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BLACKIE ACADEMIC cSt PROFESSIONAL
An Imprint of Chapman & Hall
Apart from any fair dealing for the purposes of research or private study, or
criticism or review,as permitted under the UK Copyright Designs and Patents
Act, 1988, this publication may not be reproduced, stored, or transmitted, in
any form or by any means, without the prior permission in writing of the
publishers, or in the case of reprographic reproduction only in accordance with
the terms of the licences issued by the Copyright Licensing Agency in the UK,
or in accordance with the tenns of licences issued by the appropriate
Reproduction Rights Organization outside the UK. Enquiries concerning
reproduction outside the terms stated here should be sent to the publishers at the
Glasgow address printed on this page.
The publisher makes no representation, express or implied, with regard to the
accuracy of the information contained in this book and cannot accept any legal
responsibility or liability for any errors or omissions that may be made.
A catalogue record for this book is available from the British Library
Library of Congress Catalog Card Number: 85-29147
Bulk Solids Handling Unit, have been deeply involved in these initiatives from
the outset and this book is the result of a clearly perceived need for an
introduction to the subject that would identify and set out a structure for the
area of study that is becoming known by the convenient, if not entirely
accurate, title 'Bulk Solids Handling'. Many specialist treatments are already
available: works on particle technology, hopper design, fluidization, dust
control, pneumatic conveying, and others, can be found on library shelves and
in most cases these are excellent and valuable works of reference for the
experienced engineer. However, for the student and for the engineer who
requires an overview of the emerging discipline of bulk solids handling,
supported by an adequate coverage of fundamentals, this book should
provide essential reading.
In common with most books of similar size and scope, this one should really
be regarded as the product of a team effort. We, as authors and editors, would
unhesitatingly acknowledge the contributions, both direct and indirect, of our
colleagues in the Bulk Solids Handling Unit at Thames Polytechnic, notably
Dr David Mills and Dr Alan Reed. In their various ways the academic and
technician staff of the School of Engineering, together with many of our
postgraduate and undergraduate students, have played some part in the
events leading up to the conception, preparation and, ultimately, the
production of this book. Although it is perhaps a little unfair to mention
individuals by name, we do gratefully acknowledge the patient and tolerant
efforts of Mrs Pam Colley in undertaking the massive task of typing the
manuscript. Finally, our sincere thanks and appreciation goes to our
respective families, especially to our wives Angela and Fran, for the patience,
understanding and considerable fortitude that they have shown during the
months that this book has been in preparation, and indeed during the many
years that we have both been so deeply involved in the multitude of activities
arising out of our interest in the fascinating subject of Bulk Solids Handling.
CRW
JSM
Contents
Index 513
... when you caD meaS\lfe what you are speaking about, and express it in numbers, you know
something about it; but when you cannot measure it, when you cannot express it in numbers, your
knowledge is of a meagre and unsatisfactory kind: it may be the beginning of knowledge, but you
have scarcely, in your thoughts, advanced to the state of SCIENCE, whatever the matter may be.
(Lord Kelvin, as Sir William Thomson, speaking on 'Electrical Units of Measurement' at the
Institution of Civil Engineers, London, 3 May 1883.)
(Arab proverb, freely translated as: 'Experience without learning is better than learning without
experience'.)
1 The nature of bulk solids
l.1 Introduction
A bulk solid consists essentially of many particles or granules of different sizes
(and possibly different chemical compositions and densities) randomly
grouped together to form of a bulk. The 'nature' of such a material~that is, its
appearance, its 'feel', the way it behaves in various circumstances, and so on-
is thus dependent upon many factors, but principally upon the size, shape and
density of the constituent particles.
The nature of a bulk solid, described in terms of appropriate characteristics,
is an essential consideration when designing or selecting equipment for its
handling or storage. There are innumerable examples in industry of problems
that have been attributable to insufficient attention being paid to the
properties of the bulk solid involved. Failure of a material to discharge from a
storage hopper, blockage of a pneumatic conveying line and uncontrollable
flushing of material through a weigh-feeder are typical of such problems. In
this chapter some of the principal parameters that are used to describe bulk
solids and their behaviour will be introduced.
When attempting to describe a bulk solid it is important to understand that
the characterization can be on two levels:
(i) By means of features descriptive of the behaviour of the material in its
normal bulk form; for example, the way in which it compacts, its flow
properties, the influence of moisture and electrostatic charging
(ii) By means offeatures of the constituent particles such as their size, density,
hardness, shape and surface texture.
At the present time our level of knowledge is not sufficient to enable a
reliable prediction to be made of the behaviour of a bulk solid solely from the
characteristics of its constituent particles. Nevertheless, research in this field is
progressing, and by continually seeking correlations between the observed
behaviour of various materials in the bulk form and measured particle
characteristics, a valuable database is being compiled for the benefit of
designers and users of bulk handling equipment.
There are many descriptive terms and numerical parameters that can be
used in the characterization of particulate and granular bulk solids, and these
may refer both to the appearance of the material and to its behaviour in
various circumstances. A first step in determining the characteristics of an
unfamiliar material is to consider its behaviour in very general terms; for
2 BULK SOLIDS HANDLING
Table 1.1 A 'materials personality test' helps to establish the behavioural features of a bulk solid
'Neurotic' materials }
have poor Ilowability
have too much Ilowability they move awkwardly
are sticky or tacky
tend to pack or bridge
'Sadistic' materials are }
abrasive
corrosive they attack their
toxic surroundings
explosive
hot
}
'Masochistic' materials are
friable
degradable they suffer from
contaminable their surroundings
}
'Schizophrenic' materials are
hygroscopic
susceptible to electrostatic they change their
charge behaviour pattern
1.2 Sampling
The majority oflaboratory techniques for determining the properties of a bulk
solid and of its constituent particles naturally require only a very small sample,
usually to be taken from a large amount of material. Even a minute sample
may contain many thousands of individual particles and in order to appreciate
the difficulties of guaranteeing a representative sample, one needs only to
imagine trying to collect from, say, a one-tonne load of material, a few hundred
particles for analysis by microscope! There is little point in going to a great
deal of trouble to determine accurately the size distribution or the flow
properties, for example, of a bulk solid, if the sample used is not truly
representative of the larger mass of material from which it was taken.
In many processes involving the movement of a bulk solid, such as flow into
a hopper or on to a heap on a flat surface, significant segregation by size and/or
density can occur (Figure 1.1). Thus, there must be immediate doubt cast on
any sample taken by scoop or similar device from a large quantity of stationary
material. Where possible the sample should always be taken from a moving
stream of the material in question by diverting the whole stream for a series of
short intervals of time spaced over the period of flow of the complete batch.
Once a 'gross sample' (perhaps a few kg) has been obtained in this way it will be
necessary in the laboratory to further reduce it to a size suitable for whatever
measurement technique is to be used.
l6-way dividmg
head
Cal regular hexagonal: E" 0.26 Cbl regular cubic: E" 0.48
Figure 1.6 Packing arrangements for monosized spheres.
8 BULK SOLIDS HANDLING
Writing Pp as the 'true' density of the solid particles and Pr as the density of
the fluid in the void spaces, it can be shown that an expression for the bulk
density is
Ph = (pp - Pr)(l - e) + Pr (1.3)
F or dry bulk solids the void spaces would, of course, usually contain air, and
thus the density Pr would be negligible compared with Pp so that the
relationship between bulk density and particle density becomes
(1.4)
Clearly a knowledge of the bulk density of a product is essential in order to
design storage vessels, conveying systems and the like. Determination of this
parameter from a sample of the material concerned involves measurement of
the mass ofthe sample and its total volume. The measurements are essentially
straightforward, the problems arising more from the need to decide the
conditions under which the volume should be measured than from the actual
measuring techniques. It has been mentioned that the voidage (and therefore
the bulk density) of a particulate material depends upon the packing
arrangement. Therefore it is necessary to qualify any stated value of bulk
density with an indication of the condition of the material concerned. For
example, 'loose' or 'poured' bulk density might refer to a measurement for
which the sample of product was carefully poured into a measuring cylinder to
determine its volume. Alternatively, adopting a technique in which the sample
was packed by dropping the cylinder vertically a number of times from a
height of one or two centimetres on to a table could yield a value of ,packed' or
'tapped' bulk density.
Note that the bulk density of a mixture of particles of different sizes will
depend upon the extent to which the smaller particles are able to fit into the
spaces amongst the larger ones.
Determination of voidage involves the separate measurements of the total
volume of the sample and the volume of the solid particles alone. The most
direct method of measuring the total volume is by pouring the sample into a
calibrated measuring cylinder and reading the volume from the scale, but note
the need to specify the condition of the product, as explained previously. The
THE NATURE OF BULK SOLIDS 9
determination of the volume of the particles will be discussed more fully in the
next section, but usually involves some form of fluid displacement technique
using a standard density bottle or a more sophisticated instrument such as an
air-comparison pycnometer. Difficulties arise with particles that are porous or
have internal voids (such as coke), since the definition of particle volume
becomes uncertain.
stop
reference
piston
measuring
piston
powder sample
(volume V)----..;:....___...loJ........:
in cup zero V scale
(tare)
the position of the measuring piston for a null reading of the differential
pressure indicator.
It should be noted that all these methods yield the average particle density of
the bulk solid. The densities of different constituent particles in a blended
product can only be determined with any certainty by measuring them before
blending.
It also should be noted that values of particle density obtained by an air
displacement method (such as the air-comparison pycnometer) may differ
slightly from those obtained by liquid displacement when the particles
involved have open pores, formed, for example, by air occlusion during crystal
growth. In general, the density determined for a porous material would be an
'apparent density' which could be defined as the mass of a particle divided by
its volume including closed pores but excluding open pores. If the particles are
immersed in a viscous fluid their average effective density would be the mass of
the particles divided by their volume including both open and closed pores
(that is, considering the boundary of the particle to be its external surface). The
'true density' of a porous particle should thus be defined as its mass divided by
its volume excluding both open and closed pores.
Typical
Descriptive term size range Examples
of size covered by terms such as 'granular material', 'fine powder', and so on,
are appreciated. Table 1.2 sets out approximate ranges and, in order to assist
the reader to visualize these, some familiar bulk solid materials are quoted as
examples.
A mass of mono sized, spherical particles can be described by a single
dimension-the particle diameter-and a mass of spherical particles of
varying size can be described by an 'average' particle diameter together with
some information on the distribution of sizes about that average value.
However, where the particles are non-spherical it becomes necessary to define
more carefully the parameters used for size and shape. (It may be remarked
that 'size distribution' is more a property of the bulk solid than of its
constituent particles. However, it is obviously convenient and relevant to
discuss the term at this stage along with characteristics of individual particles
such as size, shape, hardness, etc.)
In order to represent the size of an irregularly shaped particle by a single
quantity it is customary to use an 'equivalent diameter', corresponding to the
diameter of a sphere that exhibits the same behaviour as the particle under
certain conditions or that has the same value of some other descriptive
characteristics.
Thus, for example, a 'volume diameter', dv , can be defined as the diameter of
a sphere having the same volume as the particle.
That is to say,
(1.5)
quantity and therefore it is the 'surface diameter' that should be used for
particle size:
To convert Multiply by
"'"'
'"
OJ::
c U
";;; "~
0> "'
c'"~ u"''"
CD
c.
particle size
- ......
/'
100
Ql
0> 80
1\
'"
C
Ql
1\ " undersize
0
CD
c.
