bulk

SOHdS

Volume 21

Number 1

Design of Belt and Apron Feeders

January/February 2001

An Overview of Feeder

Design

Belt and
Apron Feeders

Focusing

on

Roberts, Australia

A.w.

Basic

2.

Summary

Objectives for Uniform

Draw-Down
design and performance focussing on
belt and apron feeders is presented The importance of correct
hopper and feeder interfacing is stressed The objective is to
achieve uniform draw-down in the hopper and procedures for
achieving this objective are given For the belt and apron feeder,
the required divergence angle for the interface zone to achieve
uniform draw-down in the hopper is determined Theories relating to the determination of feeder loads and corresponding
drive powers are reviewed Special attention is given to the requirements of the interface zone geometry which ensures that
belt or apron slip is avoided and wear is minimised The need for
controlling feeder loads is stressed and procedures for reducing
loads and power under start-up conditions are presented

An

overview

of feeder

a fully active hopper outlet, the capacity of the feeder must progressively increase in the direction
of feed It is important to note that the increase in feeder capacrty cannot be arbitrary Rather, it must be pre-determined if uni-

For unrform draw-down with

form draw-down

is to

be achieved This may be illustrated with

respect to some of the more common types of feeders used

practice commencing with the screw feeder
1 shows a screw feeder

Fig

which the

in

from the

rear

to the front as

arrangement, mainly due

to the fact that the volumetric effi-

ciency of the feeder decreases with the

as

A feeder

is a

shown To

tapered shaft
Fig 2

Introduction

and shaft diam-

pitch progressively increases

illustrated This is not a satisfactory

eters are each constant, while the

direction of feed The feeder will draw

1.

screw

in

overcome
in

this

expanding pitch

in

the

from the rear

preferentially

problem, the screw requires both a

expanding pitch as illustrated in

addition to the

device used to control the gravity flow of bulk solids

from storage such as from a bin or stockpile While there are

several types of feeders commonly used, it is important that
they be chosen to suit the particular bulk solid and to provide

Time 0

the range of feed rates required It is also important that feeders

be used in conjunction with mass-flow hoppers to ensure both
reliable flow and good control over the feeder loads and drive
powers Correct interfacing of feeders and hoppers is essential
if performance objectives such as uniform draw of material over
the whole of the hopper outlet is to be achieved

AAAU A A

Another aspect of hopper design and feeder interfacing concerns the need to control feeder loads and minimise drive

torques and powers In the case of belt feeders, for example,

the design of the hopper and feeder interface must take account of the need to prevent slip between the bulk solid and the
belt surface This

is

essential if belt

wear is to

Rg

expanding pitch Feed

screw

occurs

AI

v'v

diameter constant shaft diameter and

preferentially from

rear

of

hopper

be avoided

Rg 2

This paper presents an overview of relevant aspects of feeder

design which address the foregoing matters While the general
principles apply to all feeders, the paper focuses, mainly, on belt
and apron feeders A selection of references
given at the end of the paper [1 -8]

Screw feeder with constant

on

this

subject

is

Screw feeder with constant

expanding pitch Results

in

screw

diameter

tapered shaft diameter and

in hopper

unrform draw down

TTTn
Increasing

Pitch

Constant
Pitch
J
N

Roberts Emeritus Professor and Director Centre for Bulk Solids and
Technologies University of Newcastle University Drive CaHaghan,
+61 2 49 21 60 67, Fax +61 2 49 21 60 21.
NSW 2308 Australia Tel

AW

Paniculate
E mail

engar@cc

newcastle edu

Details about the author

on

au

page 113

Tapered Shafi

13

bulk
Design of Belt and Apron Feeders

Volume 21

Number 1

January/February 2001
handling

In the

of vibratory feeders, there is a tendency for feed to

preferentially from the front. To overcome this problem, it
is recommended that the slope angle of the front face of the
hopper be increased by 5 to 8 as illustrated in Fig. 3. Alternatively, the lining surface of the front face in the region of the outlet may be selected so as to have a higher friction angle than the
other faces. Apart from providing flexible support, the springs
assist in controlling the feeder loads.
case

occur

In the case of belt and apron feeders, a tapered opening is required as illustrated in Fig. 4. The triangular skirtplates in the
hopper bottom are an effective way to achieve the required divergence angle X.. It is often stated that the angle X should range
from 3 to 5, but this leads to excessively wide belts or aprons
in the case of feeders with large /_/S ratios. As will be shown, A,
angles smaller than those stated lead to optimum performance.
An important feature of the diverging skirts is the relief provided
to skirtplate drag.
The gate on the front of the feeder is a flow trimming device and
not a flow rate controller. The height of the gate is adjusted to

give the required release angle and to achieve uniform draw

along the slot. Once the gate is correctly adjusted, it should be
fixed in position; the flow rate is then controlled by varying the
speed of the feeder. An alternative arrangement is to use a diverging front skirt or brow as illustrated in Fig. 4. This has the
advantage of relieving the pressure at the feed end during discharge and forward flow.

3.

Feeder Performance
Characteristics

Fig.

