TRANSFER CHUTES Principles for calculation and design Kazimierz Golka eee enTRANSFER CHUTES Principles for calculation and designCopysight © 2013, by K-Golks, 6. Bolliger, C. Vai All ight reserved Reproduction or copying or translation of any part ofthis book without permission of the copyright owners is unlawl, Information contained in this book hes hese Summarized trom reiable sourees, publications and the Authors’ experience, Every for has been made by the Authors and Publisher to ensure accuracy in this tare However, no responsibility canbe acepted fr any loss, damage or other consequence "esltingffom is use. Where an ertor i identified by the user it would be appreciated if notification of it could be conveyed back to the Authors 30 that cumoetons wee he ‘made to fiture editions of his book, Should assistance be equted, « sotably sealed enpiner should be employed his book is intended to be a helpful tol for students of mechanical engineering and engineers involved inthe transfer tation and chute design process, The National Library of Australia Catalozuing-in- Publication entry olka, Kazimierz. Transfer chutes: principles for cleuaton and design, ISBN 975.0-646.57674.9 1. Chutes 2. Chutes -Design and construction. 3. Transfer Stations |. Bolliger, George. 11. Vasil Costa mand cover design: Ieneuse Golks Printed by Ligare Poy Ltd, Australie woe76s43 TABLE OF CONTENTS PREFAC ACKNOWLEDGEMENT ‘SYMBOLS AND UNITS INDEX INTRODUCTION, i : 44 General. Impact plates Chute wear Flow of bulk solids Methodology of flow madeling in transfor chutes, -ROPERTIES OF BULK SOLIDS = ‘1 Characteristics of bulk solids 2. Physical properties of bulk solids 3. Flow properties 4 Wall ction 24.1 Genera 2:42 Wall faction angie 2.4.3 Suraco roughness of chu lining matoriis 25. Friclon and flowabiity characteristics of bulk solids 26 Equivalent friction coeticient ey 28 Effective variably ition costicent Wall friction angle tests results 29. Wall fiction angle testing summary 2.10 Examples. CHUTE CONFIGURATION, 34 Flow rate. 3.2 Chute inclination 3.3 Chute dimensions: 3.4 Chute shapes 3.5. Shape of bulk solids ow at conveyor discharge pulley 38. Example. BULK SOLIDS DISCHARGE PROCESS . 4.4 Discharge trajectories from belt conveyors 4441 lnroduston, 412 Trajectory equations 42. Discharge trajectories rom chutes 43 Trejectores from loading spoons 44 Trajectory divergency 45. Trajectory inlrsection pons. 4'51 Stralgh at) impact la 452 Gurved impact plate 453 Loading spoon 46 Examples, 585. IMPINGEMENT PROCESS 5.1. Impingement process description 5.2. Impact theory 5.3. Impingement theory 83.1 ‘Coheslonoss bulk solids 5.32 Cohesive bulk soles. 5.33 Impingement orcs on impact pie 54. Test comparison 55 6. BULK SOLID FLOW THROUGH CHUTE COMPONENTS. 6.1 Mathematical models 8.2. Sloped and vertical chutes, 8.3. Flow round curved plate 6.4. Flow over convex chute. 65. Flow resistance of a changed stream cross-section, 6.5. Material low restriction in chutes, 8.6.1 Comer buie-upe in chute. 1582 Minimum mater steam height 6.7 Examples. 7. HELICAL CHUTES AND TRIMMERS. 7.1 Helical chutes 742 Continuous tow 12. Trimmers 73. Examples 8. APPLICATIONS ae 8.1. Transfer chute with wo cular elements 8.2. Head chute modification 8.3. Flow analysis of a transfer station chute, 8.4. Biturcated chute 85. Typical transfer chute 86. Flow modeling ina transfer chu 8. PROTECTION DEVICES... 8.1. Introduetion 9.2. Sensor types. 9.3. Involvement of Instrumentation Supplier 9.4. Safety Considerations TERMINOLOGY REFERENCES, APPENDIX. The Intemational System of Units 134 137 145 145 182 159 162 165 167 169 169 1 3 m3 05 wT 187 Science without religion is lame, Religion without science is blind. Science can purify religion from error and superstition. Religion can purify science from idolatry and false absolutes. Karl eins Pope Sob Pl) 1388PREFACE is book examines the fundamentals of bulk material dynamic syste ‘modelling ~ granular flow within confined geometrical surfaces, The main objective of the flow system modelling isto predict the performance characteristics of the system, taking info account granular material characteristics and specified operating conditions, Mathematical modelling of the system is based on the following criteria: principle of superposition that can be applied; variability of parameters depending on environmental conditions and time; and dependence of the ometrical surface shape, The variables of the system are: material characteristics — time dependent, coefficient of friction, inflow conditions and geometrical shape of impact and sliding surfaces. Force and velocity are generally used in mechanical systems as variables. The ddynamie characteristic of the system occurs when the velocity of a given mass imcreases as an integral with regatd to time forthe force applied, a follows » © Frat, known also as Newton's third law The following parameters have been used as vatiabes inthe development of the linear system model: mass and foree, kinetic energy, potential energy, and rate of dissipation energy In reality dynamic systems are a combination of parameters that are difficult to build 2 mathematical representation ofa system fiom, especially when there are now-linear system characteristics involved. Such systems can only be approximated by development of linear models, which ean be solved using a variety of analytical solutions including iterative methods, This isthe basis of the approach presented inthis book. Conveyors and transfer stations are integral parts of « modern material handling system. In the analysis and design of transfer stations multiple system characteristics need to be taken into account that in many cases are not considered andlor ignored. There is generally a shortage of information related to properties of bul solids especially in the fist design stage. In this book data has been collected fom many sources, however there still remains a shortage of practical application of engineering to progres, itis paramount that worldwide properties continue to be undertaken and the results shared esulls, For this a testing of bulk solid fiely. hook is simed at providing practical and convenient tools for engineers ae involved in the design process of transfer oth mechanical and struct stations Thaterial may be virtually constricted The Disrte Element Method (DEM), used to model and simulate the flow of Dik rts tose hse wu wily eae Tn comes vacate frm in practical software. Mach of the Ines research studies eee numeral ehniques tt reat th pranala ers axa assembly f Funles, whist te slction of now theological properties cannot provide a Fess modeling mebodoloy. “The authors trusts that this book will provide a beneficial reference for the {development of flow system modelling for particulate materials ACKNOWLEDGEMENT We would like to express our appreciation to persons whose opinions have Helped to improve the quality and readability of this book We are very grateful to Professor Edward Palezak and Mr. Zdzistaw Murzyiski fiom Wroclaw University of Technology for reviewing this text and offering Some ideas, suggestions and constructive comments. Thanks are also expressed {0 Dt, Daniel Andruceyk ftom University of Tlinois for his comments on mathematical presentation ofthe bulk solid Now‘SYMBOLS AND UNITS : bulk i aceerao, me with hate with, bk with m fu By ae bulk solid width on conveyer betem Gam) wit, chute bottom wid cohesion of bulk solid, kNm? Imeian patil size, mm ray, potential ene intl kinetic energy, 3 Aisiption energy thoigh bulk slide niger, Sisipation energy throuh flition evans constant ati ogartin) flow tinction acceleration due to gravity, ms? hte dimension, height fuk sol patie lk solid steam height at conveyer ishege oy, height of helical chute, m - cerry material bed dept, mo “proximation sep num hute characteristics at () point r il pressure gradient on chute walls fetve pressure gradient at zero material velociy chute or channel tength, m Jength o distance, ength ofthe centre ‘ass, umpypartile mass, kg ‘mit mass flow, kgs" contact pressure, Pa or Nm? flow rat, capacity, design capacity, yh, Mh! ‘eoretical flow rateleapacity, vh, kys volumetric, theoretical volumettie capacity, mb unitmass flow, unit oupuieapaciy, hes Volumetric unit flow rat, unit outpul/eapacty, m'y:! radius, chute radius, mm or m * radius of the upper stream surface at diseh ream surface at discharge end, m trajectory discharge radi m ‘chute comer radius, mm distance, m ‘cross-sectional area idles, mm oF m at conveyor discharge end, ponents of cross-sectional ea, m2 ‘components of er cross-sectional are for a given flow rate equired area, m spillage may time elapsed, s belt thickness, mm bull soli velocity, belt speed, dsc locity, intial material velocity, ms" pe velocity, ms", mis ‘material velocity at exit velocity, impact ’ discharge velocity (»~ lower path, »)~ upper path), ms‘, ms coordinates, m oF mim ied trimmer radi number of . angle, ertial angle of chute inclination, degrees oF ) m wgoment angle, degrees impact angle, impingement angle, deg impact plate angle to verticaVhorizantal, degrees unit weight of bulk material, kN divergence coefficients (base path, upper path, stream width) ‘width coefficient surcharge angle; dynamic angle of material conveyed, angle through which the bulk soli hits the impact plate, degrees contact angle, degrees area vatiation factor trough angle of conveyor belt, degrees : fiction coefficient, equivalent wall fiction eoetic effective variable frietion coeicient intemal friction coeicient for non-fcohesive materials wallsurfae fection coeficient (14, = tang,) bulk density of material, Mgm’, tim? or kgm compressive stress, adhesive stress, kN mr shear stress, cohesive stress, KN m discharge angle, radial angle, ang teajectory discharge angles, circular chutes ang e ofsrcam twisting, degrees degrees critical angle, degrees ff intemal friction ang] angle of repose, static angle of internal friction, degrees ye for non-/cohesive materials, degrees: angle of wall fiction, degrees angle of stream bend, radians or de radial angle of circular chute, radians or degreesINDEX adhesive stress 2. ‘angle, helical chute turn 7 angle, impact 5 angle, impingement 6 ‘angle of chute inclination 6 ‘angle of intemal friction 2.2, Table 2.2 angle of repose Table 2.2 angle of wal fiction belt ritieal velocity belt width bulk density chute dimensions chute length chute chute shape chutes coefficient of wall fiction cohesion of bulk solid cohesive stress consolidation stress coordinates ofthe impact plate cross-sectional area discharge velocity discrete element method ‘lissipation energy dlivergence coefficients effective angle of wal retion cffective variable friction angle ‘equivalent friction coefficient awability flow modelling flow properties flow rate flow restriction forces acting on impact plate ition, angle of wall 532,533 able 2.5 height, material stream thickness 35,412,53.2,662 hetical chute impact impact plate impact plate angle impingement incipient flow jnteral friction angle internal friction coefficient kinetic friction kinetic enerey Hising material ‘material height material stream thickness Mohr's stress circle parle size parle size distribution 1, Table 2.1 particle size variation 1, Table 2.1 plate, impact 2.53 plate, wear 3 potential energy 61,741 pressure gradient protection deviees Static friction coetFcient sutcharge angle sutface roughness ‘hoocetical flow rate theoretical volumettic flow trajectory diseh trajectory discharge coordinates trough angle Velocity, components Volumetric flow wall friction coefficient Width coefficient Yield strength, unconfinedCHAPTER ONE INTRODUCTION 14 General AA chute is a device used in the conveyance or transfer of bulk material flow from one point to another. Chutes are unique, compared to belt conveyors, in that they can transfer material flowing in one direction and plane to mest any ‘ther diretion and tower elevation. In some cases, with bifurcated ehutes, the ‘material flow can be diverted into a variety of separate paths, {Cates may alo be utilised to contol the speed of the bulk materia increasing its velocity, or retarding it 10 a complete stop in one diseetion and Providing it with a new velocity veetor in another Chutes are used to contain the bulk material as itis transferred between stages in its preparation, delivery and final application, They may be “open”, Supporting the bulk material from below, of “closed” to surround the product flow stream. The flow of bulk material causes the susrounding aie to become slisplaced. Depending on the propeties of the material being transferred, this in tum may aerate a portion of the product, eeating dust or enabling spillage Failure to completely transfer the total quantity of material lads to ince financial costs forthe process. ‘There is a cost to recover the spillage orto clean and dispose of the contaminated material. In addition, the uate dost ay erat an oecupatonl heh and safety rik fo personne working in the vicinity and have the potential to trigger an explosion/fire. For wou the need to prevent contamination may necessitate in the chute being toa enclosed, - 7 etsy sed be dcign analy becomes increasingly important os he quantity and flow edi bulk matril being tansTred Ines, A cule Blockage ca lead eerie coos a spare ofthe upsteam component inthe tun may as catire process be ale ‘Major parameters taken into consideration when designing chutes include: + bulk material properties + flow rate/velocity ofthe bulk material at ent + chute geon + chute materials + chute maintenance ‘Teaitinally litle interest was taken in design analysis of chutes; as long as the bulk of the material was transferred without spillage or blockage, only minor clfor was made to refine the design. As a consequence, chutes were often Subject to igh wear, maintenance and plant outage costs. The development c tenide impact plates to absorb the energy in the material flow stream entering the chute heralded @ new direction in chute analysis and design. 42 Impact plates “The eutiest impact plates were flat in profile and it was soon found that as the stream of bulk material impacted against them, four actions occurred: 1. ‘The material “splayed” out to hit the sidewalls of the chute and quickly abraded of wore hoes in them, ed away, The impact plate was rapidly abra 3. The velocity of the bulk material came close to a stop, ereating botleneck and increasing the opportunity for spillage and blockages (0 4, Depending on the properties of the material being transferred, it would stil and build-up on the impact plate, eventually creating a blockage. With the increase of conveyor belt speeds, the effects of these issues became ‘more pronounced and could no longer be ignored. ‘To overcome the effects of “splaying” on contact, the impact plates were fitted with sides; this gave some degree of protection to the sides of the chute, butcreated a maintenance issue as, in turn, these sides became the Focus for high Observation of the material flow contacting the surface ofthe impact plate led {o the development of “egg-crate” impact plates. The thinking behind this ‘pprosch was thatthe “egg-crates” would each become filled by the initial low of material impacting against it and act asa cushion forthe following particles to impact against. To some extent this approach was successfal, but for “sticky” materials it was more likely to increase the chance of a chute blockage 2s the following particle seam impacted and attached itself to that adhering to the’ Up to this point, design of chutes had centred on the need to transfer the bulk material. A genetal rule of thumb was thatthe cross-sectional area ofthe chute should be a minimum of four times the eross-s0 ional area of the material stream entering it. This ratio was found to reduce the propensity for blockages to occur inthe chute for most materials being transfered The cost of replacement of chute materials Jed designers to hegin observation of the bulk material low as it entered the chute. The intial impact zone of the material steam striking against the impact plate was obvious, but closer inspection revealed that there wer further down inside the ehute in fact secondary impact points occurring The flow of the bulk material could be controlled by varying the angle impact plate, where inital contact oceurted and thus relocat in secondary impact. [4, 11, 16, 21 88, 89, 109] of the he points of the 34, 39, 41, $3, 54, 89, 61, 65-79, 86, 87, 13 Chute wear The properties of a bulk material such as particle size, shape and hardness determine the magnitude of the chute wear. Chute wear occurs de to: + Impact wear and flow erosion + Abrasion, Impact wear occurs in direct tionship to the velocity and size of the bulk ‘material entering the chute. As the speed of the material increases, the forward trajectory of the particle stream also extends before the gravitational pull takes effect. If space constraints did not exist, chen the length ofthe chute could b extended to eliminate much of the impact wear that takes place, Unfortunately, n most instances; so a ideal that is not the case i re hate and extent of impact wear. [35, 6, 37, 38, 69, 70] “Abrasion isa process of scraping or wearing dawn by bulk solids friction in the hate, which is caused by sliding and rollin of bulk solids over the chute body 4.4 Flow of bulk solids ‘An important consideration for chute designers is the velocity of the bulk fraterat atthe exit point from the chute, For some applications, such as flow fato# hopper, bin or slo, there may bo a nced to minimise tangential velocity to fnsure even loading within the storage container 1 the effect of these events on operating and ers endeavour to have the