60 , IJ
Once the size distribution has been measured (for example, using one of the
methods described in the next section), it is relatively simple to develop a
suitable histogram by constructing rectangles over each class interval, the
widths of which would usually be chosen in geometric progression. The area
under each rectangle is proportional to the percentage of particles in that class
so that a smooth curve through the histogram would yield a frequency
distribution (Figure 1.8). An alternative, and often more useful approach is to
present the data as a cumulative graph in which particle size is plotted along
the horizontal axis and the ordinate represents cumulative percentage
undersize or oversize (Figure 1.8). The principal advantage of this latter type of
graph is that values not determined experimentally are reliably predicted.
14 BULK SOLIDS HANDLING
o o
+-+
o
same volume same
/
same vofume
surface area
/
~OoO[)OOD[)ooOO~ .DOOQO
/
average surface area
for the mIxture
average volume
for the mIxture
Figure 1.9 Three examples of definitions of 'mean particle size' for a mixture of non-uniform
non-spherical particles.
Also, the 'median size' (that is, the 50% size, or mid-point of the distribution)
can be read off directly.
The mass median mentioned above is probably the most commonly used
method of indicating the 'average size' of particles constituting a bulk solid,
since for the majority of materials it is the easiest to determine. However, it
may happen that the median is not the most appropriate parameter and a
number of alternative definitions of average particle size could be used. The
one chosen would normally be dictated by its relevance to the situation
concerned. Three examples will be considered; definitions are illustrated in
Figure 1.9.
(i) Surface mean diameter is defined as the diameter of a particle having a
surface area equal to the average for all the particles in the mixture. This
parameter is clearly relevant to processes in which the surface area of the bulk
solid is a critical factor. The average surface area of a number of particles can
be expressed as
(1.7)
where ds is the diameter of a sphere having the same surface area as the
corresponding particle. Thus the diameter of this particle of average surface
area (the 'surface mean diameter') is given by
A )1/2 ( 1 )1/2
dsm = ( ~n = -I-d
N
2
s
(1.8)
where x is the mass fraction of particles passing through sieve aperture of size
da·
Sieve analysis. The most popular (and cheapest) method of particle size
analysis, especially with relatively coarse materials, is sieving. A test sieve
generally consists of a woven wire screen (with square apertures) rigidly
mounted in a shallow frame (Figure 1.10a), but for coarse materials the sieve
screen is more usually a perforated plate with either round or square holes.
Traditionally the sieve size is specified by the number of apertures per unit
length (the 'mesh'), but current practice is to quote the actual dimension of the
16 BULK SOLIDS HANDLING
Table 1.4 Some familiar methods of size analysis and their approximate
range of application
Sieving:
dry 50,um-1OOmm
wet 10,um-l00mm
Electrical sensing zone
(Coulter counter) l,um-800 ,urn
Laser diffraction
spectrometry l,um-200 ,urn
Sedimentation and
elutriation 2,um-75,um
Optical microscopy 1 ,um-150,um
Electron microscopy 0.01 ,um-l,um
aperture in Jim (Table 1.5). The sieve sizes used in an analysis should be
selected to conform to a J2 series, or for more accurate work, a {12 series.
A wide variety of types of sieve is available commercially. Apart from the
standard woven mesh sieves and the perforated plate sieves for coarser
materials, a range of electro-formed sieves is manufactured for the size analysis
of very fine products (less than about 45 Jim). Specially designed sieves have
been produced for specific applications, such as the measurement of flakiness
index [7] and grain size of cereals (Figure 1.1 Ob).
The lower size limit for material on a wire mesh sieve is around 50 Jim,
although with special techniques sieving down to about 10 Jim is possible. The
recommended mass of sample to be used on standard 200 mm (8-inch)
diameter sieves is 50 g for materials of particle density between 1200 and
3000kg/m 3 , and 100g for materials of density greater than 3000kg/m 3 .
The test procedure involves introducing the sample to the top of a stack,
typically consisting of up to eight sieves which are graduated from the coarsest
at the top to the finest at the bottom. The stack is then shaken or vibrated
(manually or mechanically) for a set period of time in order to distribute the
material through the sieves. Finally, the mass of material retained on each
sieve is determined by careful weighing. A detailed procedure for manual
sieving is set out in a British Standard [6], but it is now far more usual to make
use of automatic sieve shakers (Figure 1.10c). For materials that are cohesive
or susceptible to electrostatic charging, or that prove for any other reason to
be difficult to distribute through the sieve stack, 'wet sieving' is possible. In this
system water or other liquid is introduced via a spray header into the top sieve,
and washes the product downwards before being extracted from a drain in the
pan at the bottom of the stack.
The overall size range of the sample can be specified by stating two sieve
sizes; one through which the whole sample passed and the other on which the
whole sample would be retained. Information could also be quoted on the
proportion of the sample between any two sieve sizes, or the full size
THE NATURE OF BULK SOLIDS 17
Figure 1.10 Bulk solids characterization by sieving. (a) A selection of standard woven mesh
sieves. (b) Grain sieves for agricultural use. (Sieves for flakiness measurement are similar). (c) A
variable-speed electromagnetic sieve shaker in use. (Photos by courtesy of Endecotts Ltd.)
44 325
45 350
53 300 270
60 100
62 230
63 240
74 200 200
75 200 80
88 170 70
90 170
100 60
105 150 140
120 50
125 120 120
140 100
149 100
150 100 40
170 80
177 80
180 85
200 30
210 72 70
250 60 60 24
297 50
300 52 20
350 45
355 44
360 40
385 16
similar but are based on the measurement of the proportion of the product
which is carried off by an upward flow of gas (usually air) in a vertical column
at a known velocity. For small particles having the same density, the rate of
settling is approximately proportional to the square of the particle diameter,
and consequently the concentration at a fixed depth in a sedimenting
suspension will vary with time in a manner that depends upon the size
distribution of the particulate material (Figure 1.11). For a discussion relevant
to sedimentation analysis of the theory of particles settling in a gravitational
field, the reader is referred to Chapter 3.
One of the most convenient and reliable commercially available instru-
ments using this principle of size measurement is the photosedimentometer.
For this instrument a suspension of the material to be sized is prepared in a
suitable liquid dispersant. This suspension, contained in a tall tank of optical-
quality glass, is placed into the photosedimentometer and a narrow beam of
light of pre-set intensity passed through it on to a photocell. The attenuation of
THE NATURE OF BULK SOLIDS 19
Table 1.5 (Contd.)
420 36 40
430 14
490 12
500 30 35
540 II
590 30
600 25 10
700 25
710 22
750 8
835 20
840 20
850 18
1000 16
1005 18
1020 6
1190 16
1200 14 5
1400 12
1405 14
1500 4
1680 10 12
2000 8 10 10
2380 8
2400 7
2800 6
2820 7
3350 5
3355 6
4760 4
this beam of light is continuously recorded and will initially indicate a high
concentration for the homogeneous suspension. The intensity of the light
falling on the photocell will begin to increase from the moment that the largest
particles, falling from the free surface, pass through the beam, and will tend
towards a maxim urn as the finest particles reach the level of the ligh t beam. The
variation of the photocell output with time thus allows the size distribution to
be determined, provided that the particle density and the viscosity and density
of the liquid dispersant are known.
A refinement of this instrument is a scanning device which speeds up the
analysis by allowing the light beam to scan the suspension vertically at a rate of
10 mm/min. The wide-angle scanning photosedimentometer (WASP), which
gives a readout in the form of a pen-recorder trace showing the variation of the
optical density of the suspension with time, is illustrated in Figure 1.12.
Sedimentation techniques generally are appropriate for bulk solids that are
too fine to be analysed by sieving but not so fine that they take an inordinately
20 BULK SOLIDS HANDLING
: .:':
,',': .::..:.... .:.:
..... ', ' . .
- X-
..,' .' , .:.' :.,'.' :;','
, ' ,'
-X
Cd)
~:&a)~ly~
Homogeneous Sedimenting Concentration at Concentration at
suspension, suspension: XX begins to leve l XX continuing
Sedimentation larges t partic les decrease : largest to decrease. Time
begins. settling at fastest particles have period since start
rate . settled distance allows determination
Concentration at H in time since of smallest particle
XX still sedimentation size to fall to XX
unchanged. star ted. from the free
surface.
" .
sedimentation tank ,,
zero adjustment
photocell r I i. ~~
~ ti~,}\ photocell
:0
\
I I
I
\ I
I II - . \ Iight source \bench
time clock ./ :
I I I neutral density filters
i tI:I e I (for setting sensitivity)
I
I I
r...-
I I
scanning motor
II II :
Ir----' I
I
I
I
I
Ii '~~... -'I___ _ .I.I m,""" scan/return
II l ---l LI.::.
u .. ------t
L_-r'=-,_-_..i
long time to settle under gravity in the selected dispersant. The exact size range
that can be determined by photosedimentation depends principally upon the
dispersant used and the density of the particles but, as an example, for sand
settling in water, measurement over the range 2-60 11m should be possible. The
upper end of this range could be extended considerably if a more viscous
dispersant such as ethylene glycol were to be used (Table 1.6).
B
22
.7 .6 .S .4 .3 .2.'
BULK SOLIDS HANDLING
Numerical value
(units)
1 ~ 1
Grid length 64
=i
T Grid breadth 45.3
Distance between
calibration marks 60.4
Diameter of circle 1 1.00
2 1.41
0 7
0 6
OS 0 4 0 3 0 2 0' 4
5
3 2.00
2.83
4.00
grid length (mm)
6 5.66
7 8.00
Figure 1.13 British Standard graticule (BS 3625: 1963) (Ref. 2, Part 4).
The Coulter counter. The Coulter counter, the best known commercially
available instrument for size analysis of particulate materials by the electrical
sensing zone technique, was originally developed by W.H. Coulter for
counting blood cells. A recent British Standard ([5J, Part 5) describes the
method in detail and gives useful information on suitable electrolytes.
The Coulter technique enables the number and size of particles suspended in
an electrically conductive liquid to be determined by making the suspension
flow through a small orifice on either side of which is immersed an electrode.
As any particle passes through the orifice it increases the resistance between
the electrodes momentarily and thus generates a voltage pulse, the magnitude
of which is a function of the volume of the particle. These pulses are
electronically scaled and counted and from the resulting data the size
distribution of the suspended particulate material can be determined. For
THE NATURE OF BULK SOLIDS 23
particles of diameter within the range 2- 40% of the orifice diameter it is found
that the magnitude of the voltage pulse is directly proportional to the particle
volume and it is on this principle that the reliability of the Coulter counter
depends.
A range of orifice sizes is available, so that the Coulter counter is well suited
to the measurement of particle sizes in the sub-sieve range (less than 75 Jim)
down to about 1 Jim. With special techniques this range can be extended up to
800 Jim and down to 0.6 Jim or even less. Almost any kind of material may be
analysed using the Coulter technique (except for some organic compounds
that are too soluble in any electrolyte), although the use of dispersants is often
required.
Figure 1.14 shows diagrammatically the basic components of a Coulter
counter. In operation the stopcock A is opened so that the action of the
vacuum pump causes the electrolyte to flow from the beaker through the
orifice and also draws mercury up into the siphon. The stopcock is then closed,
but the effect of the mercury siphon restoring its balance causes the flow of
electrolyte through the orifice to continue. Electrical contact of the advancing
mercury column with probes mounted in the glass tubing causes counting of
the voltage pulses to begin automatically and to stop after a pre-determined
volume of electrolyte (typically 0.5 ml) has passed through the orifice.
The voltage pulses are amplified and fed to a threshold circuit having an
counter 'start'
counter 'stop'
Laser diffraction spectrometry. During the early 1970s methods were described
for determining the size distribution of a sample of fine particulate material by
measuring the diffraction that occurs as a beam of light passes through a
suspension of the sample. Since that time the technique has been improved to
the point where the laser diffraction spectrometer (LDS) is commercially
available from several manufacturers in a form that allows a reliable size
analysis to be made by a semi-skilled operative in just a few minutes. Although
very costly, these instruments offer significant advantages in that special
electrolytes are not required and calibration is unnecessary. However, there
have been doubts expressed about discrepancies between analyses carried out
on the LDS and results from other size-measurement techniques.