3:

Vibratory feeder

Under uniform hopper draw-down conditions,

shear

zone

shear

zone

may be assumed to exist

as

an

'idealised'

shown in

Fig. 6. The
'wedge-shaped' and

is assumed to be tapered or
by the release angle tp. It is also assumed that the velocity profiles are approximately linear as illustrated. In the extended skirtplate zone, the velocity profile is substantially constant with the bulk solid moving at a average velocity equal to
the belt velocity. Since the average bulk solid velocity at the exit
end of the hopper skirtplate zone is less than the average velocity in the extended skirtplate zone, there will be a 'vena contracta' effect with the bed depth
y^ less than the bed depth /-/ at

defined

the exit end of the feeder.

The

complexity of the shear zone of belt feeders has been highlighted in a comprehensive study performed by Schulze and
Schwedes [5]. They showed that the shear zone may be divided
into three regions, the lengths of the regions being predicted on
the basis of the 'Coulomb principle of minimal safety'. This assumes

Shear Surface

that the rupture surface in a consolidated bulk solid will

a way that the bearing capacity of the solid is

develop in such
minimised.

Belt/Apron
There will be

velocity gradient developed in the shear zone, as

indicated in Fig. 5. The characteristic shape of this profile depends on the properties of the bulk solid, the feeder speed and
the geometry of the hopper/feeder interface.
Fig.

4:

Fig.

5:

Velocity profile

in

shear

zone

Belt and apron feeder

O \O

Divergent Front Skirt or

/Brow to Relieve
Pressure at Feed End

ALTERNATIVE ARRANGEMENT

14

bulk
Volume 21

Design of Belt and Apron Feeders

January/February 2001

Number 1

Velocity Distributions:
Exit
Shear Zone
^-

Vena
Contracta'
ffect

Extended Zone

Lh
Shear Zone

Fig

Bett/apron feeder

assumed shear

zone

and

veloaty profiles

where

Feed Rate Distribution

3.1

a,

Refemng to Fig 6, the mass throughput of the feeder will vary

along the feed zone At any location x, the throughput O(x) is
given by

20-h+Xo)

2(/_h +Xq)
/A(x)
v^

cross-sectional

velocity of

the belt

volumetric

efficiency

bulk density

area
or

The parameters
apron

in

Eq (6)

tamp

are

of feeder

clearance at

S,

width of opening at

divergence angle

tp

release

The volumetnc efficiency t^(x), which relates the actual throughput to the maximum theoretical throughput based on the bulk
solid moving forward with the belt or apron without slip, is given

Xq

dimension defined

length

by

Cg

t^(x)
p

in

feed

zone

y<.

(assumed constant)
(2)

2xtanX.)(y<.

(3)

where

v,(x)

(6)

(D

x)

where

average feed velocity at location x, given by

/_

3.2

Feeder

At the

discharge

rear

of feeder

angle

of

velocity

rear

hopper

in

Fig

shear

zone

distribution factor at

L^

Throughput
or

feed end of the hopper the

throughput

is

given by

v,(x)-(1+C)^

(4)

(7)
C

velocity distnbution coefficient

assumes

there

has been shown

[6-8]

Eq (4)

by

is no

at location

slip at the belt or apron surface It

throughput from Eq (3) is given

that the

where

volumetnc

bulk

efficiency

at exit

(8)

Also

the cubic equation

where

density

in

extended

zone

Q(x)

(5)

It is noted that p^ < p since the consolidation pressures

tower in the extended zone

are

15

Design of Belt and Apron Feeders

Volume 21

Hence

4.2

1+C,

(9)

Number 1

opening

be such that

to ensure

satisfactory

1.0

<

gate height

Preferably

flow in the extended

H to the width of
0.75 in order

skirtplate

Q'(x)

is

quadratic, which means that Eq. (10)

problem, an optimum
performance may be achieved by setting
cannot be satisfied. To overcome this

dQ'(x)

zone.

Q"(x)
This is illustrated

Optimum Interface Geometry

Based

0 at

(11)

by the surface profile shown

the

foregoing analysis, it has been

optimum divergence angle X is given by

the

4.1

handling

Often the requirement of Eq. (10) is impossible to achieve. In the

case of a belt or apron feeder, for example, Eq. (5) for Q(x) is

dx

4.

2001

Optimum Divergence Angle

cubic in form and

It is desirable that the ratio of the

January/February

on

in

Fig.

shown

8.

[6, 7],

that

Conditions for Uniform Draw-Down

e

Draw-down in the hopper is related to the feed in the feed zone

of the mass flow as illustrated in Fig. 7. The

tanX

by the continuity

condition for uniform draw-down, which represents the

mum performance, is such that

(12)

I-0.5

opti-

dQ(x)
constant

(10)

dx

That is, the gradient of the

throughput along

the feed

zone

constant.

is

The influence of the feeder L^/ ratio on the optimum values of

X for a range of clearance ratios is illustrated in Fig. 9. The optimum divergence angle X for uniform draw-down is shown to
decrease with increase in L^/S ratio, the rate of decrease being
quite rapid at first but lessening as the L^/ ratio increases.

yc/H
yc/h
yc/H
yc/H

Q(x)

8:

Fig.

