. This rise must be included in the vertical-lift power input computation. When the tripper is driven by the belt, allow 1 hp (0.75 kW) for a 16-in (406.4-mm) belt, 3 hp (2.2 kW) for a 36-in (914.4-mm) belt, and 7 hp (5.2 kW) for a 60-in (1524mm) belt. Where a rotary cleaning brush is driven by the conveyor shaft, allow about the same power input to the brush for belts of various widths.
SCREW CONVEYOR POWER INPUT AND CAPACITY

What is the required power input for a 100-ft (30.5-m) long screw conveyor handling dry coal ashes having a maximum density of 40 lb / ft3 (640.4 kg / m3) if the conveyor capacity is 30 tons / h (27.2 t / h)?
1. Select the conveyor diameter and speed Refer to a manufacturers engineering data or Table 8 for a listing of recommended screw conveyor diameters and speeds for various types of materials. Dry coal ashes are commonly rated as group 3 materials, Table 9, i.e., materials with small mixed lumps with nes. To determine a suitable screw diameter, assume two typical values and obtain the recommended rpm from the sources listed above or Table 8. Thus, the maximum rpm recommended for a 6-in (152.4-mm) screw when handling group 3 material is
TABLE 7 Maximum Belt Speeds for Various Materials

TABLE 8 Screw Conveyor Capacities and Speeds
TABLE 9 Material Factors for Screw Conveyors
90, as shown in Table 8; for a 20-in (508.0-mm) screw, 60 r / min. Assume a 6-in (152.4-mm) screw as a trial diameter. 2. Determine the material factor for the conveyor A material factor is used in the screw conveyor power input computation to allow for the character of the substance handled. Table 9 lists the material factor for dry ashes as F 4.0. Standard references show that the average weight of dry coal ashes is 35 to 40 lb / ft3 (640.4 kg / m3). 3. Determine the conveyor size factor A size factor that is a function of the conveyor diameter is also used in the power input computation. Table 10 shows that for a 6-in (152.4-mm) diameter conveyor the size factor A 54. 4. Compute the required power input to the conveyor Use the relation hp 106(ALN CWLF), where hp hp input to the screw conveyor head shaft; A size factor from step 3; L conveyor length, ft; N
MATERIALS HANDLING
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10.15
TABLE 10 Screw Conveyor Size Factors
conveyor rpm; C quantity of material handled, ft3 / h; W density of material, lb / ft3; F material factor from step 2. For this conveyor, given the data listed above, hp 106(54 100 60 1500 40 100 4.0) 24.3 hp (18.1 kW). With a 90 percent motor efciency, the required motor rating would be 24.3 / 0.90 27 hp (20.1 kW). A 30-hp (22.4-kW) motor would be chosen to drive this conveyor. Since this is not an excessive power input, the 6-in (152.4-mm) conveyor is suitable for this application. If the calculation indicates that an excessively large power input, say 50 hp (37.3 kW) or more, is required, then the larger-diameter conveyor should be analyzed. In general, a higher initial investment in conveyor size that reduces the power input will be more than recovered by the savings in power costs. Related Calculations. Use the procedure given here for screw or spiral conveyors and feeders handling any material that will ow. The usual screw or spiral conveyor is suitable for conveying materials for distances up to about 200 ft (60.9 m), although special designs can be built for greater distances. Conveyors of this type can be sloped upward to angles of 35 with the horizontal. However, the capacity of the conveyor decreases as the angle of inclination is increased. Thus the reduction in capacity at a 10 inclination is 10 percent over the horizontal capacity; at 35 the reduction is 78 percent. The capacities of screw and spiral conveyors are generally stated in ft3 / h (m3 / h) of various classes of materials at the maximum recommended shaft rpm. As the size of the lumps in the material conveyed increases, the recommended shaft rpm decreases. The capacity of a screw or spiral conveyor at a lower speed is found from (capacity at given speed, ft3 / h) [(lower speed, r / min) / (higher speed, r / min)]. Table 8 shows typical screw conveyor capacities at usual operating speeds. Various types of screws are used for modern conveyors. These include shortpitch, variable-pitch, cut ights, ribbon, and paddle screws. The procedure given above also applies to these screws.
DESIGN AND LAYOUT OF PNEUMATIC CONVEYING SYSTEMS