The principle of laser diffraction spectroscopy is quite complex and only a
simplified explanation can be given here. The angle of diffraction of a beam of
light passing through a suspension of particles depends essentially upon the
wavelength of the light and the size of the particles. Thus a beam of
monochromatic light (from a laser source) passing through a suspension of
mono sized particles would be diffracted through a specific angle (Figure 1.15a)
which is not dependent on the position or movement of the particles. If this
light then passes through a lens it will be drawn to a focus in the form of an
annular ring on the focal plane (Figure U5b). For a mixture of particles the
o
~ (a) ~:;~er light diffracted by
======~"m-';"d ",,;,,,,
focal plane
-~
laser light ----,__--~
laser
pump (peristaltic)
r---+--~~
Figure 1.16 The elements of a laser diffraction particle sizer.
incident light beam will be diffracted in a complex manner, but the result will
be a radially symmetrical pattern of light on the focal plane of the lens, the
intensity of this light at any radius being a function of the proportion of
particles of a corresponding size. Electronic analysis of the light pattern on the
focal plane can thus yield a size distribution of particles in the suspension. The
smallest particle size that can be measured is generally about 111m, since the
particles must be larger than the wavelength of the incident light, which is
0.6311m for a He-Ne gas laser. The top size limit is set by the smallest
diffraction angle that can be detected (the diffraction angle being inversely
proportional to particle size) and in practice is usually around 200 11m.
Figure 1.16 illustrates the essential components of a typical commercial
LDS system. The instrument may be used directly on-line or may incorporate
a vessel in which the suspension is prepared and maintained in a dispersed
state by, for example, an ultrasonic oscillator. The particles are carried in the
suspension through a measuring cell where they are illuminated by a laser
beam. The diffracted light is collected by a system which may consist of a lens
and some kind of photosensitive detector, the electrical output from which is
analysed by a microprocessor. Finally the output data may be displayed on a
VDU screen or provided as hard copy from a printer.
attempts have been made to established the use of shape factors to indicate the
extent to which particles differ from the spherical.
Probably the most commonly used of these shape factors is the 'sphericity'
¢ .. defined as the reciprocal of the ratio of the surface area of a particle to that
of a sphere of the same volume:
A. surface area of sPhere} f h I
'I' = . 0 t e same vo ume
s surface area of partIcle
It will be noted that ¢s must be less than unity and that
¢s = rcd; = (d )2v
(1.12)
Asp ds
where Asp is the surface area of the particle. Thus the 'volume diameter' d v is
always less than the 'surface diameter' ds for a non-spherical particle.
Also, from equations (1.5) and (1.6),
1.241 V~/3)2 V~/3
¢s = ( 0 564 A 1/2 = 4.838 T (1.13)
• sp sp
Figure 1.17 Micrographs ofa few typical bulk solids showing a range ofparticie shapes. (a) Dry
sand. (b) Polypropylene powder. (e) Wheat flour. (d) Hardboard fluff.
these materials and various techniques have therefore been devised to measure
this property. In general, these techniques yield the 'specific surface' of the
material, which is usually defined as the surface area per unit volume, but may
be defined as surface area per unit mass.
For a single particle the volume specific surface is thus given by
from which
6
Sp= A.. d (1.14)
'f's v
C,)
Qi en
;: Q;
-'" Q) 0
(.)
0
c: -'"
(.) 10 4
a: ~ :>
E 2
:l
en
2
(.)
a. (.)
0:l
:§ >-
OJ
C1l
70 750 103
(.)
50 500
30
250
10
100 10 2 E
:l '0
~ c:
2 a.
en ~ N
'0
c: 0
C1l '0 ~
C1l
a. 2 E
a. Qi 0 C1l
C1l
:l
cr .8 (.) '0
10'
2 3 4 5 6 7 8 9 10
Mohs number
Figure 1.18 The relationship between the Mohs scale of hardness and the Vickers, Brinell and
Rockwell C scales.
F. Mohs, who selected ten mineral standards beginning with the softest, talc
(Mohs hardness 1), and ending with the hardest, diamond (Mohs hardness 10).
Table 1.7 lists the Mohs hardness standards and indicates the type of simple
scratch tests that can be used to give a guide to the hardness of a particulate
bulk solid.
Since the Mohs scale proved to be too coarse and, with the original natural
materials, insufficiently reproducible to form the basis of a standard measure-
ment of the hardness of general engineering materials, alternative tests were
developed. These were mostly of the static indentation type (such as Vickers
and Brinell) and consequently, metal hardness came to be specified in terms of
the value indicated by either ofthese methods; e.g. 400 Vickers Pyramid (VPN),
380 Brinell Hardness Number (BHN). Fortunately, sufficient research has
been undertaken to relate the various values of the hardness parameters to the
Mohs scale, and vice versa (Figure 1.18).
500 ~m 500 ~m
a b I I
Figure 1.19 PVC powder showing the effect of electrostatic charging. (a) Uncharged.
(b) Charged.
/.
(a) Heap poured on ffS't surface (b) Tilting table
where more appropriate tests are available. In fact, it is generally safer to treat
angle of repose only as an indicator of the contours of heaps of the material.
Thus, for example, the angle of repose of a bulk solid is required in order to
determine the ullage space in hoppers or bins, the cross-sectional area of
material transported on a belt conveyor, the surface topography of stockpiles,
and so on.
THE NATURE OF BULK SOLIDS 33
1.9.2 Shear strength
As with continuous material, the application of any force to a bulk solid
tending to cause shear deformation will result in an opposing resistive force. As
the magnitude of the applied force is increased, a point will be reached where
the bulk solid begins to deform with the constituent particles sliding relative to
one another (Figure 1.21). The limiting value of the resistive shear stress (when
the bulk solid is on the point of sliding) may be termed the 'shear strength' of
the material. Naturally the magnitude of the consolidating force on the bulk
solid will have a major influence on the shear strength, and other factors
ha ving an effect will include the nature of the particles themselves, the packing
arrangement and the prior history of the material.
A plot of the relationship between the normal compressive force, F N, and the
shear strength, Sr, is commonly called the 'yield locus' for the bulk solid
concerned. A simple and convenient model of the yield locus, illustrated in
Figure 1.22, is
( l.l5)
typical cohesive
material
• coefficient
of Iriction, "
" Ta
Figure 1.22 The linear or Coulomb model for shear strength of a particulate material.
34 BULK SOLIDS HANDLING
CTy
Figure 1.24 illustrates the manner in which these stresses can be represented
by the use of the Mohr stress circle. Note that changing the consolidating or
the shear stresses on the element of bulk solid will result in changes in the
radiu~ and/or centre of the Mohr circle. Thus, for example, increasing the
applied stresses to the point of sliding of the bulk solid will result in a 'limiting'
stress circle, and a series of such limiting circles at different combinations of
consolidating and shear stresses will have an envelope that corresponds to the
so-called 'yield locus' (Figure 1.25). Note that the limiting Mohr stress circle
passing through the origin defines the 'unconfined yield stress', (le'
which represents the strength of the material at the free surface. Referring to
THE NATURE OF BULK SOLIDS 35
general Mohr
stress circle
Figure 1.21, the unconfined yield stress can be regarded as the force per unit
area applied to the top of the column of powder at the point of collapse.
,------ effective
y yield locus
F
normal load, FN
Figure 1.27 A typical yield locus, as obtained from tests using a shear cell.
(J = FN(F) (1.20)
C A
Both of these parameters are of importance when designing for solids flow,
as will be explained in Chapters 2 and 4.
The slope of the yield locus at any point defines the dynamic 'angle of
internal friction', ¢, at that condition. (Note that in practice there is usually
found to be some variation of ¢ with the consolidating load, shown by a slight
curvature of the yield locus.) On Figure 1.27 the 'effective yield locus' is also
shown. This is a straight line tangential to the Mohr circle for the initial
consolidating load and passing through the origin. The slope of this line
defines the 'effective angle of internal friction'. For a full investigation of the
flow properties ora bulk solid, graphs such as Figure 1.27 should be prepared
for a range of initial consolidating loads, resulting in a series of yield loci.
The influence of the time of storage on the flow behaviour ofa bulk solid can
be studied by applying the initial consolidating load to the specimen in the
shear cell for a set duration before carrying out the test procedure. The
resulting plot of shearing force against normal load is then termed the 'time
yield locus'.
The translational type of shear tester, such as the lenike shear cell, is subject
to a number oflimitations, the most serious of which is that it is only suitable
for use with fine particulate materials. The maximum shear displacement
obtainable with a translational cell is about 6 mm and the top size of particles
that can be allowed is therefore around 3 mm. In order to achieve unlimited
strains, rotational shear testers have been developed, such as the torsional cell
(Figure 1.28a) used especially in studies of soil mechanics, and, more recently,
the annular or ring shear cell (Figure 1.28b). The torsional shear tester itself
suffers from the major disadvantage that the stress distribution within the
sheared material is undefinable, and the annular shear cell would therefore
appear to be the most reliable means of investigating the flow characteristics of
bulk materials.
( "'y------------r .. )
~_ /
~~~-:.:: counterweight(s)
'-":
==.:- .
calibration
torque arm
~3S~~~~~~~~~~~~~~~~~S;~
t\ load
transducer
annular shoe
_ _--,- rna terial
annular trough sample
Figure 1.29 illustrates in detail the arrangement of the Portishead ring shear
cell as originally devised by Walker [13,14]. It consists essentially of an
annular trough having an inner diameter of 152 mm (6 inches) and an outer
diameter of254mm (10 inches). An annular shoe fits inside the trough, centred
on an axial spindle and having a minimum radial clearance of about 3 mm.
Radial vanes integral with the underside of the shoe ensure that the bulk
material sample is held while material in the slowly rotating trough shears
against it. The speed of rotation of the trough is about 1.5 revolutions per hour,
and the compaction pressure on the bulk sample in the trough can be adjusted
by adding weights to the shoe or to the counterbalance hanger. A force
transducer bearing against a radial torque arm fitted to the shoe allows the
shear stress on the bulk sample to be continuously monitored.
Details have been published [15] of tests undertaken with a much larger
shear cell, having a diameter of approximately one metre, which allows the
flow properties of materials having particles of up to 50 mm to be investigated.
The procedure for carrying out shear tests begins by loosely packing the test
sample into the trough and then shearing it under the selected normal load in
order to achieve the required state of compaction. The total torque required
to just shear the material can then be measured for number of different normal
loads (Figure 1.30). Since the total shear torque is given by
~otal shear = f
RO
Ri
(JR·2nRdR
(1.21 )
THE NATURE OF BULK SOLIDS 39
I I
I
I
I
V---- I-"
V- I di i--
.- .-
f
f-- /
j i
b
C
/'
,
a
I
'/
rr
\ \ ~ I
scale proportional to dlsplacement-
Figure 1.30 Typical output record from load transducer as a sample is sheared at a series of
increasing normal pressures from the same consolidating pressure. (Points a, b, c and d indicate the
yield strength in each case).
values of the yield stresses can be readily calculated and used to plot yield loci
and flow functions as previously described.
Two recently published papers [16,17] attempt to compare data on bulk
solids flow behaviour obtained from a translational (Jenike) shear cell and an
annular (Portis head) shear cell. These suggest that, although there is a broad
agreement between the flow functions obtained from the two test procedures,
there is also evidence that the correlation of results may be to some extent
machine- and/or material-dependent.
normal load, FN
Figure 1.31 'Wall yield locus' for a bulk solid in contact with a plane surface.