Where possible, to redu Iaintenance costs, chute analysts and de feajectory of bulk material discharge from the chute in the direction of travel nd speed ofthe downstream conveyor belt [84] ‘Most considerations on bulk solids flow in chutes are based on the assumption that they behave like a granular continoum with fluid or without Mid. The simultaneous flow of a large number of particles against impact plates or Jmpinging on surfaces forms a bulk solids stream subject to plastic and kinetic tleformations. The impingement is » dynamic process, resulting in a continuous series of es and a solid surface Successive impacts between bulk material part Analytical functions ean be developed to deseribe the variation of flow velocity Dfeohesive and cohesion-Less bulk solids during the impingement process, Inthe following chapters, a number of these functions are used to demonstrate how chute designers can control the low of bulk solids through different configurations of discharge and transfer chutes. The equations presented for velocities of bulk solid bir drag resistances. For particles with a mass greater than | gram, the air drag is in practical terms of no influence, If the bulk solid being tansferred is Primarily of powder form, then an algorithm for analysis of the particles being affected by ir drag may be found by reference to [46] 1.5 Methodology of flow modelling in transfer chutes A. General engineering knowledge of transfer chute design and applications. (Chapter 1 and RetRecognising the significance of knowing the properties and characteristics of the specific bulk solid’ being gravitationally transferred. Characteristics of the friction pai - bul, solid and ehuse surface - to be well known or tested, This knowledge is a base for an ‘adequate chute design. Consequences of failure to address bulk solid Properties include blockages, rapid wear and corrosion. (Chapter 2) C. The configuration and geometrical shape of the chute or transfer station to be established in accordance with functional requirements (Now rate, bulk solid’s range of granular sizes ete). (Chapter 3) ° D. Characteristics of the (Chapter 4) incoming and flowing bulk solid st velocity, trajectories, vertical streams ete Analysis of impingement process - velocities prior and after material stream impact, low restrictions - at bulk solid stream paths in chutes, (Chapter 5) F, Chute discretisation. Mathematical model formulation of chute (Giserete) componentssurfaces and flow analyses of the material stream. (Chapter 6) Analysis of flow process in special chutes - helical chutes and trimmers (Chapter 7) Modelling of chute components and simulation of bulk solid stream flow by means of suitable software. Selection ofthe bes flow option (olution) and its application. (Chapter 8) Los rotection devices for bulk solids flow systems. (Chapter 9) (cuarter TWO 2, PROPERTIES OF BULK SOLIDS 24 Characteristics of bulk solids Its of vital importance to be aware of the properties and characteristics of the specific bulk solid being transfered. Without this knowledge, there is a good hance thatthe chute design may prove inadequate, ‘Typical consequences of failure to address bulk solid properties include rapid wear, corrosion and blockages ‘This chapter describes the requirements for the classification of bulk solid properties and includes bulk solid property data available for use in materials handling, design and/or equipment selection sification General information concerning physical characteristics and a cli foie designation for bulk materials is given in Table 2.1. [30] Particle size has a direct effect on the strength and impact plate/zone Tequirements for the chute; the impact energy imparted by a lump exceeding 200 mim in size is signficandly greater than that of grain of sand, Similarly, the flowability of the bulk material has an effect on chute angles both internal and external, whilst che abrasive and corrosive properties influence the selection of materials used to construct the chute. With occupational health and safety playing an increasin control of dust through effective chute design is of rising importance. (12, 13, 14, 19, 20, 78, 83,85Table 2.1 Characteristics of bulk solid materials wilh te dimensions ini Slush no colpi, etaged Nowvslpty aasve Moder abative 22 Physical properties of bulk solids type Peteted in Tote 22. values for bulk density, angle of repose and angle of intemal friction are ‘Where possible, the particular properties ofthe bulk material to be transferred should be obiained and verified by testing, 1f multiple test data is available, fverage values may be determined and utilised, ‘Two representative values for each property should be used in the d process’ an upper characteristic value and a lower characteristic value, to fletermine the loads or required volumes due tothe respective bulk solids CCharacteristi values to be used for design purposes are: a) values agreed between partes concerned; and (6) values dorived from appropriate test data [12 91,94] For some materials the values of properties may be estimated from available data, The first parameter to determine isthe type of ul material that will be conveyed by the chute size, particle Properties of the particular material transported, such as particle size distribution, bulk density, flowability, ‘fiction coefficients between different chute surfaces, chemical composition etc. should then be obtained fiom relevant sources/ests. (3,6, 10, 17,42, 43, 1, 52, $8, 62,92 ‘Table 2.2. Typical properties of bulk solids = degrees Susceptible explosion Density of Internat Bulk Soli mevtim® | REP | Freon ks ‘Alun 080. 1.08 [35a Ash, Good ay 0. Sum] 056-068] a8 40... 45 wet 0..75mm [072.080] 45 35.45 fy cas or | a 3035, Ask, Ov. 4mm 20.45 soistre 13% 0.90. 1.60 | 43245 roistre 28% (112) alas | suspax [Aa degrees — 7 Tingle depres Burk Sota entitm® | *fRevee | “Pete Bulk Sol gut? | oCRePme 2 2 4 Begase tam dy] 008... 010 _ [iat 2i0] 32.8 imoiture40% | 065... 080 3 O10] 3040 svoistre 0% (110) | 0:70. 085 For mcinwe, d= 119m (8) | 118... 137 Bauticrm ofmine 0... 731m (28. 1a ef doit) | 45.54 077 150mm | 120.136 sci. -_ a0. 5 [Cement Fontana IS. 1.60 )iton or Fe Fe eOMOTEI] 33 af linker (107) 125180 | ono plets—_ 190 220 45.45 Clays dy, nes 160.190 a. Tm [1.00.10 | — Clay ay, lmpy 0.75 096. 120 ost wt lumpy 0175 182 160 — 370. 4s [30 lmpy, 25% molstr 133 Sam [96.51.08 3% 193 Timesones ished 36. Lad au 133 powder Lio 130 Coal, Anacie 098... 10 | 37 60 | Magesinn suphate 0.64... 080 Smm__| 096.110 | 35 [Manganese ore 200-224 Coal minowe 04mm] @ Mi dg povder 2s | OSK OJémm — fos--oss| 38 Moyen oe 1... 0."somm | o72.090| 38 Tickel sol sulphate ore 128.240 O2100mm — | 086.090] 38 Toop nck “Ta T30 rinofimine wom | 080.090 | 38 Polyetiylnepellas=3am ——| 0:56 | coal palveried 29% moist [119] | 058. 0.77 | a is 1.18 Coal beans, LS oi] a ot Potassium Ose 130 ily = 25 mm [117] | 075 ~- 080 a... 59 yes ron 26.232 oak ite ary Cr a ure cried 2m 132 wn osonon | 3 35.40 Rice O38... 075, Take 046.070] 35... | a0. 50 Salt Ost. 136 Copper os, ROME Se Gi: coans dy 28. 208 Dolemite 128. Let 35 enrse wet (81) 130. 192 Ean, exeavaeds Oy iz a goat [107] 0170 [essen wet 166 4 30.138 Sendone 36. 144] Fiver es 075 [a B30 Senge, ge O08 Furtwal 110) 40% waste os = [sinter 160.216 50% moisture ngs | 15-25 Slag 10... 1.60 Grains noises J = Sg granules 2. 4m [5] ibs Barley 73-193 |089..077| 23...30 | 26.38 Sir = 283.096 ComMaize 75.139 J 066.090 ai | an ze [solace [Loo 136 outs wieit73 foagiess| a1 | 26.32 Sulphur 080... 136 Rye Garam | as | 2ac36 ‘Wood cigs [16-048 Soya boan nu t22 [or ogo | 21-28 | 2s Zio ore 176.260 | 38...50 Whest qalii93_|om ooo] jaiia8 | 36 [Zinc oxide 75)_ 08s ss_|23 Flow properties The internationally accepted method of determining the flow properties of bull solids is by a shear tes, ‘This test provides information about the yield locus, A. cylindrical samp of bulk material, see F re 2.1, is loaded with compressive stress oj using plastic deformation/erushing of the sample, Figure 2.1 Sliding and crushing of an unsupported bulk solids sample ‘The limiting/eitical value of the shear stress x. when the bull material stats to slide and then crushes down, is called the shear strength of the bulk solid deformation or incipient flow; tis i called the unconfined yield strength cy The figure also shows the principal stresses of the Moh sree crcl Case A. represents the consolidation stress, which is equal to the unconfined yield strength (0; = 0, ; 05 = 0), Case B represents incipient Now (0) > 02; 01> 0). Case C represents the consolidation tate of the bulk material sample Points P; .. Pare points of incipient flow, also called points of yield limit thus point P, (critical point represents the end of yield limit (oy > 0: 0,2° 0) In general, two basie types of bulk solids can be distinguished: cohesion-less or five flowing and cohesive materials, usually with fluid content. Investigations ‘and tests on bulk solid materials focus on determination of thei flow propertics. Yield limits of bulk materials are determined from shear tests and the test results are presented inthe form of o~ rdiagrams, Figure2.2. Yield strength in o~ + diagram. (A general diagram, shown in Figure 23, represents yield functions of the jiteral friction angle and a graphical interpretation of the angle of internal fiction. wre 2.3. Vield functions for bulk solids The linear functions of the internal ftietion angle and feetion coefficient as shown in Figure 2.3 for cohesive and non-cohesive bulk solids ate:A. Non-cohesive bulk solids. To this group belong dry bulk solids with Particle size greater than S00 ym (d> 0.5 man); Codes $2 .. 86 see Table >| re4o my =tang, en B. Cohesive bulk solids 8. independent of stress history and without bulk density consolidation. To this group of bulk solids belong cohesive materials -Codes 83». S6 b. dependent on stess history; to dhs group belong powder and pulverised bulk materials - Codes $1, $2 from Table 21 round, e-FTeatang, 2) where: - adhesive sires, KN (Figure 2.3) ‘e~ cohesive stress, kN mt {internal friction angle for non-cohesive materials, degrees ‘bc~ intemal friction angle for cohesive materials, degrees The flowability of bull materials is an important factor in chute design, The Propensity for a bulk matsrial to flow can be determined through laboratory tests [17, 66, 75], using a ratio of consolidation stress to unconfined yield strength, called the flow ratio, which characterise the bulk solids flowability as follows: f o, e) ‘A comparison of flow function versus angle of repose is shown in Tabl le2.3. Flow ratio as a measure of a bulk solid’s lowability Flow ratio )v behaviour of balk sold | Fr Fhuidstke noodingiiee Rowing | #2 Very trecieasy flowing 3 Freer owing 4 Cohesive flowing | | FS Vary cohesive flowing | F6 Stugesh entangled not owing Moisture conten, size and shape of particles, cohesiveness and consolidation time are key factors influencing flowabilty of bulk solids [55, 73] 24 Wall friction 24.1 General ne 1s when two objects are moving relative to each other. The objects Fort move vail the frictional resistance between them is overcome by an sill not move external fore. nis onthe sricefrton coefficients of bulk sls hae led to the ramen at separate ste an Kinetico siding fcton coin can be identified tic resistance is decreasing. Th tc trl ns ving th Bienes volved ne reso wen (i636 ting an object to start siding Moses! — At his sage te object omen ; Birr cxtrally appli forces gener han he stat ein force 2, Transition stage ~ Sliding begins to commence as the static ftition fesistance abruptly decreases and the displacement increases. as The kinetic friction force, fiietion resistance force has become minimise i most cases, is approximately constant.24.2. Wall fiction angle Wall fretion is «resistance to motion of bulk solids in contact withthe wallining surfaces. The wall fiction angle depends on the force interaction between ball ‘material particles and the corresponding contact surface in both - static or dynamie plications Key factors that affet the wall friction angle for bulk solids are + particle size + particle size distribution + bull density + moisture content + flowing material bed depth _+ surface physical/chemical properties ‘chute wall sure properties + velocity of movement + eaviroamental conditions + time of consolidation. The kinetic wall yield loci for atypical bulk solid, asa function ofa variety ofthe above key factors, ate illustrated in Figure 2.5. {5 Wall yield oct for cohesive bulk solids A lineation of Figure 2 _gaphs is presented in Figure 2.6. onsen ain ie: fie meri! bed depth ia the cht. ¢, ia wll ction ange depending o Figure 2.6 incation of wall yield locus Genorlly the wall friction coefficient is identified by the angle of the wall fiction as: H,=tang, ea) ‘he linear function ofthe wall friction angles and friction coefficients ae: A. Non-cohesive bulk solids Bulk solids with particle size greater than S00 pm, Codes $2... 86 -Table 2.1 B. Cohesive bulk solids 4. independent of stress history. Codes $3 .. $6 - Table 2.1 1, dependent on stress history. Powder and pulverised bulk materials. odes 81, $2- Table 2.1 eH)2.4.3. Surface roughn 25 Friction and flowability characteristics of bulk solids < of the chute lining materials ropectes of the particular material transported, such as fition coefficients ce flowabilty with the angle of wall fretion and The wall frietion coefficient depends on the condition of the chute/lining Bo efor vaione meal seinen Based on published information, [77, 95] the surface roughness classification for different lining materials is shown in Table 2.4, ‘Table 25 Friction and Flowability Characteristis of Bulk Solids Tables 24 and 2.5 are help forthe selection of the chute wall feton —— serene 051 | cai] coeticient “pr [tT 05] rowatity | = foo, 82, 17] Where characteristic values have been derived from appropriate fst dats, then | tart ‘| these values shouldbe applied inthe chute design process. (28, 76, 90] Angle of wal kita = ews | ble 246 Surface rou 0am 4 ‘Lining material on I pz bs. Ash, (coal 0...4mm | 1B... 2 ee =e a Ca aT 1100 1% a Polished Smoot ough stu 244 (112) —+— - = Bagasse- Amn, ry Tee eee] [noise 5 110) : sat : a 0. 1s0mm A aes cowndeniponicd | Cems, Poland a |. ar ceaniette sre ae —_—_elinker_| 202.28 | 23 1s_| FS Clay ies 31 iB [cones el nied oet-fom ae B yin ae Jo wethmpy 18000 ra ‘high density amet - tumpy, 25% moisture ad = sstaniot | aplaen |r| ws 0) on the materalistream height at Jocation () on the value of wall fiction coefficient, ho a1) ‘where: Q- flow rate, Mg vin velocity at location (), ms 1p bulk density, tan 2g = chute width at location (?), m 28 Wall friction angle tests results ‘ests and observations were undertaken during a period of 50 years in Poland and Sweden and summarised in a special report [29]. This study was carried ut for run of mine coal with a size distribution of d= 0 ... $00 mm, und di 17.25 mm, as well ws for processed coal of different size classes ‘The graph (Figure 2.7) was recommended for chute design in coal pro. Industy/faciltes, ‘The upper curve for each coal moisture content repre fe fiction angle of coal sized from 0.1 (or neat) {0 dyur™ 500 mm. The lowe ve represents the friction angle for coal clas of one size d>3 mm. E.g. coal ‘of Class Size 63 — one sizeof coal particles 63 mm only, of Class Size 6 mm, or (lass Size 3 mm only; this graph identities the influence of adhesive forces, size Aistibution of coal particles on flow characteristics he method of chute angle selection is shown on Figure 2.7 for coal, and generally depends on coal size distribution and moisturelwater content forchutes made from mild or carbon stel and low alloy steel, Similar examples of these types of graphs ean be developed for any bulk material from fest results, TT I out Examples: 28 Wall friction angle testing summary se summary of tests aveilable fom different publications is presented in Figure 28 Figure 2.8 Wall frietion angle (degrees) versus particle size (mm) The upper curve represents the wall friction coetTcient for coal of 19% Moisture content on polished stainless steel, These results were published in [#2] based on information from [7 ‘The second upper curve is for coal processing rejects of 12% moisture. (29) The lower curves are for sized provessed coal, These curves are drawn from data presented in Figure 2.7. 