Optimum divergence angle

9:

4.3

U dQ'(x)

^J

dx

0.75; C

vs.

Ly

ratio for

range of clearance ratios.

0.5

Yc
+r^Vi

Use of Transverse Inserts

In the

case

L^/S

5, the

of feeders

employing long opening slots, that is

Fig. 10,
can assist in promoting uniform draw of bulk solid from the hopper along the length of the feeder. With reference to the latter,
the inserts assist in establishing the required release angle along
Fig.

16

optimum draw-down

0.2
0.3

RATIO UB

Contunuity of feed

Condition for

ti

Fig.

dQ(x)

Q(x)
7:

dQ(x)

Fig.

>

10:

use

of transverse inserts, as illustrated in

Use of transverse inserts in

long feeder

Volume 21

Number 1

January/February

Design of Belt and Apron Feeders

2001

For comparison purposes, the performance of a feeder having

the same feed rate as the optimum feeder but with a larger divergence angle of 3 is also presented The relevant graphs are
shown by dotted lines In this case, the gradient A/q'(x) for this

0.95

case increases
>

0.9

hopper

toward the feed end which indicates that the

will draw down

preferentially from the

front

>o
LU

5.

Feeder Loads

5.1

Stress Fields

Basic

Concepts

0.85

FFI
LU

0.8

LU

0.75

07

>

0.65

06
0

DISTANCE FROM REAR OF HOPPER

(m)

The determination of feeder loads and dnve powers requires a

knowledge of the stress fields generated in the hopper during
the initial filling condition and during discharge The relationship
between the vertical pressure p^, generated in a mass-flow bin
dunng both filling and flow and the feeder load O is illustrated in
Fig 12 Under filling conditions, a peaked stress field is generated throughout the entire bin as illustrated Once flow is initiated, an arched stress field is generated in the hopper and a
much greater proportion of the bin surcharge load on the hopper is supported by the upper part of the hopper walls Consequently, the load acting on the feeder substantially reduces as
shown in Fig 12
It

Fig

Throughput

11

characteristics of bett feeder

Case 1 optimum >.

Case 2 >.

1 54

the feeder The inserts also assist

in

C,

05

L,/8

reducing

is

quite

common

conditions to be

the loads on the

feeder The inserts may incorporate diverging brows as illustrated in order to smooth the flow at the transitions

for the load acting on the feeder under flow

the order of 20% of the initial load The

in

arched stress field is quite stable and is maintained even if the

flow is stopped This means that once flow is initiated and then
the feeder

field

is

is

stopped while the bin

retained and the load

on

still full, the arched stress

is

the feeder remains at the

duced value The

discussed

4.4

Belt Feeder

As

example,

is

an

is

Example

the case of a belt or apron feeder with L/S = 5

throughput O(x) and gradi-

considered For convenience, the

ent of the

in

re-

subject of feeder loads and performance

some detail in Refs [1 -4]

throughput O'(x)

are

expressed

in

normalised form

as

5.2

Feeder Loads

Design Equations

Consider the mass-flow hopper and feeder of Fig 13 It needs

to be noted that the depth of the hopper
should be such that

Zg

follows

Zg/D

>

0 67

in

order to ensure that the

surcharge

pressure

Pg

be adequately supported by the upper section of the hopper walls The design equations used to determine the feeder
loads are summarised below

can

d/Vp(x)
and

A/q(x)

(13)

/Vq'(x)
dx

11 shows the volumetric

Fig

meter

Cg

A/q(x)

and

efficiency r^(x), throughput

gradient /Vq'(x) for the case of y^/H 0
=

0 5 The full lines for

para1 and

A/q(x) and A/q'(x) correspond to the opX

front of the feeder

Fig

12

as is

bulk mass The

the feeder and

Vertical pressure and load variations

on a

corresponding power

general expression for

the load 1/

in

p^

vertical pressure

area

re-

the stored

is

y-Pvo^o
where

>Aq

expected

Initial

on

quirements vary according to the stress condition

1 54

and, as shown, the gradient

divergence angle
A/q'(x) is virtually constant indicating uniform draw-down in the
hopper The volumetric efficiency decreases from the rear to the
timum

The loads acting

(14)

on

feeder surface

of hopper outlet

feeder

Flow

Filling

Feeder
Load 4

Filling

Peaked
Stress
Field

Arched

Pv.

Stress

Field

Time
vof

(a)

Stress Fields

(b) Feeder Loads

17

Design of Belt and Apron Feeders

January/February 2001

Number 1

Volume 21

Feeder Loads

6.