Tilting plate method. In this method a thin layer of the bulk solid concerned is
carefully laid on to a horizontal plate made of the required wall material. The
plate is then slowly tilted and the angle recorded at which the layer of bulk
solid slides off. In contrast to conventional solid friction, the angle of the plate
is a function of the weight of the powder bed, increasing as the weight of
the bed decreases. An appropriate test procedure is therefore to adjust the
thickness of the layer of bulk solid on the plate until the sliding angle is in the
range 40-90°. It should be ensured, however, that the layer of material is not so
thick that internal collapse occurs before the layer slides.
Writing equation (1.22) as
mg . mg
A SIna = f.1wAcosa+ Cw (1.23)
where m is the mass of the bulk solid on the plate, A is the nominal contact area
and a is the angle at which sliding occurs, it can be seen that a plot of
(mg/A) cos a( = F N ) against (mg/A)sina( = Sw) should give a straight line of
slope f.1w and intercept Cwo The angle of wall friction, ¢w, is equal to tan -1 f.1w·
Shear cell method. An alternative to the tilting plate is an adapted shear cell in
which the base of the cell is replaced by a flat plate made of the wall material
under investigation (Figure 1.32).
The recommended procedure is to load the top cover up to the maximum
required value of the consolidating force and decrease the load in a series of
steps, recording the maximum shear force (to initiate sliding) at each step. The
wall yield locus can then be plotted as a graph of normal load F N against shear
force Sf as described above for the tilting plate method.
THE NATURE OF BULK SOLIDS 41
normal load, FN t
~ ===~ ~----~-~
Figure 1.32 Jenike-type shear cell set up for determination of wall yield locus.
material C, showing
typical effect of /.
increased moisture /
or time of storage /.
'" 'y/
£;'" material C }
'instantaneous'
'" //.
-0 ' I B flow functions
Qj // ma t ena
';;'
-0
(l)
/.,/.
c
'E
o
()
C
:J
material A (free-flowing)
ability of a bulk solid to form a cohesive arch is the 'unconfined yield stress'
which represents the strength of the material at the free surface. For a free-
flowing (non-cohesive) material, such as dry sand, the unconfined yield stress is
zero and therefore a cohesive arch could not occur. The flow behaviour of a
cohesive bulk solid can be conveniently illustrated by a plot of unconfined
yield stress against the major consolidating (normal) stress, this plot being
termed the 'Flow Function' of the material. In order to plot a Flow Function a
series of yield loci must first be drawn, using results obtained from a shear
tester as outlined in section 1.9.3. Each yield locus determines one point on the
flow function. Thus, on Figure 1.27, a Mohr circle tangential to the yield locus
and passing through the origin gives the unconfined yield stress (point F) and a
second Mohr circle tangential to the yield locus at M, corresponding to the
initial consolidating load, gives the major consolidating stress (point G).
THE NATURE OF BULK SOLIDS 43
Figure 1.34 illustrates Flow Functions for three typical bulk particulate
solids. Material A is free-flowing, therefore having no cohesion, and the Flow
Function coincides with the horizontal axis. Material B is slightly cohesive and
material C is more cohesive still; both of these materials acquiring greater
strength as the consolidating stress is increased. Note that other factors such as
moisture content, storage time and vibration can influence the strength of the
materials, effectively moving the Flow Function either up or down.
Although the tests described for the determination offlow properties of bulk
solids are relatively straightforward, the interpretation of the test data is not
easy. It is beyond the scope ofthis book to deal with the real intricacies of bulk
solids flow behaviour, but some further discussion on gravity flow will be
undertaken in Chapter 2 and the application of these various (:oncepts and
measurements to the design of storage hoppers will be further developed in
Chapter 4.
It should be noted that water may be present in a bulk solid in two forms:
(i) 'Surface moisture', which is present only on the surfaces of the particles
(ii) 'Inherent moisture', which exists as water of crystallization within the
structure of the particles.
When the surface moisture has increased to the point where all the
interparticle voids are filled with water, the bulk solid is said to be 'saturated'.
The method of oven-drying suffers from the disadvantage of taking several
hours to perform, and a number of faster methods of moisture measurement
have been developed. These rely upon a number of different techniques such as
infrared absorption, microwave absorption, nuclear magnetic resonance,
ultrasonics, conductivity, gas evolution and chemical methods.
Probably the most widely used methods are still those based on heating the
sample to drive off the moisture, as in the oven technique described above. A
refinement that has recently become popular is the 'moisture balance' which
consists essentially of a conventional electronic top-pan balance adapted so
that the pan is contained in an enclosed chamber. The sample of material on
the pan is subjected to infrared radiation and its mass continually monitored
as the moisture is driven off. The time taken to dry a sample of bulk solid for a
moisture analysis can be greatly reduced by using a fluid bed dryer in place of
an oven. This method is particularly suited to heat-sensitive products as it
offers a relatively short residence time and a uniform temperature distribution
with an absence of 'hot-spots'.
1.11 Explosiveness
Many bulk particulate solids, when dispersed in air to form a dust cloud,
constitute a potentially explosive mixture which may be ignited by a naked
flame, a hot surface or an electrical discharge. The range of products that are
hazardous in this respect is quite wide and includes common foodstuffs such as
sugar, flour and cocoa; synthetic materials such as plastics, chemicals and
pharmaceuticals; metals such as aluminium and magnesium; and traditional
fuels such as coal and wood. Other products such as sand, alumina and certain
paint pigments are non-combustible and therefore present no danger. Ofthose
products that are combustible, research has shown that it is only the fraction of
the bulk having a particle size less than about 200 Jim that causes the existence
of an explosion hazard. The picture is further complicated by the fact that the
risk of an explosion occurring depends upon parameters such as product-to-
air concentration and minimum ignition temperature and energy. Tests have
been devised to determine the 'explosiveness' of a bulk solid in terms of these
parameters, and for many products the results are freely available-see, for
example, [18]. The whole subject of explosion hazards existing during the
handling of bulk solids is covered in more detail in Chapter 7 and some
THE NATURE OF BULK SOLIDS 45
guidance is given on the precautions that can be taken to reduce the risk
associated with dust explosions.
1.12 Notation
A Area
Asrn Average surface area of one particle in a group
Asp Surface area of a single particle
Cw Adhesion parameter (equation 1.22)
da Sieve aperture dimension
ds 'Surface diameter' of a particle
dsrn 'Surface mean diameter' of one particle in a group
dv 'Volume diameter' of a particle
dvrn 'Volume mean diameter' of one particle in a group
dvsrn 'Volume-surface mean diameter' of one particle in a group
FN Normal compressive force
g Gravitational acceleration (specific gravitational force)
N Number of particles
m Mass
msolids Total mass of particles in a bulk solid
mvoids Mass of fluid in void space in a bulk solid
Sf Shear strength
Sp Specific surface (surface area per unit volume)
Sw Shear force at wall
Ta Apparent tensile strength
Vp Volume of a single particle
Vprn Average volume of one particle in a group
V.olids Total volume of particles in a bulk solid
Vvoids Volume of void space ina bulk solid
X Mass fraction
IX Angle
e Voidage or void fraction
e Angle of plane of 0'2 to vertical
f.1 Coefficient of internal friction
f.1w Coefficient of wall friction
Ph Bulk density
Pf Density of fluid
Pp Density of solid particles
0' 1'0' 2 Principal stresses
O'c Unconfined yield stress
O'rnc Major consolidating principal stress
0' x' O'y Compressive stresses in x and y directions
r Shear stress
46 BULK SOLIDS HANDLING
References
1. The Bulk Solids Physical Property Test Guide, British Materials Handling Board (1983).
2. Allen, T. (1981) Particle Size Measurement, 3rd edn., Chapman and Hall, London.
3. BS 812: 1975, 1976, Sampling and testing of mineral aggregates, sands and fillers. British
Standards Institution, London.
4. BS 4359, Methods for the determination of the specific surface area of powders
Part 1: 1985. Nitrogen adsorption (BET method).
Part 2: 1982. Air permeability methods.
Part 3: 1979. Calculation from particle size distribution. (Withdrawn 1985). British Standards
Institution, London.
5. BS 3406, Methods for determination of particle size distribution.
Part 1: 1986. Guide to powder sampling.
Part 2: 1984. Gravitational liquid sedimentation methods for powders and suspensions.
Part 3: 1963. Air elutriation methods.
Part 4: 1963. Optical microscope method.
Part 5: 1983. Electrical sensing zone method (the Coulter principle).
Part 6: 1985. Centrifugal liquid sedimentation methods for powders and suspensions. British
Standards Institution, London.
6. BS 1796: 1976, Methods for the use of BS fine-mesh test sieves. British Standards Institution,
London.
7. BS 812, Section 105. 1: 1985, Flakiness index. British Standards Institution, London.
8. Test Sieving Manual, Endecotts Ltd., London (1977).
9. Pharmaceutical Society of Great Britain (1967) Characterisation and Manipulation of
Powders, Pharmaceutical Press, London.
10. BS 2955: 1958, Glossary of terms relating to powders. British Standards Institution, London.
11. Jenike, A.W. (1964) Storage and Flow of Solids, Bull. No. 123, Utah Engg. Exp. Station, Univ of
Utah.
12. Brown, R.L. and Richards, 1.e. (1970) Principles of Powder Mechanics, Pergamon, Oxford.
13. Walker, D.M. (1967) A basis for bunker design. Powder Technol. 1, 228-236.
14. Carr, J.F. and Walker, D.M. (1967/68) An annular shear cell for granular materials. Powder
Technol. 1, 369-373.
15. Bagster, D.F. (1981) Tests on a very large shear cell. Bulk Solids Handling 1 (4), 743-746, 742.
16. Wilms, H. and Schwedes, 1. (1985) Interpretation ofring shear tests. Bulk Solids Handling 5 (5),
1017-1020.
17. Reed, A.R. and Arnold, P.e. (1985) A comparison between techniques for measuring the flow
properties of ordinary portland cement. Zement-Kalk-Gips 38 (11), 671-674.
18. Palmer, K.N. (1973) Dust Explosions and Fires, Chapman and Hall, London.
2.1 Introduction
A good understanding of the nature of bulk solids flow is an essential
prerequisite to the design of virtually any system involving the storage or
handling of such materials. Observation of a bulk material discharging from a
hopper or flowing under gravity along a steeply inclined channel will
immediately suggest similarities to the behaviour of liquids. Whilst there are
certainly some similarities between the flow characteristics of bulk solids and
liquids, the analogy is one that it is unwise to pursue. In general it is more
appropriate to model a bulk solid as a plastic solid than as a fluid continuum.
The main features of liquids which are not shared by bulk solids are as
follows:
(i) At rest, liquids cannot sustain shearing stresses. This is most clearly
demonstrated by the fact that bulk solids can be formed into a stable heap
whereas liquids at rest always have a horizontal free surface.
(ii) Changes of pressure in a liquid at rest are transmitted uniformly to all
other points in the liquid.
(iii) Shear stresses that occur in a flowing liquid are dependent upon the rate of
shear and independent of the mean pressure of the liquid.
In contrast, bulk solids at rest can transfer shearing stresses and, in many cases,
possess sufficient cohesive strength after consolidation to retain their shape
under pressure. Furthermore, when a bulk solid 'flows' slowly the shearing
stresses within it are dependent upon the mean pressure to a much greater
extent than the rate of shear.
These distinctive features of liquids and bulk solids can be illustrated and
compared by considering the distributions of pressure on the internal surfaces
of two identical cylindrical containers; one filled with a bulk solid, the other
filled with a liquid having the same (bulk) density. In Figure 2.1 a the pressure
distributions due to the bulk solid and the liquid are shown and the much
greater stresses that exist in the liquid near the bottom of the container are
immediately apparent. The reason for this difference lies in the fact that there is
no shearing stress at the walls of the liquid container, and therefore the whole
weight of the liquid is taken on the horizontal base, whereas a significant
proportion of the weight of the bulk solid is carried on the vertical walls.