29] Tests on nickel ores are presented by the lowest two curves for particles greater than 100 me. (1)determination of the wal friction coefficient, ample is presented for the when test results are known [70] test results used in the design of @ mild stec! rectangular chute for bituminous coal with different surfaces finishes are shown in Figure 2.9. internal friction angle 1.0m (constant) (For notmal stress o= 5.0 KPa) steel - rusted surface Figure 2.9 Wall Gratis: Normal stress acting on chute bottom for Al= Im and v= I mss D1 2500 9 91 360°bM 361 TI 681 kPa From Figure 2.9, for o= 6.81 kPa the shear stress 1=34 kPa Determining & for rusted steet 2-34 205; 9, = atctanyy, =266° and using equation (2.10) a” 68 70.5 +005" a0 Volumetric low for y~ I ms! o 2500 2.2500 __ 5170, ms" 3600pr ” 3600-08541 =0, From Equation (2.12) ‘and the values of the variable ition v=L0ms" = 0.5980 20 ie, = 0.5490 30 = 0.5327 v=40 b= 0.5245 0 = 0.5196 v=60 oy = 0.5168, Results: The average value of the variable fiction coefficient ean be selected 2 follows: forv=3,.6ms* — puy=0.533,..0.516 fe, = 052 forv=1..6ms" yy =0.598...0516 fi, «0.56 In similar way the variable fiction coefficient between coal and a polished surface can be evaluated,Example 2 Determination of he variable fiction coefficient. Data: tron ore pellet characteristics: bull density p=201m* (19...22tm') internal fieson angle o=40 G5"... a5) flow rate = 2500 Meh (uh) wall friction angle $2726 ...35" (foughness D2) wall friction coefficient m= 0.65 angle of repose =35 chute area Aa= 1m? axb= Im 1 m;(6~ constant) square chute Analysis: For a stool chute with surface roughness D2, the selected friction coefficient is ty ~ 0.65. Using equation (2.12), the variable friction paterial stream thickness (velocity) is 2 in 40° 0.65" eos" 40") 0,65" Fes a0 026 Volumetric flaw for y= 1 ms 2500 36oopy 300-2. -03472 m's! 4. io ib) =(r-45) u ve) iction coefficient: M,, i(k Be ae a) How 0.0903 0.7086 0.0602 0.6891 0.0451 0.6743 0.6696 (CHAPTER THREE 3. CHUTE CONFIGURATION 34 Flowrate Ahe flow rate ofthe Iateial's propertis and the capacities ofthe associated plant. The eapseity of It downstream transporting component must be at least equal to that of the preceding upsiceam component. [30, 68, 84] conveying system is determined on the basis of the bull: such as from bins or hoppers, then either the Where surges may 0 ownsiteam components should be inereased in capacity to suit, or some other fneans (vibratory feeders etc.) installed to regulate the flow. The flow rate of {conveying system isa function ofthe properties, velocity and the cross sectional ‘ares ofthe material being transported. [93, 95, 99] The flow rate Q, in Mgh or uh of a conveying system is calculated accordin {othe formulae: mass flow: Q~3600p05", Mel Gls) volumetric flow 2 mht Gb) > hte theoretical flow rate: Qy, = 3600S», mW Gite) ream om the chute, m= Where: * - cross-sectional area ofthe material ,~cross-sectional area ofthe chute, m? bull solid's density, Mg” bulk solids stream velocity, msChute inclination Ipiscaocity allows for surges and some hang-up to occur from time nthe chute without leading to blockages. Practical dimensions are The minimum or critic a, + 40 tang, = (= 8) RE — +9 o * Buf cos" Y= ~ Aang, (=e) FH 474 ane ya =n 60s, Tae Fives ~ or hy — ye equation (45) eeFigure 4.6 Traj Figure 4.5. Teajectory Case 2 Trajectory Case 3. 42 Equations for discharge trajectories Trajectory Case 2. vB vy EquationThe tmjectory velocity of the material stream at selected calculated from the following equations Horizontal velocity Vertical veloc ¥ £9, 6089) = ysing, + gu 46,) 4.109) M5, = V3 008% =v,sing, +gr(l+e,) (4.109) Trajectory velocity vein 4.106) 4.108) B. Cohesive bulk sotids Trajectory equations for cohesive bulk solids take into account number (46). The bulk solid stream will start its trajectory pat a angle as follows a dischatge cosig)= Nov (p bulk density, kem ‘1 material stream height, m irate equations (4.4), (4, (46) can be used to determine the shape ofthe trajectory fr all eases. Res anging equation (4.3a) to find a critical velocity for a specified radius = fofecorn +24) ms I (438) The critical velocity is used wo determine the applicable trajectory case model ies from chutes ischarge trajector 42 0 Jarye trajectory of bulk solids from a chute or spout is similar to the ire eischarce ee elocity can be ted using equations presented in Figure 4.7. ‘Trajectory from chutes ge trajectories from chutes Table 4.4. Equations for discharge traf [Trajectories rom ehutes a Taunton [Remarks em es divergence a aneThe coordinate system (x = 0, y= 0) is based on being located where the lower trajectory path leaves the chute The trajectory"s equations presented in Table 4.4 are identical to those of Case shown in Table 4.2 but are simplified, due to the assumptions that the chute bottom wall is in a fixed position and flat. For trajectory velocities ~ refep ‘equations (4.10), 43 This section caleulates the impact coordinates, ofthe bul solid stream onto a conv Trajectories from loading spoons ct velocity and impact angle re 48, the trajectory of the bull solid as i leaves the chute loading spoon”. As appears similar tothe shape of a spoon, ence the tem The caleulation of impact velocity and impact angle of the bulk solid stream zl to that of Section 4.2 ‘onto the conveyor bel is slighty di This is because the ight time is now dependent on the vertical (dcop height y) fall that the bulk solid is subject to (experiences) before impacting the conveyor bel Figure 4.8. ‘Trajectory from loading spoon ght y is selocted atthe Jaa case when the conveyor belts inlined, the drop he pingettent point onthe bet tajector i © 48) from the loading spoon is The trajectory angle ofthe bulk solid (see Figur a= (@,-m/2) @. ‘his i the angle the tangent makes to the horizontal at the exit point of the oon andthe velocity vertical component is dependent upon the acceleration due to gravity Velocity components: inal vrcal , 138) = vetcal ofthe ext vloty ity ato Impact velocity ’ aso ‘where: )- material drop height, m (Figure 48) ‘2 acceleration due to gravity, ms 44 Trajectory divergency The divergeney of the theoretical path is deseribod by coefficients, and efor fhe underside and topside limits ofthe trajectory path respectively. [25] When sand ; equal zero the trajectory equations (4.7 ... 4.11) represent theoretical parabolic trajectory paths. For spcitic conditions [30] the coefficients e,, cand e) can be taken from Table 45,Table 4.5. Divergency coef Description | Normat weather conditions, tow bet | D1 | speed Windy environment, igh discharge | >) speed ea | te seca as poriveornebatve vie 4.5 Trajectory intersection points 4.5.1. Straight (fat) impact plate The same rocedute is followed to determine the trajectory iaterscction pong coordinates in terms of ther distance tothe ncation ofthe impact plates Raed Position, xy and yy. This is shown in Figure 4.2, Hence yom, 4.14) where: slope ofthe impact plate tothe horizontal yy coordinates ofthe impact plate fixed position, Then the intersection points P, xi y;) and Pa (x 9) can be determined » see Figure 42 and Figure 4.7 - using equations (4.7), (48), (49) for bolh trajectories and equation (4.14) forthe impact plate Tine If B= 0 then xy = y= xp and yiy yp 6 ‘equations presented in Tables 4.1 44 determined dieetly from suitable 4.5.2 Curved impact plate To determine the intersection points ofthe bulk material trajectory against a jeurved impact plate a mathematical equation is required to ea sh the impact Plate radius and its fixed radius centre in relation tothe trjectory's enontinate system - see Figure 4.3. ‘The theoretical equation forthe impa et plate radius shall apply -x,) 49-9) 4.15) horizontal coordinate ofthe radius centre, m - vertical coordinate of the radius centre, m Yo ection points, (Pi, Ps), depending on the trajectory case (4.9) must be solved with equation (4.15). find the inte Tpations (4. noma algebraic Fe impact angles forthe intersection points ean be found as follows: be 9-9 (asa) (4.15b) 45.8 Loading epoon ‘The impact coordinates 2, 2 (see Fig. 48) can be found from equations (4,11), es and xs, the following calculation procedute For an approximate estimate of xj and x, th ean be applied hee yb soli ely athe soo nd ‘ @- trajectory starting angle at spoon end (shown in Fig. 4.8 as negative) 1 material light ime. ‘To find the fight time of the bulk solid from the spoon to the conveyor belt the following equation ean be used: 2y 4.16) ‘where y isthe height ofthe stream falling onto the bel, as shown in Figure 4.8,With the fight time ¢ and equations (4.11), impact coordinates x1, x2 can pe fin202 one me! found by taking into account the distance from their respective tajetay From equation (4.6) vy =1.6,/1s202 -2.38ms anyone aan Ricci, 4 tal fis (tas - " * 9.81(0.33+0.161) where h is the material height given by the relationship f=“ go O.and ftom Table43 =F, +h =0.33+0.161=0.491 m oe Example 1. Find the trajectory characteristics: discharge angle ¢ ~ beginning i Data: belt velocity v=L6ms" %u=0 mn ee = pulley radius r=0316m “ay ee tet eickness ho ‘material width b=12m eee HF eos’ mom sea sia: yye-0:1191n419"-0.1198-981/2:16%en"A.')40=-0.156 Solution: Cbesive balk solids rom equation (43) the a. Y2 = (tA )taM Gs Ch Kp 8 — 49 981-0. SAt-1 0-8 ¥, = (0.018 +0.220)* -9.81 /(2-2.38" cos’ 0") +0.245 = 0.196 ° jy = 1.6-cos 41.9"= 1.191 jy = L.6-sin 41.9°+ 9.81-0.1 = 2.05 Le (ifo,=0 then, = arceos— 37:74 581-038 : f 205 jeVit9 +205 237 9, «arctan 25. 59.8 : Lisi 38-sinO"+ 981-0.1 =0981 09 2.38-c0s 0'= 2.38 v The critical belt velocity for g,=0 from equation (4.36) is : FOORT =2.574 gy arctan od reso 033-9.81~3.39 84 ms!In similar way all coordinates and velo equations (4:9) and (4.10) ForN=4 r2025 4, =1.600841.9° 1.191 Lae ra [38 ‘Results: Using simple computer program, based on an algotthm pres ocities can be found i =L.6sin41 9° +981-02 =3031 [30], the following results have been obtained: aT Upper path Mere ae two top paths ~05: Trane bie Pee Corr 256 fee ee so aa0r Figure 4.9 for eases when «=O and ey sus of trajectory coordinates are presented in Figure 4.9 0.1 Trajectory plot of Example 1Figure 4.10 illustrates differences in velocity paths versus time ~ see table wit calculation results Velocity, mie Time, 8 Figure 4.10. Trajectory velocities — nd upper path (3) se path (») Example 2. Find the intersection points between the discharge trajectory and ‘an inclined chute wall, which is located underneath the discharge pulley. Apply an analytical method. Data: belt velocity v=20ms" aise n= 033m pl r=0316m bel thickness = 17mm belt inclination a-0 ‘material stream height h=020m divergent coefficients 00-0 chute wall inclination to vertical B=40 ‘chute impact wall fixed point coordinates xy =, yp Solution: Trajectories Lower and upper trajectories for non-cohesive bulk soi, From equation (4.2) 2356> 1, and For @) = =0 use trajectory Case 2 and the coordinate system ("sy starsat the top ofthe discha From Figure(45) =nth=0. ForN=0 py ForN 1 2a1= 0s 02) 9811, --0019 P9814, 402-0151 2+sin 0+ 9.81-0.1 =0.981 O98 = 2.228 uy = arctan. ~ 997 dou 307 22 2sin 0" +9.81-0,1=0.981 vi -v2* 50987Chute bottom wal is positioned by equation (4.14) vith 01962402 ~0.0038 yy =2sin0? +9.81-0.2~1.962 $1,962" =2.802 =o = 2sin0" +9.81-0. and the linear equation ofthe bottom wall is of form where: m=tan(90" +) ~tan(90" +40") =-1.1918 1555 =1962 soz Using © computer program [30], the following results have been equations (4.8 b) the following quadratic equation can be obtained: Pro. * gg 94S 0.4861 ~0.0673=0 From equations (4.8e, é) Tomer path st Note: Time /= where 0.4861-0.1081=0 Hence 1= 0.6518 s the intersection points boundary trajectories and a flat impact plate and the associat conveyor data: (reer sd material impact velocity, based on the followin Discharge mius Material height'width Dispersion coefficient Impact plate angle Plate fixed point coordinatesCase 1 Impact plate ang Solution: From equation (4.18) As v>v,, then gp,2= a= (0 and use trajectory equations Case 2, From equations (4.8) and (4.14 Trajectories: 5-01 > Impact Plate: x) =m(x =-1732(x-25)+(-0, where: m= tan( 90" + 8) = tan(90" +30") ==1.732 An approximating method is used to find the intersection point P, sing trajectory and impact plate equations. The comest value forxis determined when ay =[y|-fy,,|=0 Step 1: Let #= 1/35, then s=2:m x=20m, then ¥i--2.0?-9381/2/6} 405-0045 yj =H1732-(20-28)-0.7 =0.166m 4y=0211m Step2: Try leting 2. 981/2/6")405--0.159 7 =-0.180 m y= 0.021 m Step 3: Refining farther, try x)=2.18m, then L732-Q.18. y= -(218?-9.81/2/6") +05 =-0.1475 5)-0.7 =-0.1458 ay=-0.002 m Step 4: Finally, by a process of iteration tke 181m, then y, =-@2.181-9.81/2/62)+0 1.732(2.181-25)-0.7 =-0.148 m ay=0 148 In similar way, the interse canbe found. on pone Ps (3 Resuls:x)~2.181m y)=-0.148m = 184m y2=0437m (Checking xy and yz 13:7 1.844 m, then from equations for trajectory (48d) y, =-(1.844?-9.81/2/6")+04+0.5 =04367 m impact plate (4.14) y, =-1.732(1.844-2.5)-0.7 =0.4362m is Ay=0.5 mm the dere Average trajectory Might time: f= (2.181 + 1.844)/2/6=0.335s Average vertical velocity: 8°, =9.81-0:335=3.286 ms Hence the impact vel (equation 4.10¢) is: 3.2867 =6.84 ms" Case Plate angle f= 0° Solution: From equations (4.8), (4.84) : 1 yy na250~ +051 03516 25-981 cos Vip = Vy = 9.81 0.4167 = 4.0875 ms" (6= 0.4167 L 25-tan0” -2.5°-9.81 2-6-0050" <+0.4+405+1=0.0484 Results: = V60" +4.0875 v7.26 ms"Example 4, Find the interseeton points between the upper and lower boundary trajectories and a curved impact plate. (Refer Figure 43) Data: Belt velocity v=43.ms! Discharge ndivs 7=0327m Belt inclination a-1 Material height, 0.225 m Material width b=10m Dispersion coefficient a=e=0 Curve plate radius R= 142m Plate curve centre coordinates x=0.2m 0.6m Solution: From equation (4.18) v= V0327-981-cost =1.775 ms" Then as ¥> vq use trajectory Case 2 (Pig 4.5). Velocities v1 = vs = ofthe trajectory stream (in metres) are: Initial coordinate sin = -0.062 > sin=-0, ys = Feast =0.327eost I" =0.321 yg =i, snes = (0.327 +0.225)sint =-0.105 0.327 40.225)eosi 1" =0542 Equations (4.8) Base path Te, Dana (= ls Impact plate radius: Equation (4.13) {An approximating method is used to find coordinates of points Py, P Intersection point Py Sm then Step 1: Let x)= 3) =1.567-tanlF-(.567) 9.81/24." cos? 11) +0321 R=[(1 505-02) +(-0.050+0.]" =1.416 Step 2: Try letting s,=1.510m, then vot: 11510-C0062)~ L572) y= 1:572-tant I -(1.572)" 9.81243" cos*t1') +0321 =-0.084 R=[.510-02) +(-0.0544067]" #14192 R=1.4192< 1.420 m~ the difference is 0.8 mm. Intersection point Py Step 1: Let 0.3 s, then 2x, =1.300m Noe: (1,3004-0.105)=1.405) yy =1405-tant ' (1.405)$-9.81/(2-4.3 cost 1) 40.54 R-[0.3-02' +0.272+0.57[°=1.404 Step 2: Try letting 2, =1.340.m, th p= 1A4S-tanl I= (1445929 812-43°-cos?11") 40.542 = 0248 r=[1.340-02)' +0.248+0.67']"* =1.4208, R=1.420m~ the difference is 0.8 mm, Resuls: x) =1.510m y\=-0054m x= 1.340m —yx=0.248m Example S. Find the intersection points between the upper and lower boundary Injectries and a curved impact plate and the impact velocity of the bulk solid (Refer Figure 4.3) Data: Belt velocity »=6.0ms' Discharge radius uy miss athskoos)r)= 0.5 m Belt inclination a=0Material heighwid Dispersion coefficient Curved plate radius Plate curve centre coordinates: -om equation (4.18) 88 @1=@~0, vy = VO5-981-cos0" =2215, then, Velocities: v;= »2= vand inital coordinates of the trajectory stream (in metres) are yu =n eos =05 Yon = OF +A)e0set=(0.54+-0.4) e080 Impact plate radius: Equation (4.15) method is use to find the intersection point Py Let s= U3 s, then x= 2.0m ?-0.6:2 + (0.045)'+1.6:(-0.045) + 0.73) = 1.8601 < R= 20 Step 2: Try eting 2.20m, then y, = R=(22°-06-2. Step 3: Refining, ty x)" 2.19 m, then 9 = -(2.19)°-9.81/2168 +05 =-0.1595 19°-0,6-2.19 + (0.1535) +1.6-(0.1535) +073" =1.998 R 5a ans 98) 9.761 pears a 03 2.181)? -9.81/216+ 0.5 =-0.1553,Example 6: Find the impact coordinates and velocity for Example 6 Fi a bulk. sold tajet ig from a chute spoon onto a conveyor belt. (Figure _— Bulk solid stream height Spoon exit angle Cearance between belt and spoon Solution: Component velocities at spoon ex (4.13), (4.136) and (4.13¢) ean be applied £08 (o- 90") = 4:3 c08 (5) = 4.284 ms (see Fig ih + Dey = VOS75" 6298110 =4445 m Average flight time - Equation (4.16) The impact coordinates and angle between material sre From equations (4.17), (4.178), (4.136) 5) 1yf= 4286-04149 =1.777 m 77-0 sin(~5') = 1.812 m a, arctan 445 4.284 ‘CHAPTER FIVE 5. IMPINGEMENT PROCESS 61 Impingement process description is a process resulting in a continvous succession of impacts Impingeme cecuring intially between the bulk material trajectory and a solid surfs placed in is path. During this process the impact of the bull material particles fesulis in a change in velocity. As a consequence, successive particles from the fulk material trajectory impact on the preceding surface area coated by the ‘This provess is of particular importance when the bulk material trajectory comes in contact with an impact plate at the entrance to a chute. Regardless of the ‘material selected for the impact plate, it would quickly become wom out if very particle from the bulk material trajectory were fo make contact with it. A rate” impact plates development of this process can be found in “eg “The initial bulk material impinging on this type of impact plate is trpped inthe “egg-erate” boxes and deliberately restrained from moving through the chute in ‘onder to provide a buffer surface for the following particles in the trajectory siream to impinge against. The impingement area is that section of the impact plate where the bulk material makes contaet with the impact plate and changes haracteristics of the bulk material have an effect on the impingement Js. Where the material has a high clay and/or moisture content, there is a propensity fort to clump on impact and “build-up” rather than be deflected Three load cases are presented to determine the impact angle and velocity of discharge trajectories from conveyor belts (head pulley) and chutes. The only 1, 2 and 3 are the calculations of the trajectory angle and differences for CasExample 6: Find the impact coordinates and velocity fra bul slid tae flowing from a chute spoon onto a conveyor belt. (Figure 4.8) " Data: Spoon exit velocity we43ms! Bulk solid stream heigh h= 040 Spoon exit angle a= 85 Clearance between belt and spoon 10m Solution: Component velocities at spoon exit equations (4.12), (4138), (4.13b) and (4,13e) ean be applied 4.3 608 (-5)= 4.284 ms' (see Figure 4.8) ve yooas (on 90 vosin (o- 90") =-43 sin 5) = 0375 ms" 375° +2-981-10 =4.445 ms" Average flight ime - Equation (4.16) te Re Twsdm) 0375+4.445 Impact velocity onto belt: Equation (4.134) Web? = Si a8 64445 ~6.173 ms Results: The impact coordinates and angle between material stream and belt mn equations (4.17), (4.178), (4.138) 5, = 0yf= 4284-04149 =1.777 m 71-04si ay = vyt=hsin(, -90 1812 m = arctan(4.445/4.284) = 46.06 (CHAPTER FIVE 5. IMPINGEMENT PROCESS 54 Impingement process description Impingement is a process resulting in a continuous succession of impacts ‘occurring intially between the bulk material trajectory and a solid surface placed in its path, During this process the impact ofthe bulk material particles Fess in a change in velocity. As a consequence, successive particles from the hulk material trajectory impact on the preceding surface area coated by the intial impact, ortance when the bulk material trajectory comes flaet with an impact plate at the entrance fo a chute, Regardless of the material selected for the impact plate, it would quickly become wor out if ‘every particle from the bulk material trajectory were to make contact with i A development ofthis process can be found in “egg-erate™ impact p “The intial bulk material impinging on this type of impact plate is trapped in the epg-crate” boxes and deliberately restrained from moving through the chute in order to provide a bufler surface for the following particles in the trajectory stream to impinge against. The impingement area is that section of the impac plate where the bulk material makes contact with the impact plate and changes direction “The characteristics of the bulk material have an effect on the impingement rovess. Where the material has a high clay andior moisture content, there is @ Propensity for it to clump on impact and “build-up” rater than be deflected ‘Three load cases are presented to determine the impact angle and velocity 0 discharge trajectories from conveyor bes (head pulley) and chutes. The only fifferences for Case 1, 2 and 3 are the calculations of the trajectory angle andthe point where the bulk solid stars its trajectory. The equations sh cco angle ‘hoc distin o wed to fn the inal velocties is assumed gravity sc ony i lb duet the of he velocity will not changes at eo impingement. For each case it bulk sold! and all Hetional ef orizontal com Ponene med that the vertical velocity co Knowing the horizontal ) and the horizontal spe ponent is subjeet oaly te ‘sravitational effects [46]. distance (0 the impact plate ed of the conveyor (vy = story from the conveyor to impact pl cosa, the flight time r of be calculated a follows can be found knowing the time ofthe locity (y sina is ¥ - velocity ofthe conveyor belt, ms"! acceleration due to gravity. ms? ¥ e08er- horizontal component ofthe con veyor belt velocity, ms" ~ average distance from the pulley centre to impact plate m locity vector before impact can be presented by the following for The impingement angle cy ean thus be found, as the ofthe impact velocity (see equation 4.136 orizontal and vertical 4, =arctan(y,/¥) Ther are two diferent theories avaible the ol sd over the inp sures, which eee velocity changes of Presented in Sections 5.2 and ath cs the ba sli conn the impingement theory. " ith the impact theory being « nodel presented by Impact theory ; ; ‘method an assumption is made by Jenike & Johanson (Jed), (4, Ta alo snl ebound ote sure of hemp pat pon ‘isn thatthe velocity foss of the bulk solid as shown in Fis mode! also assumes ‘angle and the velocity normal to nce 5.1 is proportional tothe wall ito te impact surface. Figure 5.1. Velocity change on impact plate -J&J Mode! ci, the exit velocity is: ‘The equation for velocity chang 65) vy =¥,(c0s0—tang, sind) vy. impact velocity; ms angle through which the bulk solid hits the impact plate, ‘e_~the wall fiction angle, vind ~ component velocity acting perpendicular tothe plate surface, vi tang. sind component of the velocity that is absorbed by fiction, ‘Component velocity that is acting inthe new direction of the bulk solid stream after it has hit the impact plate vicos0 ‘The bulk solid's flow down velocity in the chute, deserbed by Equation ( reduced to zero when tand= Ian dn This impact theory applied to bulk solids is not under consideration in further chute analyses53 Impingement theor ae Korzen [45] concluded thatthe shear atthe contact surface is negligible and dha fhe external resistace resulting from the wall friction on the impact plate is a Experimental observations by Korzen, [45, 6, 47, 48,49 conclusions that are illustrated in Figures 5.2 and 5.3, lead to the gene A bulk solid stream ig significant factor impinging the impact plate and undergoes plastic deformation leneute material characteristis as follows: sos {sng the momentum conservation law leads to the following equations + non-cohesive continaun ~ th 1G, -9,)0R s © impinging material builds up at the tn, ~ 6) = Re > Tuy) co) surface of the impact plate, and Fiat - impulse of the principle veetor of external forces representing change in momentum | <2 eyass flow rate in the time interval dt where: Cohesive continuum - the impinging material flow’s radius of curvature is formed by the lowing material itself 5.3.1 Cohesion-less bulk solids at eae velocity vector before impact s ict surfaces at the impact zone was observed and for a har . | cohesion-less mater impinging the inact plate the shape ote a ‘evel seinen ain | did not appear to be aff ‘materials [45] -see Figure ted by the build up hom being formed as for other at created by the impinging From this equation it follows that the impul bulk solid on the impact plate is equal to the extemal forces created on the impact plate. It the vector is projected on a Cartesian coordinate system the following equations caa be obtained 2, A,p,vioo8%(at, +B) 6D R, = A,p,v3sin® (cy +B) A.D 68) R,-Rut (5.80) 10 vertical as shown in Figure 5.2 where is the impact plate an The mass density of the bulk solid as itimpinges the plate at time ¢is described P= Mt) 69) The mass flow rate must be conserved at all points during the flow round the impact area gmt Pavia A= PabAy 65.10) where: 4 stream atea, m? ‘p- bulk solids density kgs {7- mass flow rate, kes 1H - fiction coefficient ‘discharge; p- beginning, a - end of impingement Figure 5.2 Takes—_—_ Be nd equation determine the approximation tevation: on 6.16) Assuming the density stays constant throughout the impact 2one (p, ‘equation (5.11) can be rewritten as follows met toe (Os = rms, the relative deviation in the approximation process ean be 45] For bottom impact plates the same The reaction forces exerting on the and (5:88). ae al to one percent. Fe amon method can be applied fmmeplte can be determined sing equations ( 532 Cohesive bulk solids ‘A dynamie model for granule material on a flat impact plate is shown in Figure re ‘All forces acting on this element can b a 1 [sca 0) nooP a, 0 (13) flementary bulk solid: mass. ammarised as a vector of in G,+8> arctan a 6.139) soutttrmine the velocity immediately afer impact or impingement ext sony te tom the intial velocity ¥ ~ equation (5.12), a muleacy ey proximation must be carried ut using an iteration merhod, For #= (= constant, the following equations ean be used G14) a, +8)-nooa, +0] 619 {owroducing an area variation factor = A, /A, for cases when the flow rte i hot known, the equation (5.15) becomes of forms [sm a, nce, » rivigrsin 2 sit +avisin® + || -faGleose-|a]=0 (5.18) ing 2 ip) soos aGhing+{d7|=0 (S19) Substituting in previous equations with sin 42 = ©: cox @ «1; sin“ and introducing symbols: 0, as normal pressure, ¢ as cohesion, B/h as stream ‘Widththickness, he following equation system is obtained: ite te UGfoosp + la|-0 18%) ri |dGsing +a7|=0 (5.198) ‘itp [dG cose: +p pha (18h) (5.198) rdiv-[dG sing +|aN n+ cbRC@ de] =0 Eliminating di from equations (5.18b) and (5.196) Losp+ pio pd = —ridv +dG sing -eR(gbap nigh + 1 roducing dG = gR(p)—~ dp, so that Ardintroducing dG ~ eR) priviplde + eR) cospds wi @hdp= oad gR(@) sing wg) oo! 1 Hp HERO) cose + HMO) + F o mm A & ev(peRp “0 Feo atiotneangsinpirnrrorior® svn hs s-Aigiortg)= boone) «then oe a vio) 20%) aRto eng +neose — “ wae som dp “ of BPA) “The solution of equation (5.20) i of form fre “| fame! Mr dps (5.2041 PQ@)=4u 29) = 2K sino Hs0¥9 alee The solution of equation (5.20a) isAR). 2upac@) Yee os} ( ay The evaluation ofthe constant of imegration is based on the initial low and impingement conditions a follows o-g, initial angle of the impingement process vev(g)=¥, = stream inflow velocity initial steam area (Net: sh=4 R(q,) ~ initial stream eurvature The integration constant becomes of form [io 2Raye e oR, £[sysina, +(44? -Deosa, + Pe) 2upA, ce Yl T1640 The final solution of equation (4.204) is 2Rw)e 7__bR@) FRO) I su sing + (4p —No0s ick Tl6u " 7 HOA Poort (52a) Hence the stream velocity vat the end ofthe curvature can be determined, The following conditions and relationships of the impact plate are to be taken into account inthe velocity estimation process: - with # being positive ~ Figure 5:3 when = 0 when Ais negative bulk solid ares at step of approximation gee) = bulk solid velocity PA Ryn hy + inital curvature radius of material stream z + material stream thickness he pv In asimilar manner to the method presented in the previous sections, « number ff approximation steps can be selected and equation (5.16) used for the approximation deviation evaluation 53.3 Impingement forces on impact plato acting on the impact plate ean be obtained using equations ‘The enteral for , (67) and (5.82). A common ease when the impingement force is acting on an Jmpact plate is shown in Figure 5.4Impingement velocity vector vp projected on the Cartesian (x, coordinates and additional on (m1) coordinate system ereate the Following equations 008 (5239) = 1,008, (6238) sing (526) (524) vp stream velocity before impact, ms vy, ~stream velocity immediately after impact, ms {impact plate twisting angle From these equations it follows thatthe external frees and Ry (in Newtons) created by the ition on the impact pate are A,pricosc, cos, (525) (526) mass flow rate, kes a= A,pv ¥, =v, 6084, c05, velocity perpendicular to impact plate, ms 5.4 Test comparison The following Tables $.1 and 5.2 contain experimental results obtained from tests carried out on flat and eurved impact plates. [2] ‘omputer program [31], which is based on Korzen’s impingement Using the perimental resulls can be compared with the computed theory [45], the sis bituminous coal with 10.3% moisture content and Material used for the ts 734 kgm” bulk density ot impact pate Be rere Stor ula igh sult weight plyetylore (UAMWPE) Per asl ond 060 far iba Fea TableS.1. Flat impact plates Fiiion coofficent Description Tet | Chute | Test | en gomnt vty, mp | 361 | 3a. | aan Impingement vl am | 330 elution Gerd | ter foun | aur Imp: plat ange depees p| 2 2 ‘verge discs rim = | $06 913 ‘Not: UNDWPE la high moleelar weight povetilee alo kaowa a highnodulas alten (HMPE) or high ofoarunce polyethylene (FFE _ Table $2. Curved impact plates u=060 | =05T 046 | Description Rubber Mild sieel_| _Unnwer: [ise | chase] Tex | Guase tL con | oy | San H Belt velocity, ms n=35 Anpngement velo, sy | 3.67 | 3.776 3.716 3:66 Ent veleeiy, ms v {256 | aca |201 | 2652 233 Velocity dienes, (p=) | LAT | 1135 | to6 | 1124 Lois Impingement angle, depres cy | 23 | 23.75 | 28 | 23.75 2 Inge plate mpl depres 6 | 37 | 3795 [37 | 3795 3795 Average dice, com | 800 300 [927 | soo | x27 The above tes caleulation results based on impingement theory, see Figure 5.5. resulls provide a good correlation with the computer-aided| ey . Computation res ° 4 Figure 55. Correlation between test results and computational results, 5.5 Examples Example 1. A non-cohesive bulk solid stream is flowing onto an impact plate and builds up atthe surface ofthe plate. Find the velocity ofthe material after impingement Data (45): = 7694 th p= 1370 kgm? B18 4,736 Analysis: (a, + B)=36' +15 = 51 and from equation (5.138) (a, +)> arctan Jit ie. (a, +B)> 35.3, hence flow takes place From equation (5.14) the area in mis as follows: gee 3600-137 and from equation (5,15) the ble sid strea [else o)-neaa, +] 0.24309 6040 -0.5:0.3960)] A 6.42, | Solution: An approximating method is used to find the material velocity afer ‘As the initial velocity sv, = 6.42 ms and using the above equation for calculation the intermitent values ae: Step 1 2 Aa =0.2430 vq) = 4.0907 Step 2: vay=4.0907 Aqp=03813 vo = 3.2653 Step}: vaa=32633 Ay~ 04777 Step 4: vig=29174 Aye = 0.5347 Step 5: va 275T6 Aus = 0.565 Step 6: vs=26810 Aye = 0.5819 ow Step 7: Ya =2.6435 Aq, = 0.5901 2.6249 -2.6435) [psa 0.01 hence stop iteration 2.6249 From equation (5.16) Results: v,=2.625 ms ‘The estimation ofthe velocity ofthe material stream after estimated velocity is 2.64 ms" impingement i satisfactory. Tn [45] th with an error of Forces, in Newtons, acting on the impact plate are: (5.7), (5:84) R= A,p,vi00s"(a, +B) =0.243:1370-6.42? cos*(36" 415°) = S434 Ry = Ry= 5434-0.522717 R,=S44N R, =2717NExample 2. A non-cohesive bulk solid stream is lowing onto an impact plate and builds up atthe surface of the plate. Find the velocity of the material afer impingement using equations (5.218) and (5.22). Solution: An approximating method is used to find the material velocity after impingement. ne steam velocity before impingement is vp = 6:42ms', and use the Data [45]: = 7694 Vb p= 1370 kem™ y= 642 ms" ede b=10m B=15 4,=36 (0. at e=0 Stepl: v= 642 40.2430 Ry = 0.2430 vy) = 2.0447 Step2: 14) =20447 4" 0.7629 Ry 0.5030 2= 2.3904 Analysis: From equation (5.132) (a, +)=36 +15 =SI°, and Step3: vi2=23994 — 4y=016502 Ry = O86 v= 2.32 Step: 1is=23271 Am =0.6704 Re= 04567 vq = 23402 arctan {je =45" . As (a, +)>45° ie. flow takes place, Results: The exit velocity of the bulk solid stream ater impingement is 2.34 ms (Approximation error of 0.56%). 7694 3600-137 Vara Example 3. An impinging non-cohesive bulk solid stream builds up at the 1.56 4, - surface ofthe impact plate. Find the exit velocity after impingement 5692430 y= 6a > Data (45}: 0 9000 vh p=1530kgm? ——¥=6.42 ms Bris a, =36 ° = 0.65 iyth R- noon, soon st legeatnice }+9 1.634 Ga2 C~508.79- 76.4464, Velocity in ms Equation (5.12) Using equation (5.218) when ¢= 0. 2555 0 coao-045-03960) 15° and 0.005321 yy 2642 We p= 15% then 2Rye 7 + Susing +(4u2 —Deoso] v6 jose 15 =6.42 [OEE ng! (0.005321(508.79-76.46AR,)+ 1.1541 , (5.606140) yA, Solution: An approximating method is used to find the material velocity afler 2075 + 6.0632R,Step | P ym = 3.7796 Step 2: . va = 2.9000 Step 3 » va=2.5402 Step » 4ea=06183 va =23774 Step 5 x fis 0.86873 v4 ~2.3000 Step 6 vis 23000 deg =0.7105 rug =2.2622 (16 Step 7 Win =2.2622 Au =0.7223veq= 2.2435 (04380) Results: The exit velocity ofthe material stream aftr impingement is He 4. A cohesive granular material is impinging on a flat plate and flows round a curvature radius formed by the flowing material stream itsell. (Pigure 33 Data [45]: = 9000 vin* »= 642 ms 5 m (ie) p=1530kgm? — ¢=3.4kNm™ (ot m= 0.65 736 30-15 9000 133-30000 Analysis: 4 6a > 10 Rp = ho = 1.634642 = 0.2545 44, and Ry are initial values for an approximation procedure. As per ), where radius R(g)= Ry ae 4 obR, Trig lasing, +n? Noosa, beat ~ ROB. [s04sinse «(068 -rpoa6]} C=211.1242435R, Case 1 Using equation (5.218) ? -eosg]-— 2upA@) the velocities for different cases areas follows: peo’ 9=90" Note: A(@)= Ay su =A, R, = (211.1242.435R, Je 1" 821718, 1.700470 R 1 ¥ 581K, 1.709490; For Ry = 0.2545; vy) 9868 ms Approximation method to find the stream velocity after impingement: Ag 0.2545 y= 0.2545 vy) = 9868 4-0. Ra~ 05385 a= 2.6235 Step 3: vaa=26235 Am =06228 Ry=O4387 vgn=2.4441 Step 4: vas =24481 Aue = 06686 Ry=O.4615 Y= 2.4873 Step 5: vau= 24873 Ays= 0.6569 Ry=O.4557 ge 2.4764 Result: The exit velocity is vz. 248 ms. Approximation enor 0.4% © estimated velocity is 2.58 ms" with mn[45) Bais #0913109] 1 124 2.495R,)+2.5293.139 +0.179)R, 16 48.4715R, —1.7094. 642ms! Approximation proces Step I: y= 642 0.2545 Ry=0.2545 Step 2: vy = 2.7295 0.5986 R= 0.4265 Step 3: v= 3.1872 05192 Ry ~ 0.3868 Step4: vy= 30012 Aw=0.5444 Ry = 0.3995 03976 0 Step 5: a= 3 45-0540 Rp Result: The exit velocity is v= 3.02 ms". Approximation esoCase 3 p30 9-60 (211.12+2.4352,)+2.5292.815+0.354)R, 1.7094 R, 138769 +8.1744R, -1,7096 7 For y= 642 ms" 0.2545 m 3.7746 ms" Ra ‘ Approximatio Slept: y= 642 Ay = 02545 y=. 