Initial
6.1

handling

Condition

Filling

Design Equations

applies when the feed bin is initially empty and then filled
is not operating Research has shown that the
initial filling loads can vary substantially according to such fac-

This

while the feeder

tors

as

filling and height of drop of solids

pact effects

rate of

as

may

produce

im-

uniformity of filling over the length and breadth of the feed

bin, asymmetric loading will produce a non-uniform pressure
distribution along the feeder
clearance between the

hopper bottom and feeder surface

degree of compressibility of bulk solid

rigidity of feeder surface

For the initial

the stress field

filling condition,

the

in

hopper

is

that is, the major principal stress is almost vertical at

The determination of the initial surcharge factor q,
location
any
can be made by using an appropriate value of 'y' in Eq (19) The

peaked,

Fig

Loads

13

feeder

on

following the procedure established by

[1], the load may be expressed in terms of a nondimensional surcharge factor as follows
For

convenience,

following

Arnold et al

For

cases are

considered

totally incompressible bulk solid and

minimum

rigid

feeder with

clearance, the upper bound value of q, may be ap-

0 for
proached The upper bound value corresponds to y
which the vertical pressure in the hopper is 'hydrostatic' In
this case the ratio of normal pressure to vertical pressure is
=

\/

where

qYL^-^^^

non-dimensional

p g

bulk

(15)

surcharge factor

given

by
tana

specific weight

bulk

/.

length

width of slot

/Ch,

(20)

tana

density
of slotted opening
or

with y

tan^

0, the upper bound value of q,

hopper symmetry factor

0 for plane-flow hopper
1 for conical hopper

Q,

This equation

Eqs (14)

and

(15)

,2tana[

U)

w
d

nutlet

analysis

on an

For

For

very
very

feeder, y

of the pressure distribution in the hopper,

it may be shown that the vertical pressure acting at the hopper

Based

(21)

to the pressure at the outlet

corresponds

being

'hydrostatic'

that

*"

obtained from

I 3

It follows from

is

Eq (19) which becomes

diameter of circular opening

incompressible bulk solid

and

bulk solid and

compressible

0 1

stiff feeder, y

flexibly supported

0 9

For a moderately compressible bulk solid stored above

flexibly supported feeder, y 0 45

is

Recommended Value of q.

Pvo

where

Pg

The exponent

'y'

Ps"

2(/-1)tanaJLD

|/~

2(/-1)tana

surcharge pressure acting

in

Eq (17)

is

While the value of q, may be determined using an appropriate

value of y in Eq (19), from a practical point of view, it has been
established that a satisfactory prediction of q, may be obtained

given

at the transition

from

by

^'

Uy

tan(j).
-1

/^ the ratio of normal pressure at the

corresponding average vertical pressure
From

is

2p,tana
+

(22)

(18)

tana

where

I 2tana I

The vertical load

hopper wall

I/,

is

given

by

to the

Eqs (16) and (17) a general expression for the non-disurcharge pressure may be obtained That is,

mensional

(23)

Mass and Expanded-Flow

Surcharge Load
Bins
Initial Filling Condition

6.2

The computation of the initial vertical load acting

r2ps(/-1)tana

2(/-1)tana1
Two

cases are

flow condition,

18

of importance, the initial

discussed

are now

(19)
D

filling condition

and the

on a

feeder

re-

surcharge pressure Pg acting at the

transition of the feed hopper It is to be noted that the flow load
acting on a feeder is independent of the surcharge head The
determination of the initial surcharge pressure Pg depends on
the type of storage system employed
quires

knowledge

of the

bulk
$OMdS

Number 1

Volume 21

Design of Belt and Apron Feeders

January/February 2001

Dc

It

Us

is

K,

<t>

noted that

channel

is

in

for

cylinder Normally

wall friction

0 4

angle for cylinder

the case of the expanded-flow bin, if the flow

pre-formed, then the dimension D may replace D<.

in

Eq. (25)
The effective
is

given

surcharge

head for the

heap

on

top of the cylinder

by
H.

(26)

mg+2
where

Hg

mg

6.3

(a) Funnel-Flow
Rg

14

The

Referring

Fig 14,

to

the

surcharge pressure Pg

is

given

by the

use

is

'hydraulic'

surcharge

triangular surcharge

feeder

Reclaim

Stockpiles

of mass-flow reclaim hoppers and feeders under stock15 The initial load \/ on the reclaim
in Fig

illustrated
is

flow load

dependent on the effective surcharge head, while the

V, is independent of the head as illustrated.

The determination of

hwhere

0 for

piles
Janssen equation:

1 for conical

Surcharge Load Gravity

Initial Filling Condition

(b) Expanded-Flow

Mass-flow and expanded-flow bins

surcharge head

or

(24)

a,

effective radius defined

surcharge head and pressure in the case

somewhat uncertain owing to the significant
variations that can occur in the consolidation conditions existing
of stockpiles

is

within the stored bulk solid

as

bulk solid

is

The state of consolidation of the

influenced by such factors

as

stockpile management and loading history

for mass-flow bin

2(1

(25)

2(1+mj

loading and unloading cycle

times and

length of undisturbed

storage time

for expanded-flow bin

variations in moisture content

m^

/-/

0 for

degree of segregation

long rectangular cylinder

1 for square or circular

cylinder

height of bulk solid

contact with

in

variations

cylinder

walls
Fig 15

Gravrty

reclaim

in

the

quality of bulk solid

over

long periods of time

compaction effects of heavy mobile equipment that may operate on the surface of the

stockpile.

stockpile

Hydrostatic
Head

Pre-formed
Rathole

Surcharge

Initial

Pressure

FeederLoad

Effective Head

19

bulk
Design of Belt and Apron Feeders

Case 1:

Uniformly Consolidated Stockpile

Highly Incompressible Bulk Solid

January/February

Number 1

Volume 21

SOHdS

2001

+sm6

(31)

Fm

-sin

cos

2 (ri

a)

(27)
Hence
i e

the effective head

is

This

to the actual head

equal

rarely occur in practice A

applied through the use of the

most conservative solution and would

less conservative solution may be

Rankine pressure or head, i e

Pvod

the

is

is

p^

given

Ps
where

<j)

angle

^s

Pvod

cos

(33)

Ps-

2(/-1)tanaJLD

2(/-1)tana

(28)

*b

of repose

Case 2: Pre-Formed Rathole

(32)

^Fm Pvof

by Eq (17) Hence,

where

or

Flow Channel

(34)

-1

tana

Since, during the initial filling process, there will be

mation of the bulk solid

some

defor-

the flow channel relative to the sta-

in

tionary material adjacent to the flow channel at the hopper interface, the surcharge pressure will be significantly reduced
Furthermore, during subsequent filling and emptying, the
rathole that is formed acts as a pseudo bin and serves to reduce
the surcharge pressure In such cases, the effective head may
be estimated using the Janssen equation following the procedures described in Section 6 2 for an expanded flow bin In this
case the cylinder diameter is the actual rathole diameter Dj, and
the wall friction angle is estimated on the assumption that the
maximum shear stress occurs during flow On this basis, $ is
given by
=

where

In many

tan

effective

(29)

(sin )

angle

(35)
2-sin8(1
1 r
2

The force

is

wall friction

sin

angle

(j)^

hopper half-angle

effective

friction

angle of internal

at the outlet and is

acting

is

such that the

as-

where

/*

is,

(30)

K,tan<|>
In this case f?

(36)

(37)

ymptotic value of the Janssen pressure may be applied That

Ps

2(1 +sincos2ri)

of internal friction

the H/ft ratio of the ratholes

cases

and

the effective radius of the rathole

or

flow channel

l-m)

area

of outlet

0 for

plane-flow

or

wedge-shaped hopper

1 for axi-symmetric flow

or

conical

hopper

Alternatively, the non-dimensional surcharge factor q,

tamed from Eq (16)

is

ob-

Pvod

(38)

7.

Feeder Loads

Once flow has been initiated,

Flow Condition

an

arched stress field

is

set up

in

hopper Even if the feeder is started and then stopped, the

arched stress field in the hopper is preserved In this case, the
hopper is able to provide greater wall support and the load on
the feeder, together with the corresponding drive power, is significantly reduced While Eq (19) may be applied by choosing
an appropriate value of 'y', some difficulty arises due to the redistribution of stress that occurs at the hopper/feeder interface

Combining Eqs (33)

and

(38)

the

procedure, based on Jenike's radial stress

theory has been presented in Refs [1, 3] This procedure has
some shortcomings inasmuch as the influence of the surcharge
pressure Pg, although small, is ignored While the hopper halfA well-established

angle

is

included

in

the

the

analysis,

aspect

ratio

of the

=/C

Fm

2(/-1)tana

Fig

16

Stress fields at

1)tanaJ [D

hopper and feeder interface

Arched

Stress
hopper is
presented

An alternative

not taken into account

in

Refs

[7, 8]

and

is now

The redistribution of the stress field

tween the

hopper and the feeder

7.1

Flow Load

In this

case

peaked

is

the stress field

with the vertical

in

Field

summarised
in

the clearance space bein Fig 16

illustrated

Hopper
Shear Zone

Equations
the shear

zone is

assumed to be

design pressure p^ being equal

major consolidation pressure a..

multiplier /Cp^ is introduced
20

is

approach

to the

On this basis, the pressure

Pnof
Feeder

bulk
solids

7.2

Volume 21

Experimental

Design of Belt and Apron Feeders

January/February 2001

Number 1

Results

17 shows a comparison between the predicted and experimental results for the feeder test rig described in Refs [3 4]
The flow load has been adjusted to allow for the weight of bulk

Fig

material

in

the results

the shear and extended

are in

skirtplate

In

zones

D=*0S3

general,

reasonable agreement
a

=15*

as-

Belt and

8.
The

general layout of

belt

or

apron feeder

i
n

is

shown

in

Fig

o>

o
ii

'/

Apron Drive Resistances

The components of the drive resistance

/
/

18

00

are

shear resistance of bulk solid

skirtplate friction in the hopper

beyond the hopper

zone

and

in

the extended

zone

apron support idler friction

in

belt

iv

elevation of the bulk solid

or

01O ?

analysis of these various resistances are given in

[2 4] Two particular aspects concerned with the hopper/feeder interface are

Details of the

RowQ,

Refs

the force to shear the bulk solid

the bulk solid and

01

belt/apron friction

to

zone are
on

illustrated

in

Fig

18 The

the shear

(41)