The manner in which internal stresses are transmitted through the bulk
solid and the liquid are illustrated in Figure 2.lb in which the effect of
48 BULK SOLIDS HANDLING
..
-_-:-J"_-~-
liquid bulk
solid
...
liquid bulk
solid
increasing the loading on the free surfaces of each are shown. In the case of the
liquid, the excess load is transmitted uniformly throughout, so that all of this
excess load is, in fact, actually carried on the base of the container. However, at
the base of the bulk solid container there is no change as a result of the
additional loading on the free surface.
As explained in Chapter 1, the ability of a bulk solid to flow may be regarded
GRA VITY FLOW OF BULK SOLIDS 49
as the summation of a number of different effects, but it is essentially concerned
with the forces of attraction between constituent particles. Thus, when these
forces of attraction are low, the bulk material can easily be made to flow under
the influence of gravity with the particles moving as individuals relative to one
another. Dry sand and granulated sugar are familiar examples of free-flowing
materials. However, the high interparticle forces, which may be caused by such
effects as moisture or electrostatic charging and are especially pronounced in
very fine materials, result in a tendency for agglomerates to form so that the
material flows in an erratic manner as 'lumps', if indeed it flows at all.
Examples of cohesive materials which usually exhibit this sort of behaviour are
flour and cocoa powder.
The assessment of the flow characteristics of a bulk solid (i.e. whether it is
'free-flowing' or 'cohesive') is very much a matter of judgement based on
experience, but some of the various tests that can be undertaken to provide
evidence to assist this judgement have been described in Chapter 1. Having
established a method of predicting whether a bulk solid is likely to flow or not,
it is now helpful to gain some insight into the patterns of flow behaviour that
might be observed in various situations. In this chapter, therefore, attention is
given firstly to the usual form of pressure distribution that would exist in a bulk
material at rest (for example in a storage hopper or silo) and to the changes
that occur in that pressure distribution at the start of, and during, flow.
Descriptions are given of the types of flow pattern that may be seen in
gravity discharge of a product from hoppers of different configuration, and
also in gravity flow in inclined chutes and channels. Discussion of the
somewhat intractable problem of predicting the flow rate in such circum-
stances is considered to be largely beyond the scope of this book and only a
brief introduction will be attempted. In fact, although prediction offlow rate is
important, it is likely to be secondary to the task of ensuring unobstructed
flow, since in many cases the actual rate is controlled independently by a valve
or feeder downstream of the chute or hopper outlet.
The flow behaviour of bulk materials suspended in a stream of air, or at least
under the dominant influence of air or some other fluid medium, is dealt with
as a separate topic (in Chapter 3) and provides an essential foundation to the
understanding of the pneumatic conveying systems described in detail in
Chapters 12-17 of this book.
:f~~~~~'-~:\'7~
- "
dh I'w Pr 1I"D dh
pg r D' dh
t I I I
Figure 2.2 Analysis of forces on an elemental 'slice' of bulk solid in a cylindrical bin.
under storage and flow can prove to be a valuable aid when assessing the
likelihood of obstructions to flow occurring.
It has already been explained that the pressure distribution within a bulk
solid is different from that within a liquid in a similar container. The main
cause of this is the frictional forces between the solid particles and the walls of
the containing vessel which means, in effect, that these walls are supporting
part of the weight of the bulk material. Also as a result of this frictional effect,
the lateral pressure on the containing walls is generally less than the
'hydrostatic' pressure due to the head of material (Figure 2.1).
In order to develop a model for the pressure distribution existing within a
column of particulate material contained in a cylindrical vessel, consider first
the equilibrium of a thin horizontal 'slice' as shown in Figure 2.2.
At distance h below the free surface of the bulk solid, the lateral pressure is Pr
and the vertical pressure, due to the overlying head of material, is PV' In
general, for particulate materials, the ratio of Pr to Pv is found to be
approximately constant, so that
(2.1)
where k is a constant less than unity.
Now for the elemental slice of material, of diameter D and thickness dh
(Figure 2.2), the vertical forces acting are those resulting from
pressure (difference) = iD2dpv
n
gravity = Pbg4D2dh
wall friction
GRAVITY FLOW OF BULK SOLIDS 51
where Pb is the bulk density of the particulate material and flw is the coefficient
of friction at the walls.
Then for equilibrium of this element
11:
Pbg4 D dh -
2
411: D 2 dpv - flwP r1l:Ddh = 0
4fl w kPv )
- -D- In ( Pbg--- = h +c
4flwk D
where C is a constant of integration.
Now Pv = 0 for h = 0, so that
and
from which
1 _ 4flw kpv = exp ( _ 4flwkh)
PbgD D
Rearranging this to give an expression for Pr leads to
P
r
= Pbg D
4flw
(1- ex p ( _ 4flwkh))
D
(2.2)
This is one form of the well-known Janssen formula for radial pressure on
the vertical wall of a cylindrical bin containing a bulk solid.
It may be noted that for tall bins h is large compared with D, so that
(2.3)
52 BULK SOLIDS HANDLING
=ro increasing
~
bin diameter
Q)
"0
(/J_
eel:"
0-
Cl...
e
"Cn
&8
~:§
Q),~
~>.
(flU
(/J
~
a.
height of bulk solid above point P (h)
Figure 2.3 Relationship between the pressure at a point on the wall of a cylindrical bin and the
height of material above that point, from equation (2.2).
and
(2.4)
Figure 2.3 illustrates the relationship between the pressure at a point on the
wall of a cylindrical bin and the height of material above that point, as
predicted by equation (2.2).
r)n.~_ switch
Figure 2.4 Static and dynamic stress fields in a bulk solid contained in a storage bin.
c
54 BULK SOLIDS HANDLING
2.3.1 Introduction
The flow patterns occurring as a bulk particulate material discharges under
gravity from a hopper have been investigated by many research workers using
a number of different experimental techniques. One common approach has
been to carefully fill the hopper with layers of differently coloured particles so
that changes in the stratification could be observed during the flow. Such work
helped to give an insight to the nature of gravity flow of free-flowing and of
cohesive materials and allowed the influence of the wall angle and the outlet
size to be determined. It became evident that the flow patterns could be
conveniently classified into two groups which are now generally known as
'core flow' (alternatively 'funnel flow' or 'plug flow') and 'mass flow'.
Table 2.1 Summary of methods for predicting discharge rates from hoppers
[8J for core flow. Table 2.1 summarizes the applications of each of these
prediction techniques.
Carleton method. The expression derived by Carleton [5J relates the linear
velocity Uo of particles in the discharge stream to the properties of the particles
and of the interstitial fluid, and the geometry of the hopper outlet (Figure 2.7).
This expression can be written in the form
4p p d 5/3 sin {3(U6/3)3 + lOp/13 111 /3 Dc(U6 /3 )2 - g= 0 (2.7)
which is seen to be a cubic equation in U6 /3 . Although an iterative solution of
this equation should not be particularly difficult, it will clearly be useful to
have a simple graphical technique for the determination of U o from a specified
set of independent variables. Since the interstitial fluid is likely to be air under
normal atmospheric conditions, the relevant parameters are the diameter d
and density Pp of the particles, the diameter Dc of the hopper outlet and the
angle {3 that the hopper wall makes the vertical. Figure 2.8 is a line chart
developed from equation (2.7) and from which values of U o can be readily
determined.
The procedure to be followed when using the Carleton method to estimate
the discharge rate of free-flowing particles from a hopper can be summarized
as follows:
GRAVITY FLOW OF BULK SOLIDS 59
Figure 2.7 Parameters used in the Carleton method for estimating the discharge rate of free-
flowing particles from a conical hopper. Properties of particles: d, average diameter; Pp' density.
Properties of interstitial fluid: Pr, density; J1r, viscosity.
o
o
<'I
1000
--------- Pp
(kg/m')
1500
Uo o
(cm/S)
9
Figure 2.8 Line chart for the solution of the Carleton equation, equation 2.7, from [5].
(i) Note the parameters defining the hopper geometry, i.e. the diameter of the
outlet opening and the angle of the wall to the vertical.
(ii) Determine, for the bulk material, the average particle diameter and the
density of the particles.
(iii) Use the line chart (Figure 2.8) to determine a value for the linear velocity of
the material in the outlet opening. (Note that if the hopper is not
60 BULK SOLIDS HANDLING
discharging into air at normal atmospheric conditions, the line chart will
not be valid and an iterative solution of equation (2.7) will be needed.)
(iv) Calculate the mass flow rate of the bulk material from
. nD;
ms=PbuoT (2.8)
Williams method. This approach [6] takes into account the friction effects
between the flowing material and the hopper wall, and is therefore likely to
give a more reliable prediction for cases in which the outlet opening is small
(less than about 20 mm). However, no allowance is made for the influence of
interstitial air flows on the discharging particles. The model proposed by
Williams is thus based on the mass flow of homogeneous material consisting of
relatively large particles which offer no appreciable resistance to air flow.
Analysis ofthis model does not lead to a single unique value of discharge rate,
the result being instead in the form of upper and lower limits of the solids mass
flow rate. The upper limit in fact corresponds to zero wall friction and the
lower limit to the specified value of the angle of friction at the sloping wall of
the hopper. The difference between these limits is said to be sufficiently small
that their mean gives an estimate of the discharge rate which is accurate
enough for practical design purposes.
For the full analysis leading to expressions from which these upper and
lower limits can be computed the reader should consult [6], but for
convenience the data are presented here in a simplified form, using charts for
materials having angles of internal friction of 20-50°.
An expression for the solids mass flow rate is
(2.9)
where Pb is the bulk density of the material, Dc is the diameter of the hopper
opening and Kh is a coefficient which is a function of the wall slope of the
hopper, the angle of internal friction of the bulk solid and the angle of friction
GRAVITY FLOW OF BULK SOLIDS 61
3.0 3.0
\
$
0 \ I
.("
0>
2.5 \ 1
~
D
\ \ \
·E
• 2.0
\ \_ upper limit
2.0 \
l\ \ ....", Iower li mits
\ _ upper limi t
-
\\\ L~
Co
,
:.:: \ ~ Iower limi ts
,
C
0)
~
1.5 \"< ~ I" ~~
~ ~~ 0../ ~ I"\.
--
:--;::-
CD 1-.
0 2
0
1.0
~ 5 .g
c: J:.
:.:: 1 0 ~'" ~ ......
~
C .
100 ......
~ ~:t--- o5 ~
til
~ "\: (/) 0)
-0) .~
"'~g'
=01>
...
g ~ r-.-::: 1o 0>
CD 20.:3
0.5 I- o
;:
_"0
o~ o
0) ~
C.
.:
g
10 20 30 40 '" o 10 20 30 40
wall slope (j (degrees) wall slope (j (degrees)
2.o,........,.-....---,----r---,
upper limit
c:
0)
1.0
~ Co ,..,
CD :.::
oo
C
o til
0)
t=j=JE~~~~10402030 g'~
0)
~
o ~ "0
CD ~~
o ~--~---4----1---~ ~
o
~ 0·L---~1~0--~2~0--~3~0---4~0
wall slope (3 (degrees) wall slope (j (degrees)
Figure 2.9 Charts giving upper and lower limit values of flow coefficient Kh in equation 2.9 [6].
at the wall. Values of Kh giving upper and lower limits of the solids mass
flowrate can be determined from the appropriate charts in Figure 2.9.