A pneumatic conveying system for handling solids in an industrial exhaust installation contains two grinding-wheel booths and one lead each for a planer, sander, and circular saw. Determine the required duct sizes, resistance, and fan capacity for this pneumatic conveying system.
1. Sketch the proposed exhaust system Make a freehand sketch, Fig. 5 of the proposed system. Show the main and branch ducts and the booths and hoods. Indicate all major structural interferences, such as

FIGURE 5 Exhaust system layout.
building columns, deep girders, beams, overhead conveyors, piping, etc. Draw the layout approximately to scale. Mark on the sketch the length of each duct run. Avoid, if possible, vertical drops or rises in the main exhaust duct between the hoods and the fan. Do this by locating the main duct centerline 10 ft (3 m) or so above the nished oor. Number each hood or booth, and give each duct run an identifying letter. Although it is not absolutely necessary, it is more convenient during the design process to have the hoods in numerical order and the duct runs in alphabetical order. 2. Determine the required air quantities and velocities Prepare a listing, columns 1 and 2, Table 11, of the booths, hoods, and duct runs. Enter the required air quantities and velocities for each booth or hood and duct in Table 11, columns 3 and 4. Select the air quantities and velocities from the local code covering industrial exhaust systems, if such a code is available. If a code does not exist, use the ASHRAE Guide or Table 12. Use extreme care in selecting the air quantities and velocities, because insufcient ow may cause dangerous atmospheric conditions. Harmful process wastes in the form of dust, gas, or moisture may injure plant personnel. 3. Size the main and branch ducts Determine the required duct area by dividing the air quantity, ft3 / min (m3 / min), by the air velocity in the duct, or column 3 / column 4, Table 11. Enter the result in column 5, Table 11. Once the required duct area is known, nd from Table 13 the nearest wholenumber duct diameter corresponding to the required area. Avoid fractional diameters at this stage of the calculation, because ducts of these sizes are usually more expensive to fabricate. Later, if necessary, two or three duct sizes may be changed to fractional values. By selecting only whole-number diameters in the beginning, the cost of duct fabrication may be reduced somewhat. Enter the duct whole-number diameter in column 6, Table 11.
MATERIALS HANDLING
TABLE 11 Exhaust System Design Calculations
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TABLE 11 (Continued )
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10.19
TABLE 12 Recommended Exhaust Air Quantities
TABLE 13 Duct Diameters and Areas

4. Compute the actual air velocity in the duct Use Fig. 6 to determine the actual velocity in each duct. Enter the chart at the air quantity corresponding to that in the duct, and project vertically to the diameter curve representing the duct size. Read the actual velocity in the duct on the velocity scale, and enter the value in column 7 of Table 11. The actual velocity in the duct should, in all cases, be equal to or greater than the design velocity shown in column 4, Table 11. If the actual velocity is less than the design velocity, decrease the duct diameter until the actual velocity is equal to or greater than the design velocity. 5. Compute the duct velocity pressure With the actual velocity known, compute the corresponding velocity pressure in the duct from hv (v / 4005)2, where hv velocity pressure in the duct, inH2O; v air velocity in the duct, ft / min. Thus, for the duct run A in which the actual air velocity is 4300 ft / min (1310.6 m / min), hv (4300 / 4005)2 1.15 in (29.2 mm) H2O. Compute the actual velocity pressure in each duct run, and enter the result in column 8, Table 11. 6. Compute the equivalent length of each duct Enter the total straight length of each duct, including any vertical drops, in column 9, Table 11. Use accurate lengths, because the system resistance is affected by the duct length. Next list the equivalent length of each elbow in the duct runs in column 10, Table 11. For convenience, assume that the equivalent length of an elbow is 12 times the duct diameter in ft. Thus, an elbow in a 6-in (152.4-mm) diameter duct has an equivalent resistance of (6-in diameter / [(12 in / ft)(12)]) 6 ft (1.83 m) of straight duct. When making this calculation, assume that all elbows have a radius equal to twice the diameter of the duct. Consider 45 bends as having the same resistance as 90 elbows. Note that branch ducts are usually arranged to enter the main duct at an angle of 45 or less. These assumptions are valid for all typical industrial exhaust systems and pneumatic conveying systems. Find the total equivalent length of each duct by taking the sum of columns 9 and 10, Table 11, horizontally, for each duct run. Enter the result in column 11, Table 11. 7. Determine the actual friction in each duct Using Fig. 6, determine the resistance, inH2O (mmH2O) per 100 ft (30.5 m) of each duct by entering with the air quantity and diameter of that duct. Enter the frictional resistance thus found in column 12, Table 11. Compute actual friction in each duct by multiplying the friction per 100 ft (30.5 m) of duct, column 12, Table 11, by the total duct length, column 11 100. Thus for duct run A, actual friction 5.4(10 / 100) 0.54 in (13.7 mm) H2O. Compute the actual friction for the other duct runs in the same manner. Tabulate the results in column 13, Table 11. 8. Compute the hood entrance losses Hoods are used in industrial exhaust systems to remove vapors, dust, fumes, and other undesirable airborne contaminants from the work area. The hood entrance loss, which depends upon the hood conguration, is usually expressed as a certain percentage of the velocity pressure in the branch duct connected to the hood, Fig. 7. Since the hood entrance loss usually accounts for a large portion of the branch resistance, the entrance loss chosen should always be on the safe side.
MATERIALS HANDLING
FIGURE 6 Duct resistance chart. (American Air Filter Co.)