F=ngl/
(.i^
V
Rg 18

Comparison

[3 4] Bulk

plane is shown diagrammatically and will change from the initial filling case to the
flow case Under operating conditions, the resistance F parallel
to the feeder surface is given by

where

17

Force to Shear Bulk Solid

The forces acting in the feed

vertical pressure distribution

0.2

prevent slip
Fig

8.1

Experimental Values

03

04

HEAD h

(m)

(Predicted)

06

predicted and experimental results

plastic pellets

between

material

05

07

feeder test ng

or breakaway conditions are more difficult to predict

depend on such factors as the hopper and feeder interface
geometry skirtplate geometry feeder stiffness the compress
ibility of the bulk solid and whether any load control is applied In
the absence of any of the foregoing information a reasonable
estimate of the breakaway force F is

Starting
and

friction coefficient

equivalent

vertical force

(42)
on

shear surface

Hopper geometry for feeder load determination

-COS0

SECTION 3-3

21

bulk
Design of Belt and Apron Feeders

An expression for ^ based

Volume 21

the geometry of the feed

on

Number 1

January/February

jMi

2001

zone is,

[6-8],
-

smxp

Theta

(43)
(6

cos

where

Assuming

feeder

xp)

HgSin(6

-10 Deg.
0 Deg.
10 Deg.

slope

xp

release

Hg

coefficient of internal friction

that the

Theta
Theta

angle
shear stress

maximum

shear

on

plane

corresponds

to the

failure condition then

effective

By way of example, a
Eq (43) is shown in Fig
the feeder slope angle
with

increase in

sin

Hg
8

where

angle

set of

(44)

of internal friction

design

for j^ based

curves

on

19 As indicated, ^ is sensitive to both

6 and the release angle ip, decreasing

both these

12

10

19

Equivalent friction for belt and apron feeder

16

14

(Deg)

angles
Fig

8.2

RELEASE ANGLES
=

50

Skirt pi ate Resistance

In the

steady flow

Assuming steady flow, the skirtplate resistance is determined

for the hopper and extended sections (see Fig 18) as follows
Hopper Section

Wh)

where

(46)

Extended Section

(Section Beyond Hopper)

I/V^
V

feeder load
bulk

y^

y^

Ky

p g

in

the

case

of

the middle

Slope Resistance
(50)

sine

8.4

Belt

or

Apron Load Resistance

Hopper Section

J
where

Load

(45)

cos

K^

as in

for flow may be

range

8.3

(2\/

of slow feed velocities,

case

apron feeders, the value of

(51)

(47)

(48)

L^

Extended Section

(52)

density

where

average height of material against

for hopper section
average height of material
for extended section

idler friction

skirtplates
8.5

Empty

Belt

or

Apron Resistance

against skirtplates

fb

ratio of lateral to vertical pressure at skirt-

where

w^

belt

total

or

(53)

^b^b

weight

apron

per unit

length

plates
g

acceleration due to gravity

slope angle

.^

average width between

jAg

L^
Lg
W^
Wg

9 81

8.6

skirtplates

equivalent skirtplate friction coefficient

friction coefficient for

length

of

skirtplates
length of skirtplates

weight

of material

weight

of matenal

It should be noted that

in

the

in

in

hopper

Lg

(m/s^)

Hgp

length of belt

(L

L^

Xg)

Force to Accelerate Material onto Belt

1 5

or

Apron
(54)

skirtplates

for

hopper

where

section

for extended section

skirtplate

extended

zone, the

zone

[m]

of

skirtplate

Vb

mass

belt

the force

flow rate

or

apron

hopper

Usually

zone

It should be noted that for

skirtplates

are

di-

Hence the fnctional resistance, and hence the normal

pressure on the skirtplates, will be less than in the case of parallel skirts Referring to Fig 18,
^y be estimated from

speeds should

(given by Eq (8))

speed

F^ is negligible

be

kept

low

good performance, belt and

Generally ^sO5 m/s

apron

verging

8.7

Drive Powers

n-gph

^igp

Msph
where

half

rt

The power

tanX

computed from

tanX

12

Resistances)

(55)

divergence angle of skirtplates

0 6 The lower limit

The pressure ratio /<^ is such that 0 4 s K^
may be approached for the static case and the upper limit for

22

is

(49)

where

r|

efficiency

v,

average belt

or

apron

speed

bulk
SOlMS

Volume 21

Design of Belt and Apron Feeders

January/February 2001

Number 1

For start-up, v^ ay be approximated as half the actual speed

For the flow condition, v^ will be the actual belt or apron speed

A more detailed

during running

function of release

analysis

20 illustrates the

Fig
_

5,

angle

0,

given in Ref [8] As an example,

belt or apron friction angle as a
to prevent slip for the case when

is

minimum

50,

sm

0 76,

Condition for Non-Slip

9.