~/
/'
/'
/'
,,)'/ angle of internal friction, q, (degrees)
0> 0>.... ....
o~~'6
0/
g; 0 U1 0 (n
.1.1 ) & 111111 1 1 \ 1, 1", ,!, I l l ! 1 " I
I
t
I
I
I"III'P
N
I 'I' "I- ' '"1""1'1'
<.: .::t.<J'I / N
Ii' "I-
aW 0
A(,n
o :> 001 g
o 000 0 0 0 a
g 8 gg o0 .
, part iCle density Po 0 (kg/ni')
\
\
I" "I , Iii ii i '>Q:i1 Ii~ 'l' "'1 , I" "I
'" o'"
& g g g o'" g
o
o
o o
o
m \ (tonnes/hou~)
o o
o
solids flowra te
)
gggggg g o
o '"
0 00 '"
o
I\)
o
Figure 2.10 Zanker's line chart for estimating the discharge rate of a granular bulk material in
core flow through a circular orifice [8].
ORA VITY FLOW OF BULK SOLIDS 63
orifice has been presented by Zanker [8J in the form of a line chart or
nomograph. It is based on an empirical relationship, proposed initially by
Franklin and Johanson, which can be written
. ppD~
m=------'----"------'------ (2.10)
s (6.288 tanp + 23.16)(d p + 1.889)
where Dc is the diameter of the orifice, pis the angle made by the hopper wall to
the vertical, dp is the mean particle diameter and n is an exponent. For angular
particles the value of n is about 2.5, ranging up to 3.3 for spheres, and it is
suggested that, in the absence of more reliable information, the value of the
angle offriction should be taken as 10% greater than the angle of repose of the
material concerned.
The Zanker line chart is reproduced (replotted in SI units) as Figure 2.10
and its use is summarized as follows:
(i) On the left-hand scales, join the values for particle diameter dp and angle
of internal friction c/J, and extend the line to the first pivot line.
(ii) Move to the second pivot line in the direction indicated by the oblique tie-
lines.
(iii) Join the resulting point to the appropriate value of particle density and
extend this line to the third tie-line.
(iv) On the right-hand scales, join the values for orifice diameter and index n,
and extend the line to pivot line 4.
(v) Join the points on pivot line 3 and pivot line 4, and where the resulting line
crosses the scale of solids flow rate read off the value required.
Johanson method. For the discharge of a fine cohesive bulk solid from a
hopper the model proposed by Johanson [7J is based on a continuously failing
arch that is in dynamic equilibrium. In order for the arch to fail, the strength of
the material in the arch, caused by the consolidation stress in the vicinity of the
hopper opening, must be overcome. In Chapter 4 it is shown that the
condition for continuous, unobstructed flow of material from a hopper is that
the ratio of major consolidating stress to the unconfined yield strength (a dO' c )
is less than a certain critical value which depends upon the geometry of the
hopper in addition to the flow properties of the bulk solid. These ratios are
termed 'flow factors' (if) so that for fJ.ctual > f!critical' flow will occur because a
stable cohesive arch cannot be sustained.
Johanson's method of analysis leads to the expression
rh - p
- b
nD2[~(1_ ffcrit )J1 /
4 4 tan P ffactual
2 (2.11)
for the mass flow rate of material from a conical hopper, where Dc is the outlet
diameter of the hopper and pis the slope that the wall makes with the vertical,
64 BULK SOLIDS HANDLING
O.55r-------,-------r------,~----_.------~
CQ
~
c:OJ
'u
:;::
Qi
o
()
2.4.1 Introduction
There are many instances in bulk solids handling installations of gravity flow
of a particulate or granular material along an inclined channel or chute. For
GRAVITY FLOW OF BULK SOLIDS 65
example, where a bulk solid is to be discharged at a point below and to the side
of a hopper outlet, it would be common practice to rely on gravity flow
through a simple transfer chute. In such situations both straight and curved
chutes are used but, unfortunately, failure to understand the fundamental
principles of bulk solids flow often results in unsatisfactory chute
performance.
Amongst common applications of transfer chutes for bulk materials, perhaps
the most familiar occurs at the loading point of a belt conveyor. In this case it is
important that the horizontal velocity component of the material leaving the
chute is matched to the velocity of the belt in order to minimize the
acceleration of this material and so effect reductions in power consumption
and belt wear. Other situations may require that the exit velocity is as large as
possible and of a direction to obtain the maximum possible 'throw' of the
flowing material. Thus it is important that the design of gravity-flow chutes
and channels is undertaken in the light of a clear appreciation of the
characteristics of flow in such situations if the desired performance is to be
achieved.
In this section attention is directed to the characteristics of steady flow of
non-cohesive bulk solids in straight and curved chutes. Patterns, or modes, of
flow are described and an introduction is given to the complex problem of
modelling the flow in order to design chutes for specific purposes. Much of the
presently available information on flow in chutes and channels has been
presented by Roberts and his colleagues, for example [9], and by Savage [10],
and readers wishing to undertake a more detailed study are directed to these
sources. Little has been published on the flow behaviour of fine powders and
cohesive bulk solids, although Roberts and Scott [9] have drawn attention to
the characteristically different motion of such materials when compared with
cohesionless products. They report that alumina moves in a series of block wise
shears with each block elongating and decreasing in thickness as the velocity
along the channel increased. Similar types of flow have been observed by
Woodcock and Mason [11] in air-assisted gravity conveyors, which are
described in Chapter 15.
Gravity flow in vertical channels and pipes is regarded as a special case and
will be discussed in section 2.5.
angle of repose
Figure 2.13 Modes offlow in a circularly curved chute [9]. DO' chute cut-off angle; Dco ' optimum
value of cut-off angle; Dr, limiting value of Dc for 'fast' flow.
68 BULK SOLIDS HANDLING
Q)
Ol
~
L
()
U)
'6
Figure 2.14 Typical discharge graph for a circularly curved chute fitted to a flat-bottomed bin
[9].
(2.14)
70 BULK SOLIDS HANDLING
Figure 2.15 Forces acting on an elemental mass of bulk solid flowing under gravity in a curved
chute [9].
where Ao is the cross-sectional area ofthe flowing stream as it enters the chute
and U o is the velocity at this point.
Also, for the direction perpendicular to a radius of curvature (i.e. along the
chute), the equation of motion for the elemental mass is
du
6m 9 cos () - FD = 6mcit (2.15)
F or this simplified model the drag force F D comprises only the wall friction
effect and therefore it can be written as
(2.16)
where f.1E is an effective friction coefficient and F N is the normal force on the
element.
F or a chute of rectangular cross-section, taking the pressure distribution to
be of the simple form shown in Figure 2.16a, an expression for f.1E is
where f.1w is the coefficient of friction at the wall, k is the ratio of the lateral
pressure to the major normal pressure at the wall, B is the width of the chute
and H is the depth of the flowing bed.
Experimental work carried out by Roberts and others using a variety of
bulk materials showed that a more reliable model is obtained by replacing the
coefficient k with the expression
(2.18)
ORA VITY FLOW OF BULK SOLIDS 71
B
Figure 2.16 Distributions of pressure on the interior surfaces of chutes (Roberts' model).
where K EO is the effective linear pressure gradient down the wall surface at zero
velocity and C is an 'intergranular stress constant'.
Noting also that H = (uo/u)H 0, equation (2.17) becomes
(2.19)
FN=bm(gSine+ ~) (2.20)
6/l Rg ) ] 1(2
+ exp( - 2/lE() ( U6 - 4/l~E + 1 (2.25)
Using equations (2.24) or (2.25) together with the continuity equation (2.14),
the variation of the stream thickness along the chute can be investigated.
Allowance can be made for the curvature (concave or convex) of the free
surface of the flowing stream by using an appropriate value of the surcharge
angle when developing expressions relating the depth H of the flowing bed to
its cross-sectional area.
For a chute of rectangular cross-section (Figure 2.l7a) in which the
surcharge surface is parabolic, the cross-sectional area of the bed is given by
Figure 2.17 Calculation of cross-sectional area of bulk solids stream in transfer chute.
GRA VITY FLOW OF BULK SOLIDS 73
and since
Hl=H-BtanA
we have
A A-I
H=-+--BtanA (2.26)
B A
In the case of a circular cross-section, again with a parabolic surcharge, the
cross-sectional area is
where the angle b defines the contact perimeter. Also, an expression for the
depth of the bed is
(2.28)
The following general guidelines can then be given for the design oftransfer
chutes in order to ensure stable 'fast' flow conditions.
(i) Identify the requirements in terms of direction and magnitude of the exit
velocity. (The overall cross-sectional dimensions of the chute (B and H 0)
are likely to be dictated by the upstream feed arrangement, which would
also fix the bulk solid mass flowrate and therefore the entry velocity uo).
(ii) Estimate, from equation (2.17) or (2.19), an average value of IlE' Values of
the unknown parameters should be determined experimentally if possible,
but failing this, a preliminary assessment of chute performance may be
made with Ilw = 0.46 and k = 0.3 in equation (2.l7).
(iii) (a) For a straight inclined chute, equation (2.24) is used to determine the
longitudinal velocity profile, and then equation (2.26) allows the variation
of the bed thickness to be determined.
(b) For a circularly curved chute the cut-off angle should normally be
designed to correspond to the optimum value for minimum thickness and
maximum velocity. The value, which is principally influenced by the
radius of curvature of the chute, the initial velocity of the bulk· solids
stream and the effective wall friction IlE' can be determined from equation
(2.25) by setting the derivative dujde equal to zero and solving for e [12].
Typical data for the variation of cut-off angle and stream velocities at cut-
off with radius of curvature, initial velocity and effective wall friction are
shown in Figure 2.l8. As explained in section 2.4.3 the maximum cut-off
angle should not exceed the limiting slope angle er which is given
approximately by er = tan - 1 IlE at exit.
Note that for a chute of circular cross-section it is recommended that
the flow is restricted to ensure that the chute fullness at any point in the
deceleration zone does not exceed half [9].
74 BULK SOLIDS HANDLING
~ 60~----~--~~--~--~
Q)
~
Ol
Q)
;:g ftE= 0.35
/lE= 0.40
0
~u
/lE = 0.45
Q) /lE = 0.50
0>
c
co
~
'5
u
E
:J
E
E-o
2.6.....--....--..---,.."....,,.........,....,,...---..
r.
en
:g 2.61---+----+.f-I-1-I--+-----I
o
U
:J
:::: 2.41--+---+--I-I--N'---+---j 2.41---+---1--1+1'-1---+-----1
'?
'5
u
E
E2.2 2.21-----J-it+.FP->!---
li
o
Cij 2.01---+---HH----+---+---j 2.0 1-----"~4I'---+--_____+--I
:;!'
'0
o
Q)
>
1.8 0 1.0 1.80
radius of curvature R (m) initial velocity Uo (m/s)
(b) Velocities at optimum cut-off
Figure 2.18 Charts showing typical optimum cut-otT data for flow in circularly curved chutes
[12].
2.5.1 Introduction
Very little information is available on the flow of particulate bulk solids under
gravity through vertical pipes. It has been suggested [3] that dry material can
GRAVITY FLOW OF BULK SOLIDS 75
1.0
J: IJ:°
I
:>°1:>
0.5 8~~~~~~~~2.0}
0.5
~oB
1-+-+-+--,--+--1
-'
_ _ (a) Uo - 1.22 mis, 0 - 45 0
1.5
---r-
-- 600)
J: IJ:° 1.0 ~ -~- 59 0
~
O·
:>°1:> 0.5 ........ ~ 450
t--
~
~: 30:
15
(b) Uo -
H0
1.22 mIs, B - 1.0
-
0
f}
J: IJ:° 1.0
r-
0 .5 r-..... u. (m/s)
:,01:>
- Ho
1
2
B - 1.0
0
_ _ (c) 0 - 45
0
0.2 0.4 0.6 0 .8 1.0
distance down chute, s (m)
Figure 2.19 Typical predicted performance curves for straight inclined chutes [12].