7 Step2: vei 3.7746 4.2= 04330 R= 03437 5 Step 3: vm)=39153 Ay=OAITS Re=03351 tne Step: va =3.9047 Ay =O4I8S Re=03065 5 Resull. The exit velocity is ye, = 3.91 ms", Approximation exo 0.02 Case pols = 10s vere O11 1242 435K, )4289199-0.179)R, 17054 =1.812+7.5097R, -1,7094 52 A, Foryp= 642 ms! p= 0.2545 m = 14191 ms! Approximation process Step 1: v= 6.42 Ry = 0.2545, Step 2: vi = 14191 B= 00: Step3: via=24591 Ay = 0646 Ra = 0.4595 Step a: 0201 Ay 0.8089 Ry = 0.531 Step 5: 1 =2.1636 45=0.7552 Ry = 0.5049 Step 6: vys=21120 4p =0.7737 Ry=0-S141 Result: The exit velocity is v 3. ms". Approximation error: 085 CHaPrer Six 6. BULK SOLID FLOW THROUGH CHUTE COMPONENTS 61 Mathematical models, The aim of mathematical modelling is to predict the beliaviour of bulk solids flow within a complicated chute's system. This can be achieved by breaking mathematical down the system into simpler chute elements and then applyin simplified model formulation. Its assumed thatthe mathematical modelling represents the flow equations of bulk solids through components ofthe system “The basic assumptions made are as follows: replaced by The model is diserete, where continuous loads concentrated loads; b, _bullesolids characteristis remain invariable in time: © irresistance has minor influence on the bulk sotid’s velocity 4, defleetions ofthe system elements are not taken info account stochastic pracestes ae replaced by deterministic processes, 8. vatiation of flow intensity, The flow equations for components are based on the principles of flow‘A. The mathematical model of the bulk solid flow is shown in Figure 6.1 ‘The bulk solid stream will exert forces and reactions on the surroundings. ‘The resulting foree is acting inthe direction of motion as show in Figure 6 Figure 6.1 Bulk solid flow model Mathematical analysis of the bulk solids flow model leads to the following equation dh = dG-+dP, +P, +3aN 42a (60a) where i inertial forve tin ~ mass flow a6 - gravitational force a, - ental force 2a’ sum of normal force dT - sum of resistances to shears Als) ~ cross-sectional area tyouts) df, ~ adhesion force (ar ssc conn) Equstions, which describe the material stream flow, ar: si 4dv) sv = dG +d, + dF, + Balt + dT (6.08) tin= pva 5.10) ractung, as Hog Hy (+2) 2.12) w B. Where there is no transfer of energy from or to another system, the d principle of energy conservation requires the following condition to be sats within the system: AE =AE, +E, +AU (6.00) where: AE ~ change of system energy 4B, change in kinetic energy ‘AE, change in potential energy AU - dissipation function In general, the principle of energy conservation can be presented as B= Set SE SE, (60 $e, -sum okie energy ofthe inowng bk sai’ steam - sum of potential energy dissipation function ‘The diserete model of the system, the chute is ereated by means of dividing the chute into finite elements, which each have a determined geometrical shape, material characteristics and chute wall properties.6.2 Sloped and vertical chutes A straight flow down chute - shown in Figure 6.2 ‘or narrowing ehute outlet. is analysed witha widening sure 6.2 Flow down sloping chute ‘The only forces acting on the bulk solid are gravitational and the wall friction between the bulk: slid and the wall surface ‘The dynamical equilibrium (6.0) lead tothe dif ial equation (65, riod dGsina—dGucosa ay ~m®¢ mgsina—meqicosa=0 at 1) ay and the acceleration is © = hence equation (6.1) becomes of form deat i inee+ coser)=0 ae and the Solution is v? = yj +2gx(sina- woos) hence HM = Ji vDgetsin poosea) (a) The exit velocity of the flow using equation (6.14) isthe velocity the bulk solid flow actually reaches tthe end ofthe chute Ip vertical chutes there exists a freefall zone, where the lowing bulk material An analysis of the fall process of bulk solid particles carried out in (46) has shown that in most cases the drag resistance has a non-significant influence on tne particle's end velocity ‘Taking in equation (6.ta) = 0, »~ 0 and replacing ehure ‘vertical height H the following know formula can be used for vertical chutes: vag vet 2RH (61) where: H fall height ofthe bulk soli particles, m If a variable friction coefficient and a widening/narrowing_ profile of the chutelspout are taken into consideration, the bulk material flow calculation procedure ean be eatied out using an algorithm presented in Figu ‘Symbols used inthe algorithm ~ Figure 6.3: 2 — -Mlow rate, vb Y “initial material velocity, ms pp — ~bulk density, tm D_—~inlet chute widi, m pressure gradient on chute walls L——~chutelengthm (= .,a8 per Figure 6.1) Alyy ~length ofthe chute at (9) point (A, = Ly Ey) = width coefficient numberof chute elements Approximation mamber — level of accuracy ~ approximation number for velocity vy. ~ chute width at () point ~ chute height at () point y= Velocity at () point /a, ~angle of chute inclination, degreesadians at) point u/ to, ~ friction coetTicient variable friction coefficientliao Fori= 10 Algorithm structure for chutes/spouts of varying width “Test comparison Roberts and Scott [67] published test results related to steam thickness and velocity variation in a straight chute of circular cross section, 73.2 mm in diameter and 2 m Fong ‘Material tested was powdered Alumina (ALOx; p = 1000 kgm”), Foe th analyses the following input data have been established: a. q= 0833 kgs b= 1389 kgs" =0.6ms! a=38 y= 0.0267 m 1.495 ms a=45 y= 0.020m and as per (67): tu = 0.45, k= 0.2, €= 0 and a flat material stream, The only forces acting on the bulk solid are gravitational. Velocities were measured at distances of x=0, 0.2,... 1.6, 181m. The calculations were carried fut using a variable friction coefficient, Additional data has been established! dey = 4.2084 E-3, m*- chute cross-sectional area, m? (d= 73.2 min) Altes - chute fill for minimal velocity - Refer Section 3.3 where: A= 9/vp cross-sectional area of the material eta, mn Velocities in this ease were determined by the use of equation (6.18) and the Variable friction coefficient (Equation 2.12) asa funetion of the variable chute filing - Refer Chapter 2~is of form: 4 1,) 1+ k2| He 0.000833 m's" y= 0.6 ms Chute inclination @=35° q = 0.833 kgs! forv-0.6ms" A=13883E-3 Ald =03299 8 =70" p= 0.4764 forv=2.5ms' 4=03320E-3 — Aldy=00792 6 =20" p= 0.4978 Chute inclination a= 45" g= 1.389 kgs" q,=0.00139 ms y= 1495 ms" fory~ 1.495 ms" 4=0,9291 E 04 F MA =0.2208 3=| 4097 fiAay=0.0880 5=25" y= 0.4849 forv=3.75ms" 4=0 Angle 26s an angular aperture ofthe bulk solid stream and vaties ftom 0° (lack ‘of stream) fo 360" (fulfilled cross-sectional area); hence b= dsind63. Flow round curved plate Forcaleulation jt 0.50 has been sele [Apartcl, or callection of particles forming a bulk solid moving ov igure 6.5, is subject to a gravitational force, peripheral force and 4] Initial velocities for = 35"and a= 45%are vy = 0.6 ms: and vy = 1495 ms For distances x~ 0, 0.2... 1.8, the velocities were ealeulated in accordance with ‘the following formu plate, vei results [31] are presented in Table 6,1 and Figure 6.4 ‘Table 6.1. Test and caleutation results is [ser | as 276 | a0 [aus | 3433s | a8 Figure 6.5. Flow over cireular path ‘The flow (6.08) ofa given particle is defined by the following equations: [24] di sdising-aF =0 Ys mgsing-T=0 62a) Note va test ress, ¥~ compute val dh, rdGcosp-di-0 = emgeosg=N =O (626) Figure 64. Compa n between test results and theoretical prediction tt Using 7= 14", and © equations (6 1 on Nie es There is a satisfactory ag predictions, cement between test results and computational sine oosp)=0 (63)Hone l[ fomel”™* apse ‘The solution of equation 6.3ais of form Aeeyece fate Sting t-24 mg] oe v? = 288 _[3using + (1-24 eos] +Ce™ (64) el MPM 2 are integration factors, a Susing, +2" cos (6.5) and the solution of equation (6.3) is [foretr Inpoctcal terms is more convenient to use a different coordination sytem a8 : shown in Figure 66a and Figure 6.6, ]= Reine “noose dg = = S2Relsing)e™ dip f2Re(noose "dg Solution of Patt 2Refsinge™ de (-2using-cos9) Solution ofPart Il -2Rg fsinge ' . @ (b) Adding Part I and Part I Figure 6.6 Flow over circular chute elements (-2using~cosp) -2Reu, (2008 +sing) t an A. For bulle solid flow over the concave eireular path as shown in Figure 6.63, substituting « = (90 ~ g) equations 6.4 and 6.5 become of form: 2using~c0se 424° cosp—nsing)} 1 )sino] +e (ata) bead) RE jsyos, +(1~2")sna] (658B. For bulk solid flow on the curved impact plate as shown in Figure 6,6b, @) equations (6.4) and (6.5) then become substituting = (270 2Re arrrs| sucose—(1~24?)sina] sce oD) ane RE Da pcoey -(h 4u wl : Caetly sine] (650) The steam height due to continuity low is And the exit velocity at angle ais (66) Fora concave chute where oy = 0 equation (64a) becomes of form [64, 66 uke i Sus (64 asi) ; «variable iston cooficont i taken into account the calsulation algorithm 16] presented in Figu Symbols used in the algorithm: - flow rate, Meh! += inital material velocity, ms" fp ~bulk density, em? = inlet chute wide, m FR -chute radius, m width coefficient ‘inital angle ofeteular chute ‘g:~ end angle of circular chute iy ~chute width at () point ‘iy ~ material height at () point locity at (i) point Aei~ chute inclination a () point t.- variable fietion coefficient a ~ wal ition eoetficient rhumber of chute elements K. approximation number — level af accuracy j, approximation number For velocity x, at () point This algorithm is limited to a concave citculae path (Figure 6,5) and a square Wwidening/nartowing outlet 6 = D(L+) atthe discharge end, where €>- Gm) 106.7 ees exp) Algorithm structure for calculation ofa circular chute‘Test compaiso Roberts [64] published test results related to stream thicknes variation ina circular shaped chute. Material tested was millet and veloct ity The tests were caried out on a special stand, which consisted ofthe chu two diffrent radii and a hopper with a ‘variable aperture controlling the stream flow ate valve for Test results [64] and computational results [31] are presented in Figure 63. The basic data is as follows: Chute rai R=1Sh —R=1. Aperture hip b= U1" gx b= 05" I” Chute wiath ber fective friction coefficient =.= 0.5 Regression analysis leads to oblaining @ functional relationship between two variables and a measute of the degree of compliance between them, The test results (bold) and computed values ofthe steam thicknesses (in inches) are presented in Table 6.2. Comrelation coefficients fr the data st in Table 62 are shown in Figure 63. Table 6.2. ‘Test and calculation results 7 Tad ase T=0s » [os Test results, inches 1©69 Correlation between test results and computational results There is a satisfactory agreement between the test results and the theoretical predictions.oa Flow over convex chute irene. A particle, or a bulk solid moving over a convex chute, see Figure 6 Subject to gravitational force, peripheral force and resistan« ‘ 10, ig © 10 motion, ‘the solution of equation (6.8a) is he motion of a gi siven particle, ba following equations ed on Equation (6.02) is defined by ake al sdGsing [farmer dg] f2Recing-neosp)e "d= av mB mesing—T 0 (or = f2Retsingde™ do~f2Re(ucosp)e™"dp Pat Parc ~AedGcosg-diin0 so a4 ae ncosg+sing)] ucmnp sing Solution of Parl -2Rgfsinge*" d= Adding Part and Part IL 7" (ausing-cosg) -2Reu—=, —(2ucosp+sing) a’ Hea Monet ene con > 2Re: ae . W2yeasel ea Law = 28 [using +2 Figure 6.10. Flow over a convex chute element olution of equation (68a) is r ations (674) and (6.70 canbe rewriten as erg ene tie eco aa ! Uv". dp-+2uv? + 2Retsing—e0s9)=0 (6s) 1__2Re aoe ! [fornr!™™" apse] (6.88) The ext velocity at ange @ is Ya V7 ams pel where: P(@)=2y 29) = 2Retsing-ecosg) gw ola and the stream height isThe bulk solid will start its trajectory off the conv: force is equal to the gravitational force as follows te when the centrifugal R = goose uy The critical velocity and angle for the specified chute eonvex radius gives (6.18) (61th) gravity, m 'R- radius of the convex chute, m (9,-intial angle c specified angl specified angle of stream velocity Np eritcal velocity at g*, ms" ‘The critical velocity is used to determine the flowing range or distance travelled by bulk solids on the convex chute. In practice this typeof chute is rarely applied. 65 A collection of particles forming a bulk solid stream moving through a part ofthe chute, where the stream is changing the shape of its eross-setion, is subject 0 & ement of particles within the Flow resistance of a changed stream cross-section ravitaional Force and internal stream, esistanee to displ Figure 6.11 repr solid stream flow through a section of the chute, where the ma changes its shape esents mathematical model used to predict the behaviour of bull al stream The conservation of energy principle - equation (6,08) - in a case when the bull solid stream changes its crose onal shape leads to the flowing equation EE 12) which ean be writen in the form Lin mgui(gr +s (6.128) were: m unitstrea 7 equivalent stream radius 3 stream displacement 1 internal friction coefficient (p- angle of stream twisting Figure 6.11 Mathematical model of cross-section The equivalent stream radius is of form -4 (6.126) where A-=/ (3600: pv) isthe stream cross-sectional area Hence 6.129 Ite then a 6.120)6.6 Material flow restriction in chutes Cohesive materials have a tendency to build up fines in chute corners end this process impedes the proper flow ofthe bulk materia The build-up process can be minimised by placing fillets, lat or rounded, in the bottom comers of chutes For cohesive material flow to occur there i a requirement that there i suficient material bed height to allow a slip to develop in the chute and overcome the cohesive resistance forces, tes. 664 ‘The analysis ofthe fillet size in a chute { into account forces activating material fiow along the chute path and the cohesive resistances ofthe material adhering to the bottom comers ofthe chute Comer build-ups in ct 82] as shown in Figure 6.12, takes Figure 6.12. Cor in chutes F,=mg(sin—scose) Force activating slip F=2er-Al 6.14) Cohesive resistance Mass ofthe material adhering to chute walls, kg 6.15) where: material's bulk density, kgm fe acceleration due to gravity, ms 1- fition coefficient c2- chute inelination/slope angle, degrees ‘e-cohesion, Nim +r. ~tadius of adhering material to chute corner, m Al unit chute length, m ‘Ab unit chute wide, m ‘The adherent material starts to slip down the chute when the force activating material flow is greater or equal othe resistance force If the above condition for flow is met the following Formula allows ealeulation oftie cohesive radius: Pal=a74¥sina— 00a) (6:18) Equation (6.15) applies to bulk solids of low cohesion, A circular fillet applied in each comer of the chute should theoretically eliminate problems caused by fines adhesion. Where its impractical to fit a circular fillet inthe chute comers, the use of flat come fillets will also help to limit the amount of fines adhesion 6.6.2 Minimum material steam height The minimum material bed height required to allow slippage to occur inthe chute dopends upon the bulk density, the gravity force activating material flow. friction force and wallmateral cohesion properties. An analysis (9, 82] takes into account all he above-mentioned forees as follows! component of gravity force Femgsina 17) Fiction resistance force (Fig 6 mgucesa (18)Unit mass m can be replaced by p-Al-Ab sh and the material stats to sip down Primary approximation (/= 1) .=05 (constant) the chute when a - vyems! aos) can in pa-Al-Ab-hsinac = pg-Al-Ab-hucosce+e-Al-Ab ee ee | re aes me ty os 12.1797 where Aland Ab are unit area dimensions ie. A/-Ab=1 m= 3 6 08 0.190 05 B.ba6 4 8 090458 05 140247 5 1 Lo 0136 05 M4615 (619) 7alinap080) ndary approximation / Equation (6.19) is @ convenient tool for early recognition of the influence of ee Pp Yo om: Ae rk a 10 als on chute performances 12 06 0.305 p.7495 10.9216 2 4 07 02m 0.6676 11.8392 6.7 Examples 3 6 080.196 9.6190 127281 ae ee viel 0.3880 3813, Example 1. A straight flow down a widening chute ee eS eee Find the exit velocity ofthe bulk solid lowing down on widening chute when the friction coefficient is varying Figure 6.13. Apply = S and j= Approximating 14,3981-14.8615} 143981 ation (errr) - sing equation (5.16) is a8 follows: 0.032-3.2%. As the error fs greater than (19 Data: Q=72000h p=L0tm? w= 10ms x aos Bal Daosm the fer eproinating tp require ae ae Vora ear Tertiary approximation (j = 3) Me variable AL=LIN= 10/5 = 2m fel approxima » = variabh ‘ Loy hie te Mp ms Solution: From te algorithm in Figure 63 is found that oO 0.400 3 12 06 0283 0.7543 iogi7t ’ + 2pAl. (sina 1,008) 2 4 07 o2s ora ea - 3 6 08 ose 0.6227 12.7176 fay = 41 B 1% 1 at 0.5909 13.5693 4 ‘ eo g) 0ua9, 0.5694, 14.3852 After tertiary approximation the deviation (erro) is 43852-14.3981 14.3852 = 0.09% Result: The bulk solid’s exit velocity is 14.4 ms + 2g Al (sine—u,cosed)Approximation steps: Three straight and differently sloped chute segm he segments are changing ther slope angles as follows: 90/50/40 degrees. solid flowing through the three sogment 16964-0.38~ 16.41 = 6.57? -0.06964/0.1129-0.38 =10.11 = 04575 ms 4, =0.4575/y = 0.4875/3.18 0.06964 /0.1438-0.38 = 7.95 slope ofthe chute segr wall ition factor initial bulk solid velocity 0.4575/y= 04575/2.82 = v= 0.06964 0.1623-0.3 total chute length tical segment (ct The material velocity on the bend, between the first and the s impingement is determined using equation (6.15, 0.06964 0.1726-0.38 = 6.62 segment and befor = 0.5754, = 045751257 0.06964 /0.1780-0.38 = 642 =\0eD ORT DD 0.06964 /0.1808-0.38 ~6.32 B=-90" +00= 40" Material velocity a the end of the chute's second segm Impingement on segment No 2. Velocity - use equations (5.12), (5.14) jement using equation (6,12), is as follows: 251° +2-9.81-4.5(sin50" -0.500s50")~ 45.56 ora, + 3] Segment No. 3 La From equation (6.138) (a, +B)> arctan then (4, +)> 353° 50 von = 4.05 ms 2sims! v= 6.75 m 90° + a=-50, am velocity after impingement on segment No.3, flow takes place, sin? 50° -05c08" 50° =0.38, Bulk solids area as function of velocity [Ae sine, +B) m00s*(a, +B) = 1400 1000 /3600 /850/ y, =0.4575/»‘The bulk solid area, initial velocity and flow conditions are: (Fig, $2) 6 Sms! a, +f=(130"-S0")=80" >35,3° Approximation steps Note: sin? 80"-0 Seos? Ay = 0457516.15 = 0.0678 v4, = 6.75" 0.0678 /0.0678-0955 =43 51 As 0.4575/y)= 0.457516,60 = 0,0693 V8, = 6:75" -0.0678/00693-0.955 ~ 42.5 v7 6.52 3" A.= 04575 ¥), = 6.75" 0.0678 /0.0702-0955=4204 yy) -6.48 ms"! 