1+C,
The volumetnc

The condition for non-slip between the belt and bulk solid under
steady motion can be determined as follows

(56)
VCOS

(<l>s

v)

with the belt

or

^e"1-05

total

F=

weight of bulk solid

^sph

in

the

""

^spe

t^l

is

skirtplate

by

on feeders and the torque during start-up may be

by ensunng that an arched stress field fully or partially
the hopper just pnor to starting This may be achieved
procedures as

F^

in

such

cushioning

resistance

in

the

hopper,

that

is

leaving

quantity of

mater-

buffer storage This preserves the arched

stress field from the previous discharge as illustrated in

(normally

the hopper

in

Fig.

feeder load acting on shear surface

the flow load is relevant)

Controlling Feeder Loads

exists

hopper outlet
used)

For normal feeder speeds

V

for the feeder

plotted

The loads

force to accelerate the bulk solid

have been

skirtplate zones

lal

Fg

graphs

contact

in

force to shear material at

The

controlled

(normally F, for flow

^sp

and

Hv(^-

apron

MgV

such that

is

slope angles, -10, 0, and 10 As indicated, the minimum belt

^
tan
angle <t^
|^ are shown to be sensitive to both
changes in feeder slope and release angles

10.
=

efficiency

friction

COS 8

Wj

friction coefficient for bulk solid

0 05-.

as

21

starting the feeder under the empty hopper before filling

commences

cos

(<(>s

v)

using transverse,

Neglecting Fg,

alternative expressions for n^. and tan

j^

Vcos

(<|>s

u)

WV

inserts

raising the feeder up against the hopper bottom during filling

and then lowering the feeder to the operating condition prior

(57)

Mt>s

tnangular-shaped

are

to

cos 8

starting In this way

an

arched stress field may be

partially

established
or

Rg

21

Application of load cushioning

to control feeder loads

C,,,)co.e

cos(e, -)p(c,

(58)
W
where

C,

We
and

C^

Also, for small clearances y^.

0 5

H
Fig

20

Minimum

belt/apron friction angle

^-5 '^.0

6-50-

Ms -si6-0

to

prevent sip

76

OpdrrwnX-1 54-C,-0

Hh

non

No

Cushioning

Feeder

35-

Load

HA
4

RELEASE ANGLE y

10

(beg)

12

1 0

Hh

23

bulk
Design of Belt and Apron Feeders

Volume 21

Number 1

January/February

2001

handling

Initial

Jacking
Screws

Clearance
Use of

22

Fig

jacking

screws

to lower the feeder

The choice of mounting arrangement for a feeder can assist in

generating a preliminary arched stress field near the outlet suffi-

References

cient to moderate both the initial feeder load and

[1]

In

some

cases

belt feeders

are

mounted

on

where the initial deflection of the springs during

can assist in generating an arched pressure field

starting power.
helical springs,
filling of the bin
near

arrangement is to incorporate a jacking system to lift the feeder up against the bottorn of the hopper during filling. Before starting, the feeder is released to its operating position sufficient to cause some
movement of the bulk solid

feet. The use of

order to generate

cushion ef-

slide gate or valve above the feeder is another

the initial load and power. The gate is closed dur-

way of

ing

in

Solids:

[2]

interfaces
Vol. 2

[3]

in

belt and apron feeders; bulk solids

Roberts A.W., Ooms M. and Manjunath K.S.: Feeder load

bulk solids from mass-flow bins; Trans.

'emergency' purposes, the provision of jacking screws as ilin Fig. 22 can be used to lower the feeder should a
peaked stress field be established on filling and there is msufficient power to start the feeder. Lowering the feeder can induce,
either fully or partially, an arched stress field and allow the feeder
For

to be started. This

stockpiles

1000 kPa may be

precaution

is

[4]

surcharge
experienced.

pressures

as

high

Manjunath K.S.

Vol. ME9, No.1,

in

mass-flow

erence

of feeder

design and performance

pp. 769-775; Part II Vol. 6

(1986)

No. 5, pp. 903-911.

as

[5]

Schulze, D. and Schwedes, J.: Bulk Solids Flow

in

the

Proc.

Symposium on Reliable
Flow of Particulate Solids (RELPOWFLO II), Oslo, Norway,
23-25 August, 1993.

specific refpresented. The

with

[6]

Roberts, A.W.: Interfacing Feeders with Mass-Flow HopOptimal Performance; Proc. Intl. Conf. on Bulk

pers for

geometry of the hopper and feeder interface for optimum draw-

Materials

down

of

hopper has been examined. It has been shown that

the required divergence angle for the hopper and feeder interface decreases with increase in feeder length to width ratio, approachmg limiting values as the length to width ratio exceeds 5
to 1. The influences of the release angle, divergence angle, aspect ratio of length to width of opening, volumetric efficiency
in

pressure-feeder
hopper/feeder combina-

tions; bulk solids handling, Part I Vol. 6 (1986) No. 4,

Concluding Remarks
to belt and apron feeders has been

I.E.Aust., MechanApril 1984, pp. 49 -61.

and Roberts, A.W.; Wall

load interactions

useful for feeders installed

where

Engineering,

Hopper/Feeder Interface;

overview

handling,

(1982) No. 2, pp. 281-294.

and power requirements in the controlled gravity flow of

been started.

lustrated

An

Univer-

Reclaim power and geometry of bin

Rademacher, F.J.C.:

ical

11.