FIGURE 7 Entrance losses for various types of exhaust-system intakes.
List the hood designation number under the System Resistance heading, as shown in Table 11. Under each hood designation number, list the velocity pressure in the branch connected to that hood. Obtain this value from column 8, Table 11. List under the velocity pressure, the hood entrance loss form Fig. 7 for the particular type of hood used in that duct run. Take the product of these two values, and enter the result under the hood number on the entrance loss, inH2O line. Thus, for hood 1, entrance loss 1.15(0.50) 0.58 in (14.7 mm) H2O. Follow the same procedure for the other hoods listed.
MATERIALS HANDLING
MATERIALS HANDLING
10.23
9. Find the resistance of each branch run List the main and branch runs, A through F, Table 9. Trace out each main and branch run in Fig. 5, and enter the actual friction listed in column 3 of Table 11. Thus for booth 1, the main and branch runs consist of A, D, G, H, and I. Insert the actual friction, in (mm) H2O, as shown in Table 9, or A 9.54(242.3), D 0.42(10.7), G 0.19(4.8), H 0.20(5.1), I 0.50(12.7). Determine the lter friction loss from the manufacturers engineering data. It is common practice to design industrial exhaust systems on the basis of dirty lters or separators; i.e., the frictional resistance used in the design calculations is the resistance of a lter or separator containing the maximum amount of dust allowable under normal operating conditions. The frictional resistance of dirty lters can vary from 0.5 to 6 in (12.7 to 152.4 mm) H2O or more. Assume that the frictional resistance of the lter used in this industrial exhaust system is 2.0 in (50.8 mm) H2O. Add the lter resistance to the main and branch duct resistance as shown in Table 11. Find the sum of each column in the table, as shown. This is the total resistance in each branch, inH2O, Table 11. 10. Balance the exhaust system Inspection of the lower part of Table 11 shows that the computed branch resistances are unequal. This condition is usually encountered during system design. To balance the system, certain duct sizes must be changed to produce equal resistance in all ducts. Or, if possible, certain ducts can be shortened. If duct shortening is not possible, as is often the case, an exhaust fan capable of operating against the largest resistance in a branch can be chosen. If this alternative is selected, special dampers must be tted to the air inlets of the booths or ducts. For economical system operation, choose the balancing method that permits the exhaust fan to operate against the minimum resistance. In the system being considered here, a fairly accurate balance can be obtained by decreasing the size of ducts E and F to 4.75 in (120.7 mm) and 4.375 in (111.1 mm), respectively. Duct B would be increased to 6.5 in (165.1 mm) in diameter. 11. Choose the exhaust fan capacity and static pressure Find the required exhaust fan capacity in ft3 / min from the sum of the airows in the ducts, A through H, column 3, Table 11, or 3300 ft3 / min (93.5 m3 / min). Choose a static pressure equal to or greater than the total resistance in the branch duct having the greatest resistance. Since this is slightly less than 4.5 in (114.3 mm) H2O, a fan developing 4.5 in (114.3 mm) H2O static pressure will be chosen. A 10 percent safety factor is usually applied to these values, giving a capacity of 3600 ft3 / min (101.9 m3 / min) and a static pressure of 5.0 in (127 mm) H2O for this system. 12. Select the duct material and thickness Galvanized sheet steel is popular for industrial exhaust systems, except where corrosive fumes and gases rule out galvanized material. Under these conditions, plastic, tile, stainless steel, or composition ducts may be substituted for galvanized ducts. Table 14 shows the recommended metal gage for galvanized ducts of various diameters. Do not use galvanized-steel ducts for gas temperatures higher than 400F (204C). Hoods should be two gages heavier than the connected branch duct. Use supports not more than 12 ft (3.7 m) apart for horizontal ducts up to 8-in (203.2-mm) diameter. Supports can be spaced up to 20 ft (6.1 m) apart for larger ducts. Fit a