1 = 0.457516,52 = 0.0702 Solurion: Material velocity a the chute end using equstion (6.13) is £, = 648" +2-9:81-2,0(sind0" -05c0s40") = 52.18 Results The exit velocity ofthe bulk solid stream flowing through all chute segments is Yay = 7.22 ms Flow over a concave circa Figure 6.6, Figure 6.15 Example 3 path Find the exit velocity of the bulle solid flowing through the concave chute Case A. Use equations (6.5, 64) Dawa: R=1m — w=0ms' w=05 = 60 = g=30° Figure 1s samely 218 (3.9.5sinea"+(1-2:05")co60"l] TOs Analysis: C =0.3509-(-15.196) = 5.3323, {05s +01-2-05%)an30]-529-2 Sotution; v2 ~9.8U0.75+0.433)~5:332-1.6881 = 2.604 Result: y= 1.614 ms Case B. Use equations (6.53, 642). w=l0ms! yw. 60" Dama: R=1m a= a (3-0.5c0830" +(1-2-0.5")sin30 Analysis: C= e2099%4[ 10 ios (© =1.6881-84.804 143.16 218 5.9 scot" (1-2-0. snd] +148.16-¢ ross Solutions v* =981(0.75+0.433)+143.16-0.3509 = 61.835 Results v= 7.864 ms" For diferent coefficients of fiction the exit velocities ae a flows a oe a Te os wma [T0355] 9.85 [Bate [7.435 | 6.028 | 5.890 (0 (in Case B) then C = 1.6881-(-15.196) =-25.652 and Note: IF 8(0.75 40.433) -25.652-0.3509 =2.604 , hence (Compare with Case A)Example 4. Flow over a circular impact plate Find the exit velocity ofthe bulk solid flowing vera circular impact plate, Se Figures 6.66 and 6.16 Dato: R=1m loms" 6 =30" = 05 Use formulae (6.50) and (6.46) Figure 66 10* 2:2 _(3.0.5c0s60' --2-05")sin60) J Analysis: C= Tose €=0.3509-96.89=34.0 EEE [3-0.5e0s30°—(1-2-0.5*)sin30"] +340: 22050 Foss Solution: v* =9.81-1.0$9+34.0-1.6881 = 67.686 Results v=8 For different coefficients of ction the exit velocities ate as fllows a a mms [70.355 | 9.430 | 8.606 | 7.870 | F215 [6 Example 5. Flow over a spoon The end of a transfer chute is equipped with a spoon to deliver bulk solids anto a conveyor belt. Find the exit velocity, See Figures 6.60 and 6.17, Data: R= 11m =10 a= a= 85 Analysis: From equations (6.5) and (6.43) ¢ [or on" 1-2105in0 #1 6881-84803-143.16 “ 3.0 5es85 +(1-2-057 xin] 9143.16-€ Postel I Sotton: =981-O$285+143.16:0.2268 «38.642 esl: v= 6216s" (f= Othen C=90.19 and y= 10478 ms") Example 6, Bulk solids low overs conver chute | -———— i point y= Soe Figure 6:10 08618. Te YS ier 10 be consid wih two ren ital | 7 telocis = Dw: R=1m 705 (g4=266) mo ga" Case 1. Initial velocity vp=0 Case 2, Initial velocity y= 1.0 ms Analysis: From equation (6.118) the critical velocities are: 2918s! at @)=30',and Yoo= 2215 ms" at @n= 60 As the angle gs greater than the wall fiction angle the material is noving down lo angle g Using equations (6.9) and (6.10), the results for the two different casesQULK SOLD FLOW THROUGH Example 7, Stream cross-section change during 2 flow (1+2-0")c0s30°I]-17.37 Find flow velocity reduction forthe following data: (sce Figute 6.11) ia bauxite ata: bulk ma 0 Ssin6o’ 142-05" oos6ar] +17. 37-209 oe eet internal ston angle 6-40 (= 084) 2 9814-03170) 41737-0385 fet throvahput 92500 th v8 =9.81-(-03170)+17.37-0.3509= 2.9855 y= 1.728 ms i? Lal ae ccm need Aaa Analysis: Equations (6.128, d) to be used: 2500 3000-13-675 flow area o.ssin6o" -(1+2-0, poss 1S Hehe equivalent stream radius 1096 + 6.6885 = 3.5789 =1.892 ms n velocity y = Denese 242) Results: The bulk solid stream does not leave the surlace path of the chute before reaching the angle of 60" - the end ofthe assumed travel length. Equation (6.115) tobe applied VF 26.154 =2-981-0:84:0,1587-(3.1416/2+2)=56 602ms" ne Case 1 v= 1.728ms' gf sarccost 72 Result: Vience the difference between the velocities before and afer stream Case2 y= 1892 ms arccos 68.60 Tosi Example & Chute corner build-up radius and minimum filet size (9, For slide without friction i.e. when ¢= 0 and vp = 0, using equations the fillet size in a chute forthe following flow conditions: (Fig. 6.12 (69) and (6.10), the integration constant and the bulk solid velocity are Find the fil Jute forthe following flow conditions: Fig. 6.12) C= 16991 v= 2.68 ms" respectively A. Chute corner build-up radius For five fll (w= 0) Data ate coal (0.25 mm) Cont bul density p= 800 kgm «th height is = R(costy ~ 059) =1.0-(c0s30"~ 0560") = 0:36 Soa le seeing friction coefficient eoal/chute wall = 0.84 ‘chute inclination angle a~ 60) gh = 042-981-0366 = 2.68 ms" =the velocity is v= Yi +Solution: Equation (6.16) is applied CHAPTER SEVEN 7. HELICAL CHUTES AND TRIMMERS 2-100 ne #01266 m 800-9.81 =a 4¥sin 60 .84- 00860") B. Minimum chute corner fillet size Dara: material ash (13% water content) bulk density p= 1200 kgm cohesion = 200Nm friction coefficient coalchute wall y4,= 0.38 (21°) chute inclination angle a= 60" elical chutes Solution: Equation (6.16) ee Figures 7.1 and 7.2) are subject to i a . Two cases can be distinguished: 2200 gravitational force and resistances to motion. -0.234m 1200-981 (I= /AY(sin6O" 0.38 e060") chute, and = inflow case, when the bulk solid is directed from asta continuous material flow along the chute path Result, A fat fillet Fillet, using a 45" angle (see Figure 612) 11 be applied in each commer of the chute. The ) is ¥2234= 330 mm rhe two cases ate analysed in terms of bulk solids velocity determination. Example 9. Minimum material bed height [9,82] TAA Inflow cas The conservation of momentum (energy) law (6.06) leads to the follow ata: materiel as (13% water content) aa bulk density = 1200 ke 4 oa) cohesion = 200Nm fiction coeficient-coaVchute wall 4,=0.38 (21°) sa where: Ea inflow kinetic energy, chute inetination angle a= 60 Tina E,- potential energy, J rT etion resistances, J dissipation energy from load friction resist : Fa dissipation energy due ta resistances from peripheral forces, J Ey ~ dissipation energy through bulk solids impingement, J ‘Solution: Equation (6.19) 200 - ~=0.025m 200 OAiisin " —0Reo8 uation (7.1) ean be written in the form as follows: Result: Minimum stream height is 25 mm. vg +mg(S? +5" )sine (v0 Ya) -mg($° + )noosa~ 2% S'Hwhere: v~ bulk solid velocity, ms = inflow initial velocity, ms im ~ bulk solid stream unit mass, kg S ~ chute length in the centre, m Sf ~ chute length of radius A” at angle (@ ax), s? chute length of radius 2 at angle ay, m ic of chute inclination, degrees ‘@ ~chute tur angle, degroes ‘ay - angle of material stream bent, degrees .-helicalhorizontal chute radius, m R= flow stream radius affected by peripheral force, m 1 - coefficient of friction between bulk solid and chute bottom 1 ~ coefficient of ition between bulk solid and chute wall va~ bulk solid velocity beforeaftr impingement, ms Figure 7.1 Helical chute with an inflow head The required chute parameters can be found using the following formule: _ Jength ofthe chute along the centreline - assumed angle of stream bend radius of the flow stream chute length of radius Rat - chute length of radius Rat (p- on) - chute eight 2) 180 “cosa Rob) 1 = arcoos «3 " ) R=R+(025..03 (74) Sm RI (75) 180 "cose y= 1 og 180" cosa"? H, =Ssina on The impingement dissipation energy of the bulk solid stream can be determined through the calculation of the velocities. before equations (6. la) and (5.15): - before impingement y + alter impingement y Hence from Equation (71a) {14S )v8 (vom) +20(S°+ [Sa =o (rev) +24( where: a, +-=(90" ay) @ A "py o Pray =-2 - bulk soid’s cross-sectional area t nd aller impingement using +235" sina wcoset) )-1cos'(a,+B)] 8°){sina— coset) ms tb) sas por Figure 5.2 ep of approximation, nv74.2 Continuous flow For # continuous flow around the helical chute path - Figure 7.2, where no pingement takes place i. (vy ~ Ya) = 0, the following formula is applicable 42¢8"sina~cosa)f* Tee SPR Ce) where: 5° = 2% yt 180” cosa + distance slong circular flow path, m R’=R+(025 ..0.3)b - radius of flow stream affected by pe force,m (Equation 7.4) Note: Radius R* cn slated pera 1" ~ coefficients of friction ~bottom/wall igure 7.2. Helical chute 7.1.3. Steady continuous flow In [114] can be found design procedures for helical chutes, which allow savitational flow of the bulk solid stream down the determining a steady helical chute Such chutes are used to lower the processed coal in high eapacity bins to avoid coal degrading. qe height of the helical chutes varies from 15 to 30 metres with a standard diameter of R= 3.0 m. The chutes are provided for processed bituminous coal of maximum size 200 mm and ~ 8% of moisture content. The following experimental formula for a steady gravitational flow around the helical chute is used in the coal industry 1) sms" 08) du kinetic friction coeticent {%, ~angle of chute inclination, degrees {2 -acceleration duc to gravity, ms" recommended pending he initial coal velocity (which is not included in the formul 8 vo = 2.0... 25 ms" and the maximum moving velocity is 5 m ‘on the selected friction coefficient. It is recommended that the radius of the stream eross-section centre R, be lected as follows R,=R-(OAS .. 0.20), Where Ris the helial chute horizontal radius. The kinetic fiction coefficient between coal an alloy cast steel used in the chute manufacturing tends to vary between 0.45 and 0.6,72 Trimmers Shiploaders are often equipped with a telescopic discharge chute with different kinds of trimming devices to ensure each hold is evenly filled to capacity This seetion refers to a gravity trimmer design fer oF discharge spout as the simplest ‘The design coucept is based on the flow theory of non-cohesive granular ‘materials along the specified flow paths, which enables optimisation of the trimmer geometry and range of the discharge tajectory “The trimmer inlets can be made with a squared or circular cross-setion (oe ‘ther shape), widening from basic size to ba, as shown in Table 7.1 ble 7.1 Type of tr Type of trimmer eros ection a Cicer Squared —— = Figure 73 Example of a trimmer outlet desk culation algorithm based on [24,2 Ac 26) is presented in Figure 74 The width ofthe bulk solid stream within the trimmer outlet ean be determined using the following equations ‘Symbols used in the algorithm: . Q flow rate, uh de ~1mit volume lw ate, ms! 4. Circular inlet ~ quasi ellipse outlet by. =[(07...08)+0.58]¢,m lets veloysme! vam velocity, is p= bulledensity, em? 4b inlet size, m b. Square inlet rectangular outlet, by =(14058)4,m Fo “teimmer rai, m Yen velocity at) point £” = width coeticient, a uit inctnation, degrees ) trimmer width at) point Fy. steam height at 0) point The material thickness a trimmer end is: 2 2 m number of elements Kj. ~ approximation number Seno}, “wall friction coefficient, ~ number ofcurve segments Yatiable friction coefficient = segment number A detailed trimmer design is presented in FigZ| 4-240 Figure 74. Algorith crueture for calculation of trimmer exit velocity Examples nple 1. Flow through helical chute. Find the stream exit velocity R=35 chute horizontal radius b=12m chute width = 80" turn angle, sadial angle a=sT slope ofthe chute w= We=08 friction factors 0 intial bulk solid velocity Solution: Given the above data the exit velocity ofthe chute is to be found. R=354025-12-380m 4 35-3315 m GO -34t 385602 m S45" 29415 m Hab 9T3ang7 2135 m sins — 0.800857) (+3208) Ya = 5.844 ms Cas With impingement resistance («,+A)=90"-0, =90'-34' =S6" As (a, +8)> arctany| (c, +)» 41.8" and bull sotid flow takes place. Velocity Before impingement. Using equation (6.18) + 248°(sinca—jeooset) §,-04.2-981-381sinS7 08-c0s57" 5.491 mscity after impingement ases vy=0 Equation (5.158) Comparison of calculation results ~in all 0 si? + B)-no0s", +B) steel H, ah chue R==, 08, 57, 58973 m ‘helical chute Case 1 inflow «y= 34, S°= 5.602 m 25 m, Equation (6.1b) vel 8.423 ms! =5491°-0.S0(sin®S6°-0.8-cos'S6')=6.59 mq =2.567 ms ‘helical chute Case 2- inflow with impingement loss Note: Inthe above equation = Aol, 0.5 was taken atittly. Hence in z en eee the next step 02.5675 491 = 0.47 canbe adjusted ‘helical chute Case 3 - continuous flow «n= 0 y=5.025 ms f= 5.491°(047-04372) «6.1956 n= 2.489 ‘9=2489/5,491 "048 Example 2. Flow-down helical chute[82). Flow rate not known. Find the " stream exit velocity. =5491°(045-0.4372)=59319 ye #2436 : 0~ 243615491 = 044 Dota: R=16m chute horizontal radius 5.491 (@.44-04372)=5.80 ny = 2.408 b=06s chute width 0=2408/5491 = 0439 o=78 radial angle ~5491°(0.439-0.4372) = 5.7869 ne = 2405 a3 sop ofthc ands 491 0.4379 = = 0.466 rietion factors 7 ene mn-20ms" initial bulk slid velocity, Nove In aoordance with 16) the deviation i ss than olution: Sg . 180 "cose =2.665m equation (7.18) BR =16+025-06=1.75m O8cos5T) _ (0-92 98L-9AisGin ao) a 7; 502.95) H,=Ssina=1.648m S845 #2796 } | g -@-mn _E So ®22.915m 180 cose 180 coset ya5.457 ms Results: Case |. Impingement energy neglected — Equation (7.1b) Case3, Ian assumption is made that a» = 0 and R'=3.8 m, ie. continuous material flow from a previous similar helical chute segment +{ve}22.0ase)- then the flow path length forthe stream is ras °°} Oa 20? +2-981(1.269+1.527}(sin38.2"~0.466c0538.2") s)-% 1.85.99 1 29.742m, hence , ; 180" cosa” 180" c0s57 y= 3.561 ms =O IETS TAGE -ORSOIT) ops Case2, Flow with impingement resistance (4, +P)=50=0,~ \ baa 0° +2-9381-1 26%6in58.2'-0.46600838.2)=10. 3.206 ms (90.5 taken arbitrarily in equation (5.15) y= 5.025 ms!206[0.5(sin® 54.3° -0.466c0s" 543 206(0.5-0.501f* = 1.6043 i = LOO43 hence next = 1,6045/3.206 = 0.5008 = 3.206[0.5004-0 501] =1.6052 vy = 1.605 9=05007 = 3.206[0 5007-0 501] =1.6057 = 1.606 ms! In accordance with equation (5.16) the deviation is less than 1%, thas = (0.206~1.606) =2.56, Fence 6+2-981:2.796(sn38.2 0.466c0s38.2") 3.295 ms Case 3. Continuous radial flow along the chute ie. a =0 15g agg 180°" st _2915 m 205382 v*(1+2218-o4os) 2° 42-981-2913(in382”-0465co82) Comparison: Velocities in ms fee fall w=Oms? — p=yr=0, 1, 1648 v= 5.685 ° Fall with 2ms* =O, H,= 1.648 m 6.026 * straight chute vp =2ms', $=2.665 m, a=38.2', w= 0466 v=4.150 * helical chute Case 1 ~ inflow oa) = 35.7", 5° = 1.269 m v= 3.561 * helical ehute Case 2 ~as Case | with impingement resistance y= 3.295 * helical chute Case 3 continuous flow «a)=0',§°=2.915 m_—y=3.2: Example 3. low-down helical chute with two full turns. Find th Aelocty iFimpingement does not occur. Data: R=16 hut hrizoil nie b=06m ehhute wiih o= 720 chute tur angle, radial angle a= 382 slope ofthe chute frietion factors areal initia bul solid velocity A. Applying formuta (7-16) Solution =| 9 ne 1 sage $190 "cosa Hi, = Ssina=25.585si K =R40.25b=1.64025-0.6=1.75 m B _os.sg5878 ® 16 (sin38.2° -0.46600538.2") = 0.2522 oor 279840 v4(1» 22% ones) x25%42-981-27 984-0252 175 ‘Note: When (sincr- os) = 0 then = 0.78 Result; y~ 4.138 ms" ula (7.8) B. Applying Solution: Where: R= 1.6-02=14m, a @=382, == w= 0.466, Result: y= 4877 ms Note: When (ne, a) = O then = 0.78Exan tangular outlet is bul with two radi and each segment are OF 60 © 7.3. Find the exit velocity igure 6.6a and Fig Daw: — Q=2500Uh — =20ms" —_p=0.764m" ww =046 kel d=by=05m Reon = 16m y-0Sm 2 a=30 a= 607 = 120 Nel K=1 Zz, Symbols used in caleulations ~ see Section Solution: q,~2500/3600/0.76 = 0.9137 ms" First concave segment: 2=1 b= 05...0.75m Ri=16m Aa =O Segment’s starting point Trimmer width bp f 2M} os-05 4 Variable friction coefficient for » =20 ms Equations: See Figure 7.4 R, Ey mexpl2ud (aye +1) =2-98 (2-0 5441-0). 1.6/2.1842=14.3724 Fy =3ieuyny= 0544-00" 1.6323 B,=(1-242 yyy = (1-2-0540 )in0" «0 GFL Mayol jo 0-202 Me ]) Gq -1ofo0?-14.3724-[632340}} 37654 R= 1.6m Aa=60" —— Segment’s end point le 4, A gravity trimmer [26] with a vertical inflow, square inlet ang Refartg exp(20.5441-1.0472) =3.1254 + exp(-2-0.5441° 1.0472) ~0.32 exp hey, = Expl 2H, Ad, = Bigguy = 3°0.5441 00860" = 0.8162 = (1~202 )5q ja) = 1=2:0.5441")sin60" «0.3533, Vy #1437 (0.8162 +0.3533)+376.5-032=1373 1 = Wag Est Ba)* CE Yigg 21 72ms" Second concave segment 2=2 b= 0.75...10 R:=05m Aa=60° Segment’s starting point Trimmer width +20/D]oseo75 ax[ia2!*tt} 05-100 4 é 4 Variable fiction coefficient for y= 11.72 ms m - oy Equations (pe +1)=2-9.81-05/20977 = 4.6766 29953 exp(2-0.5238-1.0872 =3-0.5238-cos60" = 0.7857 sin 60" = 0.3908, C= B,(08 Wj lWi aja) A202 Huy hf = 2.9983{11.72 -4,6766{0.7857+-0;3908]} 395.0 m a= 120° Segment's endfexit point2) ,=W, fg 1 4m pre 0) 20 1 (sass 2 16.829 3 1S454 4 ass 5 Bor 6 11.906 Ry (0 11.906 1 10.866 9.902 9.004 81683 6 6623 Result: Ey -exp(-2u,Aey By = 3iegyq) =3°0.5238-c05120" 0.7857 = (1-2-0.5238")sin120" ~0.3908 (Ey+B)+CE (5166 (-0:7857-+03908)+395-0.1114 = 42.156 ‘The exit velocity from the trimmer is Yq = 6.49 Using a computer program, where each ofthe timmer’s segments was divided ino six elements ie. N= 6 and a higher approximation number was selected as 2, the following computation results were obtained Me osaai 0.5334 0.3296 66 05244 03227 0.227 08217 032i 05209 032 05219 05232 it velocity of 6.62 ms! is a more accurate computational result as tho increased number of elements has an influence on the variation of the fiction coefficient ‘of the trajectory stream leaving the trimmer can be caleulated using equations (4.11), exp(-2:05238-2,0944) oant4 gsm bay 0.0914 050 0.0838 osai7 0.0848 05833 0.0861 0.825 0.0879 0.667 0.090) 0.7083 0.0928 075 0.0928 o7s 0.096; 07917 0.1007 0.833 0.1054 0875 0.1108 9167 oun 9583 0.1248 1.00 CHAPTER ElcHT 8. APPLICATIONS 8.4 Transfer chute with two circular elements [A transfer chute for a receiving conveyor at 90° to the delivering conveyor a shown below bas been analysed in [68] — Figure 8.1 Looghan ealelabon re8.1 ‘Transfer chute The transfer chute specification is as follows:Bulk Material Bauxite Bulk density p= 130tm Throughput = 2500 uh Belt velocity v=5.0ms! Conveyor inclination a= Contact angle an (= 90" a) Wall fiction coefficient Me= 0.58 on 40" Lateral friction coefTicient = 0.84) Dimensions are shown in Figure 8.1, Impact plate radius centre coordinates fiom head pulley centre (x= 0, y= 0) are: x, = 238 mm and y, = -1960 mm A. Intersection points Find the intersection points between the upper and a eurved impact plate, (Refer Figure 4.3) 1 lower boundary trajectories = V0.6-9.81-c0s10" = 2.408 ms", then as v> vy use From equation (4.18) v trajectory Case 2. Velocities = 15 =¥ Trajectories: Applying equations (4.8) base path = (= Dane =a = (+h oosa Initial coordinates of the trajectory (in metres): 06sin10" =-0.104 1 =0.6cos10" = 0591 Ya "(0.64 0:215)c0s10" = 0,803 =-(0.6+0.215)sin}0° =-0.142 Jimpact plate radius: Equation (4.15): Ro (4-0238)+[y-C196 An approximating method is used to find coordinates of points P,P Injetsection point Py Step 1: Let¢= 1/2, then x; =2.5 m, then = (2540 104)an10"-2.604 9.81/25" cos"10") + 0.600810" =-0.322 2.5-0.238)" +(-0.322+1.96) o3actandin, ie. (a, +)>373", hence flow takes place, ‘The areas ca eulated in ordance with equation (5.14) in mare as follows: 2500 05342 1 534 2500 4 8 4, 2058 3600-13 3.28 and from equation (5.15) the material stream velocity ater impingement is 83.54’ -0.58-c0s" 83.54] (oT saan on (ETT! 1012 .9873-0.58-00127)] te 2917 An approximating method is wsed to find the material velocity after 28 ms, and using the above equation for impingement, Let v= ¥p~=5.28ms", and using the above eq calculation yy the intermittent values Step I {yy 0.1012 vq) = 5.2268 Sep2: fin 0.1022 v= 52011 Ais=0.1027 v= 5.1885 10.1080 vee = 5.1820 Step |s.isss—s.1820) From equation (5.16), 0.13% hence stop iteration. “The stam velocity after impingement is = 5.18 ms C. Flow over a circular impact plate. The exit velocity of the bulk solid lowing over a circular impact plate from an le of ox 62.41" to ue =O" and for v4 = 5.18 ms (see Figure 8.1 and Figure ) and (6.40) is. 6.6) using formulae (6.51 2-28°8 9 saconezat ~(1-2-0:58%)xi6241)] Pose 7 coesmin|s 1g C-0.27-1472397 [3:0:58cos0" —(I 20.58" sin0"]+397-<°" = 6.68 msing flow between two circular D, Stream cross-section ‘chute components, Equation (6.12, d) to be used to find the velocity reduction: 250 30-13-6658 = 008 m’ flow area: - equation @.1a) A. {A 0.08 a Var “V3.416 vy = 3521 - 5.93ms Hence the difference between the velocities before and after stream erosse is 0.75 ms" seetion cha E, Flow over concave transfer chute This component ofthe transfer chute delivers bulk solids onto a conveyor belt The exit velocity - see Figure 8.1 and Figure 6.68 -is as follows: ‘,= 55° and from equation (654) ForR=3m, wy ~593ms", a=0" $93" Tose +1 Cre G-0.58e0s0" +(1-2-0.58")sind” c=-8.50 From equation (6.48) = tag 7058 41 [posteoss 40-2-05 = 511.266 4 (-12.3)0.3284 = 28,99 =538ms" F. Flow from the concave chute onto conveyor belt The impact coordinates and velocity fora bul solid trajectory flowing from the concave chute onto a receiving conveyor belt (Fig. 4.8) are exit velocity van clearance between belt and chute yo02m discharge a m= 55 ‘Component v £0s(90" a locities at chute ext: Equations (4.134), (4.13b), (4.136) 5.38c0835'= 4.41 ms" o9ms" 090" — 0 = 30972-9810. voi Day stms Impact velocity onto belt: Equation (4.134) Maa He VAT BF = 5.24 ms G. Comparison of test and calculation results Compatison of test results published in [68] and above carried out leulation results i presented in the following table: ober | Gocaton [Erion con Vetocty | tea) | A Remarks 30 Bek diargsvloiy 528 ‘eloiy before inpingsmen 5.8 elo ar impingement u | se | 8S Velocities a two curves joint | 593 457 | 4at Horizont exit vey Impingement ane Notes: 1. Average impingement coordinates forthe upper and lower ajetories are: mm and 5-250. 