Handling: TUNRA, The

limiting
filling and opened after the feeder has

under

Flow and

Storage,

sity of Newcastle, 1982

the outlet

and reduce the initial load. An alternative

Arnold, P.C., McLean, A.G. and Roberts, A.W.: Bulk

the

[7]

been reviewed and the influence of the interface geometry

on

Roberts, A.W.: Feeders and Transfers

Recent

Instn.

Develop-

ments; Proc. Bulkex '99, Australian Society for Bulk Solids,

The Instn. of Engrs, Australia and the Centre for Bulk
Solids and Particulate

and bulk solids flow properties have been identified. Procedures

for the determination of feeder loads and drive powers have
the shear resistance and belt and apron slip has also been exammed. The advantages of the arched stress field in the hopper

Storage, Handling and Transportation, The

Engrs Australia, Wollongong, pp. 459-468, 1998.

Technologies, Sydney, pp.

1-1 to

1-27, 29 June- 1 July, 1999.

[8]

Roberts, A.W.: Feeding of Bulk Solids Design Considerations, Loads and Power; Course notes, Bulk Solids Han-

in controlling feeder loads and power have been highlighted and

methods for achieving load control in practice have been identi-

dhng (Systems and Design). Centre for Bulk Solids and

Particulate Technologies, The University of Newcastle,

fied.

1998.

24

bulk
solids

Volume 21

Appendix:

Feeder

Design of Belt and Apron Feeders

January/February 2001

Number 1

Design Example

a reclaim hopper and apron feeder for reclaiming

gravity reclaim stockpile similar to that depicted in
Fig. 15 is considered The stockpile height is 25 m. It is assumed that the surcharge pressure on the hopper is calculated using Eq. (30). The data and calculated loads and pow-

The

case

bauxite

ers are

of

in a

given below.

Hopper Details
Hopper type

plane flow

Hopper half-angle
Hopper opening

dimension S

0m

25

Hopper width at transition, D

Height of hopper section, z
Length of hopper opening, L^

Centre for Bulk Solids &

1.25

5.5

4.5

6.25

Participate

The Centre for Bulk Solids & Particulate Technolois

gies

Feeder Details

Technologies

joint activity of the Universities of

Wollongong, unifying two strong
expertise in bulk solids handling.

Newcastle and

Length of hopper
Length
Total

zone,

/.,

of extended zone,

of opening at exit, /-/

Release

angle,

Skirtplate half divergence angle, X

Volumetric efficiency at exit
Bed depth

extended shirt zone, y^

Width between skirtplates, ,.
in

per metre of

Weight
Belt/apron

belt/apron

idler friction,

streams of

Lg

length of feeder, L

Height

6.25

u^

1.5

8.5

0.8

6.4

1.54

0.8

0.64

1.3

0.05

throughput, Q^,

speed,l^

of:

Bulk Solids

Bulk

Testing, Storage

& Flow

Handling Plant Design

Instrumentation & Control

3kN/m

Feeder

areas

Feeder

The Centre is involved in industrial research in the

Belt

1350t/h

Conveying

Mechanical

Handling

0.3 m/s

Pneumatic

Conveying

Bulk Solid Details

Effective

angle

Wall friction

of internal friction

50

for hopper

30

30

angle

Dust & Fume

Wall friction

angle for skirtplates

Bulk density for hopper section,
Bulk

density

Slurry Systems

for ext. skirtplate zone, p^>

Hopper surcharge pressure, pg

Initial surcharge factor, q,
Flow surcharge factor, q,

t/nrv*

1.7

1.5 t/nrv*

133 kPa

4.42

1.05

Loads and Resistances, Initial Condition;

Feeder load, initial condition,

Shear resistance,

V,

F^

Resistance, hopper skirtplate

zone,

F^

830.6 kN

361.6 kN

198.1 kN

2.61 kN

OkN

Empty belt/apron resistance, F^

2.68 kN

Total initial resistance,

595.5 kN

Resistance, extended skirt

Slope resistance,

zone,

F^

F^,
F

Feeder load, flow condition

Vp

Centre

The

provides a Master of Engineering

(Bulk Solids Handling) and associated
Professional Development Programs embracing
the above topics. Courses are offered throughout
Practice

on a one

week modular basis.

regarding these events,

professional development programs, Master
of Engineering Practice degrees, or the Centre for
Bulk Solids and Particulate Technologies, can be
obtained by contacting:
For further information

other

Particulate
=

F^,

Resistance, hopper skirtplate

Resistance, extended skirt

zone,

zone,

Slope resistance, F^,

Empty belt/apron resistance, F^
Total flow resistance,

Systems

Centre for Bulk Solids &

Loads and Resistances, Flow Conditions

Shear resistance,

Freight Pipelines

Physical Processing

the year
=

&

F^

F^

102.5 kN

52.4 kN

2.6 kN

OkN

2.7 kN

160.2 kN

Feeder Power

University of Newcastle, University Drive,

Callaghan, NSW 2308, AUSTRALIA

Tel.:+61 2 492 160 67
Fax:+61 2 492 160 21
Email:

Power, initial conditions,

40.0 kW

Power, flow conditions,

18.0 kW

P,
P,

Technologies

170.2 kN

engar@cc.newcastle.edu.au

URL: www.bulk.newcastle.edu.au/cbs/

25