0.6 I I I
",I ~o _ 0.651
1
rh - 2.87 lonnes/hour
0.5 uo - 0.315 mls -
Ilm I'b= 1000 kglm' ~
'"c:-~ 0.4
1\ I a:
I 0.25
Q)
~~
Q)Q)
L
~
.x;Q)
oE <0
>
:E .~ 0.3 0.5
"'""- I ~ 0.75 0~
l~ ~
- '0 ~
~!!l
Q) :> 0.2 t:-- 1 I
~ 1.0 '0
!:OU '":>
'" Oco 10, I '6
o. 1 I
~
o I
10 20 30 40 50 60 70 80 90
posilion along chule, 0 (degrees)
Figure 2.20 Typical predicted performance curves for circularly curved chutes of circular cross-
section [9].
discharge from a filled open-ended vertical pipe two or three times faster than
through a circular aperture of the same size positioned in the centre of a flat-
bottomed bin. Consequently it would not be possible to obtain steady plug
flow through a vertical pipe fitted to the base of a flat-bottomed container
because the pipe could not be filled at a rate to match the potential maximum
outflow. Nevertheless, it seems likely that the discharge from a hopper or flat-
bottomed container could be increased by fitting a vertical stem to the outlet
76 BULK SOLIDS HANDLING
and evidence suggests that, especially with fine particulate materials, the rate
of discharge rises as the length of the stem is increased.
plugs may
form
Figure 2.21 Gravity flow of a fine cohesion less bulk solid in a vertical pipe from a flat-bottomed
con tainer [9].
GRAVITY FLOW OF BULK SOLIDS 77
illustrates the entry region to a vertical pipe from a flat-bottomed container.
Within the container the movement of the bulk material is likely to follow the
'tulip' pattern first reported by Brown and Hawksley [3], but once the
particles enter the discharge zone they are able to fall under gravity through
the orifice into the pipe as a smooth stream. The cross-section of this stream
initially decreases as it accelerates but, after a short distance, particles begin to
come into contact with the pipe wall and soon a condition of more or less stable
plug flow will be attained. At this point there may be observed what appear to
be 'bubbles' rising up the pipe through the downward flowing material. This
effect is probably due to 'free fall surfaces' developing within the flow.
The existence and motion of a free fall surface can be readily demonstrated
by filling vertical tube with fine sand, sealing the top end and allowing the sand
to discharge from the lower end (Figure 2.22). Immediately sand particles will
fall from the lower surface of the plug and as a result this 'free fall surface'
moves slowly upwards (Figure 2.22b). At the same time the whole plug of sand
begins to slide downwards, the upper free surface and the lower free surface
approaching each other until they meet (Figure 2.22d). This behaviour occurs
only because of the low-pressure region existing at the top of the pipe; any air
entering this region (for example if the closing seal is removed) will cause the
sand plug immediately to fall out of the pipe. It is thus evident that, where a
container discharges through a vertical pipe, the flow behaviour in the pipe
will be greatly influenced by interstitial air flows and therefore by the size and
density of the particles, the length and diameter of the pipe and the conditions
existing in the exit region of the feed container.
sand 'p lug' moves
pipe filled slowly down the pipe
with sand
rubber
seal
..
".'.
:",
(b) (d)
(a) ;\
'free-fall surface'
moves up the pipe
Figure 2.22 'Free-fall surface' in a cohesion less bulk solid discharging under gravity from a
vertical pipe.
78 BULK SOLIDS HANDLING
10 - -- --t- t-t-t- ~ -1
-t- - -- -
--
5
.... +--w-
3 -
4
t- =- I Ie
'"
-
~
2
+-
I"-
!!! - H
-
co -~-"-
~ 0.5
g 0.4 :::;!!:---
:;;;;"'(
CI) 0.3
E 0.2
CI)
--
CI)
~
"0
CI)
0. 1
~~ -
- I-
0.05 0:;;::
0.04 "'--
l-
i- -
0.03
0.02
~
-
0.0 1
0.5 , 1.5 2
pipe length (m)
Figure 2.23 Experimental data for the flow of two different sizes of sand particles through
vertical pipes fitted to a flat-bottomed container [13]. Mean particle size of sand:-- 206 pm,
--- 112 pm.
Tests carried out at Thames Polytechnic [13J seem to confirm that the rate
of discharge from a circular aperture in the centre of a flat-bottomed bin can be
substantially increased if a vertical downpipe is fitted, the amount of the
increase being mainly a function of the length of the pipe and its diameter. The
effect is particularly marked for very fine free-flowing products in small-
diameter down pipes. Figure 2.23 shows, for example, the results for two
different sizes of fine sand discharging from a flat-bottomed container through
vertical pipes of various sizes and lengths.
It has been suggested, from observations of downward flow in relatively
large standpipes [14J, that the maximum flow rate that can be attained will
depend upon the extent to which the flowing bulk solid can become
compacted. Aeration of the material needs to be undertaken with care in order
to reduce the chance of flow-obstructing 'pseudo-bridges' developing in the
standpipe.
Some measure of flow control can be exercised by allowing an influx of air
near the top of the vertical pipe, but a more effective method, allowing
GRAVITY FLOW OF BULK SOLIDS 79
complete shut-off of the flow, involves the use of a non-mechanical valve, such
as a 'J-valve' or 'L-valve' at the lower end of the pipe.
(a)
a ir in air in
(b)
Figure 2.24 Non-mechanical valves (L-valve and I-valve) for the flow control of bulk solids in
vertical pipes.
(a) The valves in the 'closed' condition.
(b) The addition of air reduces the angle of repose ofthe bulk solid and effectively 'opens' the valve.
80 BULK SOLIDS HANDLING
the static material in the vicinity of the bend, reducing its angle of repose and so
permitting it to negotiate the bend. The flow of the bulk solid should then
continue smoothly until the air supply to the valve is stopped, and when this
occurs the bulk solid flow will also cease. It should be noted, however, that
whether the flow ceases initially or not will be very much dependent upon the
capacity of the bulk solid to retain air in its interstices and so maintain, for a
time, a 'fluid' state. A typical application of J- or L-valves is to feed directly into
a dense-phase (fluidized-bed) environment, but they are also suitable for
feeding into a dilute-phase system such as a pneumatic conveying line or the
freeboard above a fluidized bed.
Much of the work on the development and performance of non-mechanical
valves has been undertaken by Knowlton and Hirsan [15, 16], who state that
the maximum flow rate obtainable is a function of the length of the vertical
downcomer above the L-valve or J-valve, and suggest techniques for
determining the length of down comer needed in order to achieve a specified
flow rate.
Some insight to the operation of the device can be gained by recognizing
that, in a steady-flow condition in (for example) an L-valve, the pressure-drop
over the downcomer must be equal to the pressure in the L-valve plus that in
the outlet pipe since both the inlet to the system and the outlet are open to
6.p downcomer
(v) Determine from experimental tests the required flow rate of air to the
aeration tap, which should be positioned about 75-100 mm above the
centre line of the horizontal section of the valve.
2.6 Notation
A Cross-section of flowing stream in chute
Ao Cross-section of flowing stream in chute at entry
B Width of channel
C Constant of integration; 'intergranular stress constant' in
equation (2.18)
Diameter of storage container or pipe
Diameter of outlet (circular-section hoppers)
Width of outlet (rectangular-section hoppers)
Particle diameter
Drag force on element of bulk solids stream
82 BULK SOLIDS HANDLING
References
1. Arnold, P.c., McLean, A.G., Roberts, A.W. (1979) Bulk Solids: Storage, Flow and Handling,
TUNRA Ltd, Univ. of Newcastle, New South Wales, Australia.
2. Jenike, A.W. (1964) Storage and Flow of Solids, Bull. No. 123, Utah Engg. Exp. Station, Univ.
of Utah.
GRAVITY FLOW OF BULK SOLIDS 83
3. Richards, J.e. (1966) 'Bulk solids in motion', in The Storage and Recovery ofParticulate Solids,
IChemE Working Party Report, Institution of Chemical Engineers, London.
4. Draft Code of Practice for the Design of Silos, Bins, Bunkers and Hoppers, 2nd edn., British
Materials Handling Board (1985) edn.
5. Carleton, AJ. (1972) The effect of fluid drag forces on the discharge offree flowing solids from
hoppers. Powder Technol. 6, 91-96.
6. Williams, J.e. (1977) The rate of discharge of coarse granular materials from conical mass-
flow hoppers. Chern. Engg. Sci. 32, 247-255.
7. Johanson, J.R. (1965) Method of calculating rate of discharge from hoppers and bins. Trans.
Min. Engrs AIME 232,69-80.
8. Zanker, A. (1975) Estimating the flow of solids through openings. Process Engg (July) 66-67.
9. Roberts, A.W. and Scott, O.J. (1981) Flow of bulk solids through transfer chutes of variable
geometry and profile. Bulk solids Handling 1 (4) 715-727.
10. Savage, S.B. (1979) Gravity flow of cohesion less granular materials in chutes and channels. J.
Fluid Mechanics 92 (1) 53-96.
11. Woodcock, e.R. and Mason, J.S.(1977) Theflow characteristics of a fluidised PVC powder in an
inclined channel, in Proc. Int. Powder and Bulk Solids Handling and Processing Conf,
Chicago, May 1977,466-475.
12. Roberts, A.W. and Arnold, P.e. (1971) Discharge-chute design for free-flowing granular
material. Trans. ASAE 14 (2), 304-308, 312.
13. Bishop, A. W. (1982) A study of the flow of bulk solids through vertical downpipes and the
effect of downpipes on the discharge rate of hoppers. Unpublished report, Thames
Polytechnic, London.
14. Dries, H.W.A. (1980) Packed-bed solids downflow in a cat. cracker standpipe: solids
compaction effects and flow instabilities, in Proc. Powder Europa Conf, Wiesbaden, January
1980.
15. Knowlton, T.M. and Hirsan, 1. (1978) L-valves characterised for solids flow. Hydrocarbon
Processing 57, 149-156.
16. Knowlton, T.M. and Hirsan, 1. (1980) The effect of system parameters on the operation of
dense-phase vertical lift lines and J-valves, in Proc. Pneurnotransport 5, BHRA Conf., London,
1980, Paper E3.
3.1 Introduction
In modern industry there is an increasing number of situations where
particulate and granular materials are handled in bulk, and there is a greater
awareness than ever before of the importance of safety and efficiency in
processing and handling such materials. Designers and plant operators,
perhaps schooled in traditional fluid mechanics involving only liquids and
gases, thus have a considerable task in understanding and predicting the
unfamiliar flow characteristics of bulk solids.
Chapter 2 dealt with the flow behaviour of dry bulk solids under gravity.
Although there is inevitably a considerable overlap, it is convenient to make a
distinction between gravity flow and the motion of two-phase (gas/solids or
liquid/solids) systems. In this chapter, therefore, attention is given to the
modelling of a number of readily identifiable flow situations involving the
relative motion of solid particles and fluids: flow through beds of fixed
particles, particles settling in fluids, fluidization and spouting, and finally two-
phase flow in pipes. Each of these is directly relevant to some practical
measuring, handling or processing operation involving particulate or granular
materials, and an attempt has been made to present the models in a way that
will be immediately useful to a practising engineer. The mathematics
underlying these models has been deliberately kept to the minimum consistent
with providing a satisfactory prediction of flow behaviour but, for students
and research workers who wish to attempt to unravel the mysteries of, for
example, pneumatic conveying, references are given to more specialized
works.
(3.1)
but note that this expression assumes that negligible surface area is lost due to
contact between the surfaces of particles in the bed.