TABLE 14 Exhaust-System Duct Gages
duct cleanout opening every 10 ft (3 m). Where changes of diameter are made in the main duct, t an eccentric taper with a length of at least 5 in (127 mm) for every 1-in (25.4-mm) change in diameter. The end of the main duct is usually extended 6 in (152.4 mm) beyond the last branch and closed with a removable cap. For additional data on industrial exhaust system design, see the newest issue of the ASHRAE Guide. Related Calculations. Use this procedure for any type of industrial exhaust system, such as those serving metalworking, woodworking, plating, welding, paint spraying, barrel lling, foundry, crushing, tumbling, and similar operations. Consult the local code or ASHRAE Guide for specic airow requirements for these and other industrial operations. This design procedure is also valid, in general, for industrial pneumatic conveying systems. For several comprehensive, worked-out designs of pneumatic conveying systems, see HudsonConveyors, Wiley.

Materials Handling: Section 10

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Source: HANDBOOK OF MECHANICAL ENGINEERING CALCULATIONS

Bulk Material Elevator and Conveyor Selection 10.9

CHOOSING CONVEYORS AND ELEVATORS FOR SPECIFIC MATERIALS TRANSPORTED

Physical condition kg / m3 Reaction on conveyor Comment Preferred conveyors* Preferred elevators*

Fragile Packs Sluggish e e e e e e e e

Sluggish Fragile Sticky Sluggish c c c c c Corrosive Free-owing Free-owing Keep cool

May be tough Poisonous

Pulv. Dry 1200 b b, c b b, c 163,200 Abrasive May be sticky a, i, j

Sometimes difcult Dusty Sticky Polisher Difcult Corrosive if wet

MATERIALS HANDLING 10.4

DETERMINING EQUIPMENT DESIGN PARAMETERS FOR OVERHEAD CONVEYORS

MATERIALS HANDLING 10.6

FIGURE 2 Clearance design for overhead conveyor turns and rises.

TABLE 2 Selected Load Clearance on Inclined Track for Overhead Conveyors

30 1038 1378 1558 2078 26.4 35.2 39.7 53.0

40 914 1214 1378 1838 23.5 31.1 35.2 46.7

50 734 1038 1138 1512 19.7 26.4 28.9 39.4

60 6 8 9 12 15.2 20.3 22.9 30.5

MATERIALS HANDLING 10.8

FIGURE 3 Power- and free-trolley overhead conveyors.

BULK MATERIAL ELEVATOR AND CONVEYOR SELECTION

MATERIALS HANDLING 10.10

TABLE 3 Bucket Elevators

TABLE 4 Conveyor Characteristics

MATERIALS HANDLING 10.12

TABLE 6 Minimum Belt Width for Lumps

SCREW CONVEYOR POWER INPUT AND CAPACITY

TABLE 7 Maximum Belt Speeds for Various Materials

MATERIALS HANDLING 10.14

TABLE 8 Screw Conveyor Capacities and Speeds

TABLE 9 Material Factors for Screw Conveyors

TABLE 10 Screw Conveyor Size Factors

DESIGN AND LAYOUT OF PNEUMATIC CONVEYING SYSTEMS

MATERIALS HANDLING 10.16

FIGURE 5 Exhaust system layout.

TABLE 11 Exhaust System Design Calculations

TABLE 12 Recommended Exhaust Air Quantities

TABLE 13 Duct Diameters and Areas

MATERIALS HANDLING 10.20

FIGURE 6 Duct resistance chart. (American Air Filter Co.)

MATERIALS HANDLING 10.22

FIGURE 7 Entrance losses for various types of exhaust-system intakes.

MATERIALS HANDLING 10.24

TABLE 14 Exhaust-System Duct Gages

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