2 Impact angle according to [68] x: 0, =90"—0. = $0°=742°=155 3. The values of frition coefficients were not published in [68a2 Hoad chute modification The chute's specification and initial conditions areas follows (111) Balk Material cout Bulk densityfcohesion p= 0.85 t meg Throughput Q=25001m Discharge velocity 495 me Beli width 44") B= 219mm —Conveyorinclionion aa Material he A= 268mm Friction eoeficient n=05034 Paley discharge diameter (ley diameter bl ike) D= 800mm {he chute design and estimated material velocities at critical impact points are Shown below in Figute 8.2, Prior to modifications being underaken the chage experienced permanent blockages and outages in coal supplies Figure 8.2. Head chute before modification After dynamic analysis, the following modifications were carried out application ofa circular impact plate to redirect material onto the chute wall, ereasing the inclination ofthe outlet sloping chute segment ‘The base dimensions of the modified chute components are presented in the following drawing: (Figure 8.3) Figure 83 ead chute modified In accordance with existing geometrical conditions, a radivs of R = 1100 vas chosen for the impact plate and radius centre coordina centre (r= 0, )= 0) are:x,= 700 mm and yy =-250 mm from head pulleyA. Intersection points at impact plate and lower bome 43 and 8,3) In the fits step the intersection points between the uppe trujectories and a curved impact plate are found. (Refer Fi Fr 1) _ = NO ORT cos10" =1.966 ms" then as v> v, use trajectory Case 2, where stream velocity is ‘The coordinate system isthe pulley shaft centreline. Trajectories: Equations (4.8) es) Initial coordinates of trajectory boundaries (in 0 Acost0" =0.394 fo" -Ossin0’ =-007 a 12 ~-(04+0.268)si 10" 0.116 Yq. =(0.4+0.268)c0s10" = 0.658 Impact plate sadius: Equation (4.15) B=(-03)'s[y-025)} An approximating method is used to find coordinates of points P,P, Inisrasction point P Step 1: Le y= (.8+0.07y.a010°-(1.8 = 1.8m then 9.81/(2-4.95" cos'0") + 0.4e0s10" = 0.002 , R-[a.8-0.77 +@002+0257]* =1.128> 8 Step 2: Try leting x)= 1.7m, then y= (1740.07 ,an10'-(1.84)*-9.81/(2-49 cas?10") + 0.4cos10" =0.02 =151035- 8 R= 1.1 m-~ the difference is 3.5 m Intersection point P: seep 1 yy =(1.736)-tan10"- (1,736)?-9.8142-4.95 36, Then £05710") +065) n. Note: a3 —xa= 1 R=[1.62-027 +00. Ps 40.25/79 =1094=R R= L.1 m—the difference is 6 mm or an ert of 0.5% Results: Py y1=0.020m P, 0342m The impact area is considered as a flat area between points Py and P. Figures 42and 43), hi ie the impact plate ares angle to vertical i 2 0,466 Y= 03M2-0.02 (Fig. 42) p25 The angles fj and f, betwee points Py and P. (Figure 4 the radius and the horizontal at intersection Hyp _0.020-(-0. 5 23 A=253 Am B. Impingement velocity Stream average intorsction coordinates ae: vy, 002.6042 =0.181m Bip ~aretan0 6096 = 31.3 L695 Stream flying time to impact plate r= 0.348 ease ” 5.95 -c0s10= veoser= 495: cos10" = 4.875 vy svsinees gt = -4.95-sin 10" +9 81-0.348 «2.56 9, = ory =a 2561 From equation (5.134), (a, +) = 27.7" +25" = 52.7", then (a, +)>aretan Ji, ie. (a, +)> 353°, hence flow takes place, areas calculated in accordance with equation (5.14) in mae as Follows and from equation (5.15) the material stream velocity after impingement is 1 fn? 527-0500 52.7] vq #551 |83/0,6328-0.5-0.3672) 10666 as . V Ae An approximating msod is ued to find th stra velocity fer Sep: a5. y= 01483, vai 3.6905 Sep; wi e34025 402812 mae 3.031 Steps: wu=30231 Ag 02708 v= 27383 Sip: y220383 dn 0298 mae 2e0i8 Seps t=2e0l8——Ay=03140 vie 25316 Sepé — yme2s376 = A= 0.3000 y= 2.3060 Sep” vee28060 46 03260 ves 24008 5050 - 2.4905) 72.5060 From equation (5.16), 0.62% hence stop iteration, The steam velocity after impingement is vj = 2.49 ms C. Flow over a circular impact plate. The exit velocity of the bulk solid flowing over a eireular impact plate from an angle of ay = 313" (0, = ia) 10 a=-23" (ay =67 —W0" =-23'); (00 Figure 6.60) and for v,~ 2.49 ms (see Figure 8.3) using formule (6.55) and (6.4) is cars| go! BANE 0 Scos31 5 -(-2-05")sin313 Fos? €=05791--48271 =-2.1957 2idbe 7 7 ase4me ve ¥05cos(-25)-(1-2-05" sin(-23°] +(-2.7957)e rosa » =108-1.576-28-067=15.1 v= 3.89 ms D. Flow over chute’s sloped wall “Material velocity at the end of the chute's second segment before impingement using equation (6a) is: Fr v2 = 3.89 mss x= 2.82/sin67"= 3.068 m; e= 0.34 vf 23.89" +2-9.81-3,064(sin67" -0.34c0867")~ 62.49 y= T9Lms! 44, =7.91e0867 =3.001 4, 209 ms Vip =(791sin67') +2gy=3.09142-981-1017=7297 v4, =854ms" Bulk material thickness atthe chute end or stream height leaving the second cule segment using equations (2.13) is 2500 < =0.103m 360-085-7911 E. ‘Trajectory fe ute and intersection points with chute outlet. ersection points (in metres) between the upper and lower boundary leajectories and chute outlet can be found using equations (4.11), carried out only for chute outlet inelination of = 70", (Refer Figures 4.7 and 8.3) =0.1035in67"=0.095 yy =0 yp =0.103c0s67°~0.040 Flat impact plate equation (4.14) (18 %,)+Yy = tan 70°C = 0.655) -0.459 ~2.747(x-0.655)-0.459 0.8e0835' =0.655 my, =0.8sin35° ~0.459mAer approximate calculations, the coordinates of points P,P. were found an only a check-up is presented using equation (4.14), Intersection point P, For coordinates x, = 0.424 m y=-1.002m y= tan70°(0.A24~0.655)-0.459 =—1,004 The difference is only 1.6 mun (1.0936 - 1,092) or an error of range 0.15% intersection point P; Forcaordinates x» =0.480m y=0.942 m y= tan 70°(0.480 0.655) -0.459 =-0.940 The difference is only 2 mm (942 940) or an errr of range 0.21%. F. Flow over sloping chute end. The calculation resulls for the final ma main chute are shown inthe following table: ial stream velocity as it leaves the 8.3. Flow analysis of a transfer station chute. ‘A transfer chute was designed with a 3-way chute diverter [28] to accommodate and to ensure a consistent and uninterrupted supply of Goal to an out-loading process. This chute (Figure 8.4) was designed on the basis of Korzen's impingement theory [45] for granular materials (see Section 5) in intial stage through hand calculations and other empirical means [28 AA computer program named ChuseCale [31] was developed for the modelling of ransfer chutes based on impingement theory and flow properties of blk solids, ‘The proposed transfer chute was verified by means of dserete element method (DEM) [113] using Jenike’s mode! [80}. The following table of computation results of the steam velocities at sel points (No. | to 11 ~ see Figure 8.4) ean be used as a comparison between the two methodologies. = [=e emails — Computer progam | DEM 2 ORT a au a3 Remarks a — me : Fn oer poate] = [3 eae re eee sine 70.07 oie | 300/834 mel ol 80/5.03 [7.042 | Fl A slope of = 70° was selected for the modified chute end to avoid the chute blockage 188 ‘The calculation results are presented in Figure 85,Computer cnelton recut, i (1) 85 Compa n between computation results Bosh approaches are unique in theit respective methodology and assumptions. Some differences are to be expected. The main differences in transfer station all fietion coefficient 03 instead of 08 cohesion 50 [N/mm instead of 0.0 [Nm] 1 adhesion 0.0 [NJ instead oF 0.0 [Nm] It should be noted thatthe adhesion, cohesion and frition coefficients used in the DEM code are not direct correlations of the above named parameters used i the classe theory of granular material flow [33, 40, 44,50, 57, 60} ement method is actually sufficiently advanced to be Despite that dhe diserete fof benefit in the design process, however the existn curacy of flow gineering service is a significant Kmitation to modelling and cost of such an e the wide application ofthis methodology Figure 84 Three-way transfer ehute (25,015)84 Bifurcated chute ‘The chutes spocifeation and intl conditions are as follows: (31) coal Bulk density/cohe on p= 049 tm Friston coeticen Cabesion Throughout O=8650em —ekewidth 2 = 2000 mm Belt sped ¥=624ms" Conveyor inclination a= Pulley diameter —-D=1282mm Impact plate radius_&,— 2100 Spoon radius R= 1000 mm Materia Reig fh 485 mm ‘The eleulaton results for the bulk solid velocity immediately before and ater impingement are indicated below, Figure 86 shows the layout and tavellingdstnesy ofthe ll materia Figure 8.6. Bifureated chute Equations 219,05 ntl Conditions enn tesla ‘m Dyers coefens ment Eaton (48), (410) Imac veloc came Enitveloeiy Titan impoct plate Equations 6) Fi overimoc pte Eauaone() eft avation (610) nial velocity sans Baten ation 5.15) co sera Equations (6,18) Flow down cts 1 Tra oc west Che nat Impalas ace Datunceoimpet phe %~ 1083.n Fretall? Fall eh featam tute batom2. Egeaion (515) Impact an sion Flow down shete2 Equation 18) Inia etc nears irelar gvation (8)In the following table the computational results are summarised for the volocties in the transfer chute determined using three different friction coefficients, In the table's centre column the results from Figure 8.6 are repeated for comparison ‘Velocity ofthe material stream, ms" CCharacteritie points in the chute (Fig 8.6) Coefficient of vietion 1. Os os [to | — oa a nga plate / olision SaeIt | 6enasT | eases Timpsct plate siding 30 $33 195 F Saght sloped chute Seam uajecory ealision | 140306 Fee fil colision 2) 5 9615.64 Senight sloped chute @) al collision () | T08652-| TOs 72 | Taso | Sone Dp | inso [i070 [93 aa For simulation purposes the friction coefficient has been selected with the values of y= 05, 0.8 and 1.0, Inthe primary chute analysis it was established that the geometrical shape of the chute is optimal and it romans unchanged, The basie considerations are focused on a constant stream flaw through the system. In this case the minimum stream velocity is o 8650 36005; —3600-1,56-0.83 =1.86m nd where the chute outlet is 100% filled with the material stream. The following table shows the stream exit velocities for the spoon for different friction coetficients, os 06 [07 ase [409 [337 | The calculation results are presented in Figure 8.7 trea welch, Figure 8.7. Graphical illustration of frietion coefficient simulation rom Figure 8.7 it ean be seen thatthe criteal component of the chute is the spoon andthe friction coefficient should be selected ina range oF 0.5 to 0.6. For this data the exit velocity from the spoon is estimated fo vary from 4.9 t0 4.1 ms and the filling ratio is about 40% ofthe chute outlet area, 85 Typical transfer chute The chute specification and basic data areas follows: [31] Flow ruieimass flow Q=7000h Chute with B= 1.0m Material densityisoesion = 850 ke mi"/e=0 Impact plate radius = 2100 mm fr 403 mi Spoon Radive R= 1000 mm ~2000 mim Drop heist = 800 Material Conveyor angle Friction coef Paley diameter Conveyor belt speed The chute model with addtional dimensions and calculation results is shown in Figure 83, To calculate the steam velocity, the ChuleCale program [31] was applic8.6 Flow modelling in a transfor chute The chute specification i as fallows: : Flow ateimass flow Q= 1400ch ‘chute width . Material density 1-850 kgm? Cohesion aaa Impact platcradios R= 1050 min Material height c x Paley diameter = 634 mm Rel thickness Conveyor elt width B= 1080 mm Conveyor ang Conveyor betspeed — v=38ms" Friction coolicient pO sn Dimensions ~ as shown below (31 iat y 8 1h Figure 8.9 transfer chute Figure 8.8 Model of a typical ra 168 167in the following table. ‘ “a =o Discharge angle wd Dimensions nm Symbols wos | 742 sin Figure 87 7 | 1303 | 1450 y | 3034 | 3800 1a_| 5a | “Material flowing prosest Velocity, ms Discharge trajectory =} iit eo Impact plate: isle r tr nat impingement | o=sar atplte cent mya suplae exit Trae stat 7 before impingement | vy afr impingement |, Free fill p02" lezmm_ | Impact angle: p18 ® 68 Impact angle: = ® a Flow seam exitat 66 mse | sa | o The material stream after impingement with the impact plate forms a trajectory, which ends in different places depending on discharge angle a 4. For ws = 50° the stream trajectory strikes the vertical wall at » = +162 mm with a velocity vp 7.07 ms" and the sear flows down vertically to 2 = O-with the velocity of vp = 7.29 ms", The stream exits the spoon a vn.= 582 ms b. For w =45" the material stream strikes upon the spoon bottom at an angle of {B=-18" (see Figure 5.2) ic. atthe point 2 = -542 mm with a stream velocity of 5.68 ms" and exits the spoon at v= 541 ms" «. For oy =40" the material stream strikes the spoon bottom at an angle of {B= -60" and a depth of 2 = -1521 mm (close to the chute outlet), where the Stream flow stops Hence the impact plate discharge angle should be selected in the range between a5... 50 degrees, 108 CHAPTER NINE 9. PROTECTION DEVICES 94 Introduction There is often a need to monitor the movement of bulk materials throughout a process to ensure that there are no flow problems. The most frequent area for blockages and spillages to occur is at the process transfer points, where chutes The most common problem to occur at a transfer point is a blocked chute hich is usually caused by one of the following: The chute being under-designed in cross-sectional area to convey the ansferred; and/or ‘quantity of bulk material required to be Sticky” of wet bulk material adhering to the sides) of the chute and ‘building up tothe point where a Blockage oceurs; and/or Internal ledges formed within the chute enabling material to build up on tually black the chute; and/or Incorrect ehute geometry causing the velocity ofthe bulk material flow to be reduced and succeeding material to “back up"; and/or Dowastream process not operating correctly and not being able to ‘Bulk material transfer by a chute requires electrical instrumentation sensors to be installed for alarm and control purposes to protect the system against flow problems and mitigate the risk of system damage, spillage and disruptions to ‘operations. A system with inadequate sensors and their correct positioning, andappropriate controls would be at tisk as a small blockage in the chute ‘icky become a fll blockage within a very short time very rormal and abnormal operation craton, This conveyor wil ome toa ak Very gui Nowehee i feeding conmeyer wil be sped by te conta systm with » eR Daring the day atria fom theferd conveyor wil contin to be axa culo the downstream conveyor throug the chs. The cut. wil fa tecumolate the materi The chute needs to be sized 0 accommoda Iter acumlation tut also te sensor mt be isalled fn poston fa thove he evel at nhsh the materi may aceumalate Ieis common practice in larger systems that main transfer chutes are provided with two sensors; one at the lower level and one at the upper level Activation of the lawer sensor will generally raise an alarm for the operator {8 take appropriate action or fr the control system to reduce the upstream eed Activation of the upper sensor will lead to an emergency shutdown of the feed conveyor and continued operation of the downstream conveyor to clear the ‘material (Once the material is cleared both sensors should indicate a clear chute condition tnd therefore normal operation may resume. This could be programmed a an utomati Funetion a a8 one which requires operator initiation, The upper sensor also provides redundancy forthe lower sensor and it may be hhard wited to the feed conveyor motor circuit. IFonly one sensor is installed snd that sensor fails to operate correctly then there is strong likelihood that spillage and mechanical damage 40 equipment will accut, In such circumstances bull material flowing out of the head box will be deposited onto the return belt and spilled along the conveyor length, It is also likely to be deposited on idlers and pulley surfaces. In large systems itis not uncommon to find a sensor installed ‘within the head box to protect against a blockage above the upper sensor in the chute 92 Sensor types There are various types of sensors used in different industries. It is important thatthe right sensor be selected for the right application, I is also important that the sensors are installed in a fail-safe wiring configuration to ensure that the tof loss of healthy signal from the conveying system is protected in the eve this deviee has been available for many decades and is found in stallations such as coal Tit Switeh rmany bulk materials handling fonnage of material is conveyed. The switch is within a robust steel enclosure fand mounted inside the chute. I¢ is normally hung in the chute with an adjustable chain however out of direct impact ftom the flowing material. In the event of material accumulation in the chute the switch tilts and breaks contat ‘and the control system caries ou the programmed for a blocked chute condition would be 15 to 20 d dislodged from its chain support the control system will detect this asa loss of signal and therefore interpret it asa blocked chute condition. That is, it is fail safe. A problem experienced in some installations with the tilt switeh is that i the chate were to fil up very quilly the switch may be quickly engulfed hy the material and not have the opportunity to tilt, Therefore, the control system ‘would interpret ths as a normal condition struction, Typical tlt angle ees, Should the switch be nology was introduced ata later stage however it the love Microwave Sensor — this t has been available for some decades also. This device is not placed it stream and is therefore not subjected to the mechanical damage from the bulle 2, Which sends out a continuous low material. There is a mierowave $0 frequency microwave signal and the receiver installed on the opposite side of the chute receives the signal. As the material flows the signal still reaches the receiver however if a material blockeg eed by the material and therefore the conti system interprets this as a blocked chute condition and takes action as programmed, Failure of the mierowave source the receiver is also intepreted a a loss of signal and therefore its also fail safe Externally fitted devices such as the microwave sensors are more convenient to ‘occurs the signal is bl js also mature and has been available for e membrane is activated when rembrane. The Pressure Switch — this technology some decades. A pressure switch behind a durabl the material in the chute builds up and places pressure on th ‘membrane can be damaged by abrasion. The switch behind the memirane then The device is also installed in @ fail-safe arrangement, Maintenance access is external tothe cut.Acoustic Emission Sensor ~ this is a noninvasive device and the sensor mal no contact with the material. A specially designed crystal within the sensgeip excited by a certain frequency and generates a continuous electrical signal ‘which is proportional to the acoustic energy received. The inbuil electron conver he signal into a usable format, which can be interpreted by the eontg system Gamma Type Sensor ~ is device operates on the principle of gemma tay absorption. It consists of a gamma emiting source and a gamma sensor installed fon the opposite side of the chute, When the material builds up there is an absorption of gamma rays. The inbuilt electronics convert this signal signal for the control system. An outpst is provided when a predefined absorption condition is exceeded Flap Switch ~ the flap switch is installed in the chute with a proximity sensoe installed from the outside, As the material accumulates in the chute the flap switch rotates and its new postion is detected by the proximity switch. The flap switch is prone to wear and impact damage and therefore requires regular Utirasonie Sensors ~ te ultrasonic sensor is suspended in the chute ot fixed to the chute however notin the fo area. Tt monitors the level in the chute from the top and provides a signal that is useable by the control system to alam 4 high level or trip the feed conveyor. The transducer fires an wlizasonie pulse into the chute and receives an echo signal from the material. This sensor may not Doppler Microwave Switch — A beam of microwave energy is emitted fom & transceiver unit, Small amounts of energy from the heam are reflected back from the material in the view of the sensor, Ifthe material is flowing, there will be a ‘Doppler’ frequency shift of the reflected signal, Frequency shift will not occur ifthe object or material is stationary, or does not reflect energy. Any frequency shift is detected by the transceiver unit and used 1 switch a relay for indication or control purposes. This chapter isnot intended to describe all devices that may be available on the market, There may be other devices available for special applieations. 1 9.3. Involvement of Instrumentation Supplier Supplies of proteetion devices develop extensive knowledge of their deviees by being involved with the materials handling) instrumentation designers at the carly des mmmend the most suitable devices forthe application The suppliers may also be involved in the commissioning process to ensure the devices are correctly installed and calibrated. Where an operational problem ‘occurs duc t9 a protection device the supplier will certainly be requested by the plant owner of contactor to provide support to resolve the problem, Unfortunstely, very often the supplier is not invited to be involved at an early stage and is only requested to resolve a problem after the device has been installed and commissioned. Under such circumstances the designee would have deprive him/her self of the supplier's extensive experience which may span actoss many installations and diferent applications for the particular protection device, The authors recommend that designers discuss their protective devices requirements with reputable suppliers atau eal stage of desig. 9.4 Safety Considerations All designers have some responsibility for safe design to ensure thatthe plant and equipment can be safely installed, operated, maintained, demolished and disposed, Chute Door Sensors Most chutes are provided with doors to facilitate inspection and cleating of any blockages that may occur under abnormal conditions. In these doors can be sufficiently lage to end flow systems a person to enter the chute. If such a door is opened by maintenance staff while the bulk material is Moving in the chute then there is a risk of that material escaping from the chute through the opened door and causing serious haem to anyone in its path In addition, the material will continue to escape creating further hazards with dust, pillage and equipment damage. This risk is generally mitigated by the provision of a sensor on the chute door which ean be programmed to shutdown the supply conveyor. Some material will sill escape however the risk is considerably mitigatedThe most common sensors fitted to chute inspection doors ate limit switches and proximity switches and they are normally wired ina failsafe configuration Failure of the switch or loss of a wire will be interpreted by the control system as an open chute door condition. Where a chute inspection door is loc ed ing Position where material escape is highly unlikely then the limit switch op proximity switch may be configured to simply alarm an open door condition, ‘Thermal Detection In some pplications such as coal stockpile reclaim systems some de provide thermal detection inthe sist box just downstream of the chute. I bulk material is transfered through the chute the thermal detector inthe skirt box will detect this condition and ether shutdown the conveyor system or just raise an alarm for the operators attention Special Ratings for Devices For some bul materials such as coal, dust genersted inside the chute may lead ‘oan explosion under some conditions, An explosive mixture may be created if the dust and air are sufficient and an ignition source exists, Any electrical could provide the required ry (© trigger the explosive process unless that device is specially desioned to mitigate this risk Since the mid 90's there has been a strong trend in engineering Standards to address this risk by the installation of suitably designed protection devices inthe hazardous areas of the installation. The inside of a chute is considered to be a hazardous area and therefore selection of protective devices requires ‘compliance to the relevant Standards. The chute instrumentation designee is advised to gain a thorough understanding of the relevant Standards before selecting protective deviees. ‘TERMINOLOGY Abrasion ~ a process, which occurs when a bulk solid slides under foad or its ‘own weight aver a wear body Angle of repose ~ angle between the surface of a piled-up bulk solid material and the horizontal plane (4). Angle of wall frition ~ wal tition angle ofa bulk solid material sliding on a intemal chute surface; a kinetic angle of wall fiction or Sliding Angle of wall feietion (44) Adhesion he molecular force exerted across the surface at contact between Adjacent bulk solids particles which acts to resist their separation. 2. is @ iendency of certain dissimilar molecules to cling together due to attractive forees. 3. the molecular attraction exerted between the surfaces of bodies in Bulk solid (material) —any material, of varying patile size and properties that or conveyed in a bulk state. is transported, store (Chute -« device that uses the inherent velocity or potential energy present in & bulle material to enable it to transfer or flow fom one point to another. In its simplest form, a pipe may act as a chute hetween two reservoirs; other chutes fare more complex, with varied geometric shapes and bifurcations to transfer bulk material between conveyors and flow process systems. Coefficient of wall friction ~ isthe tangent of wall friction angle ie. «= tan. Cohesion (cohesive force) ~ 1. the state or process by which the particles of bull solids are bound or stick together. 2. is a component of shear strength of bulk solids that is independent of in-particle fiction. Effective angle of internal friction () (cffective yield locus) - angle betwee: the abseissa and the tangent of the curve representing the relationship of shear stress to normal stress, Equivalent friction coefficient ~ a wall fiction coefficient which take into faccount the pressure gradient against side walls; also additionally takes into unt high speed bulk solids lowFrietion coefficient ~ descries the resistance to the relative motion of surfaces tnd bulk solids in contact; is a measure of the surface/bulk sold’s shear resistance end depends on the state ofthe lk solids consolidation. (1) Impact ~ a collision process between two or more objeets. Forces ereated by impact are exerted and disappear in avery short interval tm 4 Impingement a process resulting in a continuing succession of impacts between a bulk material and sold suri Kinetic angle of internal friction ~ the angle at which the bulk solid will continue to slide until a steady-state of shear-stress is reached on the shearing surface Plate, Deflector ~ soo Plate, Impac! Plate, Impact - replaceable plate made or costed with a wear resistant material used to absorb impact of bulk material and re-direct the flow of the bull ‘material to another direction, Plate, Liner ~ sce Plate, Wear Plate, Wear ~ roplaceable plate, generally made or coated with a hardened surface, and used a8 ¢ sacrificial lining within the chute to protect it against sliding wear. ‘Static angle of internal friction ~ the angle at which the bulk so slide on itself when subjected to stress acting onto the shearing surface (4) id will beg Surcharge angle dynamic angle ofthe material conveyed (8), ‘Surface Roughness ~ is quantified as the mean centreline roughness of the chute wal surfaces, Trajectory, Discharge - the path followed by a particle, or stream of bulk material on leaving the point of discharge. Factors affecting the discharge trajectory include velocity, particle size, moisture content, shape and mass, cross-sectional area of discharge flow 176 REFERENCES 1. Amold, P.C. 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Australian Bulk Handling Review, Volume 15 N° 7, November/December 2010 Benjamin, C., Hugue, S,, Donecker, P: Designing wansfer chutes using Australian Bulk Handling Review, Volume ids vig, M. amular Solids” Rheology: Comparison with dings of the COMSOL Conference 2008 discrete element modelling. IGN? 2, March/April 2011 Mullaney, M. P,, Leyva N: Modeling Pharmaceutical Powdler-Flow Performance Using PartleleSize Distribution Dara, Pharmaceutical Technology. Volume 33, Isue 3, 2009 Molenda, M., Horabik, J: Mechanical Properties of Gramular Agro Materials and Food Powders for Industrial Practice. Part I. Institute of Agrophysics PAS, Lublin 2005 Donocker P Dynamic scale modelling (DSM) of transfer chutes Australian Bulk Handling Review, Volume 16, 6, Sept/Oct. 2011 Schalk van der Merwe, Nico van Aarde: Dynamic chute application. ‘Australian Bulk Handling Review, Volume 16, N° 5, July/August 20150. ates, 1. Deotng vith wet and sticky bulk solide. Australian Bu Handling Review, Volume 16, N” 5, July/August 2011 APPENDIX. _The Intemational System of Units 51, Beckley, D.- Belt comeyor transfer cues tips for designers Astalan Bulk Handling Review, Volume 17, N° 1, Jasuary/Febrary Quanity Symbol nie Base nia: —— — 152, lis, D., Donohue, 1. Transfor cite analysis ~ current practices Tene wer a Involving continuum, DEM and practical validation. Austeaian Bulle | sass kilogram is Handling Review, Volume 17, I, donuary/Februay 2012 Time sscond : Inesiy oteleticcurent | ampere a‘ = Thermodynamic tenpernure | Kelvin x Lino conden fa Supplementary wns Plane angle radian Solid angie storadin Derived units ‘Angee velocity radian er second “Angular acceleration radian per second squared | _ilogram per cubic me ken newer N Moment of force, torque newton Nm Werk, energy, quantity of heat | joule, newton-metre [Nm] 1 Power watt Wis] w Linea ood newton per met Non! Sites, pressure pscal, newton per mote squared. | Nm Mass moment of inertia Silogram metre squared gm | Viscosity, kinematic ete squared per second m Visoosty, dynamic pascal second (sem) Pas Frequency ert FT ia Electrical tension valt v Magnetomotve force ampere A etic resistance ‘hn [V/A] a lestriceapecitance firad [ASV F Magnetic fed strength ampere per metre Ant (Quantity of electricity covlomb [As] ce | nductanee henry {V/A} H min candela per square mete dm‘Table A. Conversion table imperial to metric units Conversion table meti to imperat — _ Ssem ‘Imperial eo [ ‘System Metre = cee a= = are met | Seton a Tea assay ho zara aro ae |. wom] is Rca 109Examples, Conversion imperial units to metric units Ac Density Tempera Tongue: Conversion mi Volume: Mass: Force: Stress Energy Velocity Mass moment Reference AS 1000 The International System of U 100 Table Al 20 A= 120-0.3048 = 36.576 m 2.4 fle = 24-3048 = 0.73152 mvs 18 hp = 18-745,7 = 13422.6 W = 13.4 kW 50 Ibg/f? ~ 50> 16.01845 = 800.9225 kg/m" 68 F~ (68.32V1.8 = 20°C ~ 293.15 K 25 psi = 25-0,06804757 = 172368925 bar = = 172368925 kPa 400 Ib ft 400- 1.355818 542.3272 Nm mits to imperial wnits Table A2 1.2m? = 11.2- 10,76391 = 120.5558 fe 20m ~ 20-35.3147 ~ 706.294 ft 68 kg = 68: 2.204626 ~ 149.9143368 Ib, 32 N= 32-0.224809 = 7.1939 Ib 280 Mpa (N/mm) = 280- 0.14508 = 40.61 ksi 350 5 =250-0.737562 = 184.4 lb 6.1 m/s = 6,1-3.28084 = 20.013 tvs 38 kem’ = 38 = 901.7852 Ih its (SI) and Its ApplicationsRoe cee eee ag This book is @ convenient and practical ool for mechanical and structural engineers Ce ee nc ee eae re Oe ce eer eet geet The fundamentals of particulate material flow systems and dynamic modeling of ‘granular low within confined geometrical surfaces are discussed and demonstrated with examples, The main objective of the flaw system modeling isto predict the performance characteristics of the systom, taking into account granular material characteristics and specified operating conditions, [Mathematical modeling of the system i based on principles of lw and conservation ‘of energy, principle of superposition that can be applied, varabilty of parameters ‘depending on environmental conditions and time, and dependence of the geometrical ro The system variables are material charactaristics (time dependent), coefficient of Cee eRe en ees ! Kazimierz Golka has worked as design engineer and consultant on numerous ‘materials handing projects for over 40 years in Europe, Asia and Australi, He gained his ntarnatinnally recognised mechanical engineering qualifications of BE, Master and PhO at the Wroclaw University of Technology. Qver the years he has developed design procedures and computer programs for various processing plant Ne eee ne ee eae ty rs Costa Vasili nas worked as design engineer and project manager in coal red power Station and materials handling projects for 30 years in Australia and overseas, He CO ee ie oe ae tee is 1977. His experience spans aoross the electrical and mechanical discipines. Re eee ee ‘Manegement) from University of Technology, Sydney. He has been involved in the Ce en meee ey Cee tee EO eae ee ee Cute ee ee es JM il 0