In general, the particles in a bed would not be of uniform size. Although this
analysis is developed on the basis of monosized particles, the more usual case
of particles of similar shape but non-uniform size could be covered by the use
of a volume-surface mean diameter dvsm in place of dv '
For a cylindrical bed of solid particles (or a bed of any other uniform cross-
section) the voidage, or porosity, can be written
D
86 BULK SOLIDS HANDLING
where A is the total cross-sectional area of the bed and Ae is the average
effective cross-sectional flow area of the voids.
If the total volumetric flow rate of fluid through the bed is V, the effective
mean axial component of velocity in the voids (called the 'interstitial velocity')
will be
Ii Ii 1 U
U =-=-'-=-
e Ae A eo eo
where u is the mean approach velocity, or 'superficial velocity', of fluid.
N ow the effective length Ie of a fluid path through the interstices of the bed
(the actual distance that the fluid travels) will be greater than the height of the
bed H. If the bed is modelled as a set of discrete flow passages, each oflength Ie,
the velocity of the fluid in them will necessarily be greater, and can be
expressed as
I Ie U Ie
U =U -=-'- (3.2)
eH eo H
Furthermore, if the flow in these passages is laminar, we can write an
expression for the pressure-drop based on the Poiseuille equation for laminar
flow in circular pipes, thus
L1 - k J1u~/e (3.3)
Pb- A?
where Ais a hydraulic radius of the void passages, J1 is the viscosity of the fluid
and k is a constant.
Now hydraulic radius is defined as
A= flow area
wetted perimeter
and multiplying by the length of the void passages this could become
A= volume of fluid in bed
wetted surface
total volume of bed - volume of solid particles
wetted surface
That is,
A= eo (3.4)
Sb
Substituting for u~, from equation (3.2), and for Ain equation (3.3), we have
DYNAMICS OF FLUID/SOLIDS SYSTEMS 87
and writing
(3.5)
or
(3.6)
(3.7)
where Rb is the resistance per unit area of the bed surface and Vb is the volume
of the bed.
Now A. x (depth of bed) = volume of voids = eo x (volume of bed)
volume of bed eo Vb
.'. A. = eo depth of bed H
and thus
(3.8)
(3.9)
For most practical examples of beds of fixed particles, it is found that the
ratio 1.1H is effectively constant and is usually dropped from the dimension-
less Reynolds number and friction coefficient terms.
Thus, we have the definitions
and since this expression has been developed from a general analysis of the
flow through a packed bed, it should be applicable whether the flow is laminar
or turbulent, provided that an appropriate value of the coefficient kf is used.
For the case of laminar flow the pressure-drop can be expressed by the
Carman-Kozeny equation,
(3.7)
from which
2 k"
kf =-- (3.15)
9 Reb
k _ 100
f - 3Re
(3.16)
b
I"
'"'"
kf = 100 + 0.58
3 Reb
10
'" , ~
"- c-::-
-,
~
0.1
0.1 10
Reb
Figure 3.1 Dimensionless plot of friction coefficient, k f , against Reynolds number, Reb' for flow
through a packed bed, as defined by equations (3.13) and (3.12). After Ergun [2].
~~
Provided that the particle is completely surrounded by the fluid, the gravity
force and the buoyancy force will remain constant, but the drag force FD will
change, increasing as the particle accelerates from rest. It is clear from
equation (3.21) that as FD increases the acceleration of the particle will
decrease until a condition is achieved in which the net downward force on the
particle (F G - F u) is exactly balanced by the drag force FD' The acceleration of
the particle will then be zero and the steady velocity so reached is called its
'terminal velocity' or 'free-fall velocity'. Although for large objects, and for
smaller bodies of extremely low density, the time taken to reach terminal
velocity may be significant, in the majority of situations involving particulate
materials the acceleration period is virtually zero and for most models of
settling behaviour it is ignored.
For a particle falling at its terminal (steady) velocity, the drag force can be
expressed as
FD=FG-Fu (3.22)
and if the particle is spherical with diameter d and density Pp
(3.23)
(3.25)
Clearly the usefulness of this expression for the prediction of settling rates
depends upon a knowledge of the drag coefficient Co. Where the particles are
very fine, and especially if the viscosity of the fluid is relatively high, the motion
ofthe particle will be predominantly influenced by viscous effects. Under these
conditions the drag force on the particle is conveniently modelled by Stokes's
law as
Fo = 3ndPrvu (3.26)
24 (1
Co = Re + 0. 15Reo.p 687 ) (3.29)
p
i\.
0 10 2
"\
0
cj
01
\
-0
(5
C 10
~~
Gl
'<3 Stokes law
~0 C D =24Repl I'
u "'-
-
0.01 0,1 10
Reynolds number. Rep
Figure 3.3 Dimensionless plot, from experimental data, of drag coefficient against Reynolds
number for spheres moving in incompressible fluids.
'\ \.
~
Stokes law
CD =24 Re p- 1
~ ~./C 0 =Rep
li..(1 +0 15Re 0.687)
. p
~,
'~ -06
~CD=18.5Rep .
~ / C D=0.44
~, /
......... , ....
0.01 0. 1 10 10 2 10,3 10,4
Reynolds number. Rep
Figure 3.4 Some mathematical models of the relationship between CD and Rep.
DYNAMICS OF FLUID/SOLIDS SYSTEMS 95
From the set of equations
24
CD = - for Rep < 0.2 (3.30)
Rep
18.5
CD = Re o.6 for 0.2 < Rep < 500 (3.31 )
p
and
CD = 0.44 for 500 < Rep < 2 x 105 (3.32)
the following expressions for terminal velocity can be derived having, of
course, the same ranges of validity:
gd 2 (pp - Pc)
Ut = 18 for Rep < 0.2 (3.33)
Pc v
_ d1.14[g(pp-PC)JO.71
ut - 0.153 ---043 for 0.2 < Rep < 500 (3.34)
v. Pc
dg(P P ) JO.5
Ut = 1.73 [ ~: c for 500 < Rep < 2 x 105 (3.35)
CD R e 2 -_ 4d g(p p - Pc)
3
(3.36)
p 3Pc V2
which is independent of the terminal velocity and
CD 4g(pp - Pc)v
(3.37)
Rep 3pcu~
\
\
\
/
\ /
.\
/
\ / 10
/
\ CD
\ Rep V
1\ :/
/
1'\V
°1
Q
2
C DRep /
V
\ () a:Q)
/" \
./ '\.
/ '\.
'/ "r\
1,\
10
V- r\
./ "-
,/ "-
1
/ "-" 10 -3
0.1 0.4 4 10 40 100 400
Reynolds number. Re p
Figure 3.5 Chart for the determination of terminal velocities of spherical particles of known
diameter. or the diameter of particles settling at a known velocity.
10 5
1.1.
sphenclly, <PS
I /"
/ /,,/'
/ 1Y'
"'a.
<I>
a:
Cl
10 4
O'O.~::::-::~.
0.4
0.6 l~ ,:'f/? V /
U 1 . ~ -......,..--,.: ~y
"'1..- I!'>'
.!!, /; ~r /~
~;.
< 10 3
/ /,/'
~
.c
E ~ ~V
..........
/¢
:::J
c: 10 2
'"
<I>
V . . .: (;7
'0
<I>
E /::: ~~
:f,Y
~
10
~
0
""'-~ ,,?p
< -';~ f'"'
(3.41 )
and
usd
Re =- (3.42)
p Vs
bulk solid A
bulk solid B
-
::J
in size and/or density. Figure 3.7 illustrates the relationship between terminal
velocity and particle size for two bulk solids, denoted A and B, the material A
having the higher value of density. If a mixture of these two materials is being
sorted in a fluid stream having a uniform velocity u, all particles of material A
having diameter greater than dA will fall whilst those of material B with
diameter less than dB will rise. Thus, for satisfactory separation into two pure
fractions it would be necessary to prepare the mixture so that all the particles
are between the size limits dA and dB' In order to sort materials A and B having
particle sizes outside this range, it would be necessary to increase or decrease
the velocity of the upward-flowing fluid, or to use a fluid of higher or lower
density.
3.4 Fluidization
transition
n"d bod ,,,;m~ I fluidized bed regime
r-~--~------~'------
Umf
,-~ ,-~
,-~ ,,- ~
t
Cc) Intermediate channelling Cd) Slugging
t
Figure 3.9 Behaviour of poorly-fluidized beds.
variety of characteristics depending upon factors such as particle size and size
distribution, particle shape, degree of cohesiveness, and so on. Some kinds of
'imperfect fluidization' are illustrated in Figure 3.9 including partial fluidiz-
ation, where a portion of the bed remains unfluidized (Figure 3.9a), channel-
ling (Figure 3.9b), intermediate channelling (Figure 3.9c) and slugging
(Figure 3.9d). The type of plot that might be obtained of pressure-drop against
superficial velocity in each of these cases is shown in Figure 3.10. Note that
Figure 3.101 represents the form of plot that would usually be obtained with
materials that fluidize reasonably well, the length of the smooth curve joining
the 'packed-bed' and 'fluidized-bed' regimes depending largely upon the range
DYNAMICS OF FLUID/SOLIDS SYSTEMS 103
.c.p .c.p
17 :/
(a)
"m'
U
(b)
U
.c.p .c.p
U U
(c) (d)
,/
./
.c.p .c.p
I
I
I
I
I
I
:/
I ufs
u u
(e) (I)
Figure 3.10 Pressure variation in fluidized beds. (a) Ideally fluidizing materials; (b) materials
exhibiting moderate channelling; (e), (d) more severely channelling materials; (e) cohesive
materials exhibiting 'slugging' behaviour; (f) materials having wide size distribution.
of particle sizes present in the material. Where the particle size distribution is
very wide, or where the material consists essentially of a mixture of two or
three powders of relatively uniform size, segregation may occur as a result of
the finer particles becoming fluidized before the coarser ones. Such behaviour
can cause several peaks to occur on the plot of pressure-drop against
superficial velocity.
104 BULK SOLIDS HANDLING
(3.47)
Now the left-hand side of this equation is a form of Archimedes number for
the bed:
(3.52)
and
(3.53)
(3.56)
However, this appears to result in a very considerable underestimate of Umf
for non-spherical particles.
It is clearly not easy to predict the behaviour at incipient fluidization of
irregular particles. A decrease in the sphericity of an isolated particle would
cause an increase in the drag exerted on it at a given velocity. However, in a bed
of particles a decrease in sphericity would normally be accompanied by an
increase in the bed voidage, which in turn would cause a reduction in the
interstitial velocity. The effects might be expected to oppose each other to
some extent so that particles of the same size and density should in general
become fluidized at around the same value of superficial fluid velocity. There is
thus good justification in using a correlation, such as equation (3.54) or (3.55),
that is independent of cPs and emf'
DYNAMICS OF FLUID/SOLIDS SYSTEMS 107
~ ~
4
Os=1
r- ",-
",
r-
",-
~",
~f3j"'-
A
"" 1, \ .6 /
r- ~
r- ~/ ""
7
r- 7/ '/ /
!e'// ,-
- entrainment ~ /. z ' / /
//
10
~~ /
r-
r- ~Y "" V
/
~/ /
a. r- /.~/ /
CD ~/ /
a: r- ~,,1 /
A.~
E -- 11.' /'1,- //'/ / V
/" .,
Q>
a:
- 6 //
~I',/'
/
-
1 11'/.
/
~'l
-- /1-// K
/
'// / ...
~
'// minimum lIuldlzatlon
.",
/v
'l/
2 ~/
~
f-
f-
f-
3
~
-
4
-
- t t t I t t t I
10
Archimedes number, Ar
Figure 3.11 Correlations of Reynolds number against Archimedes number for isolated particles
at terminal velocity, and for a bed of particles at a condition of minimum fluidization.
velocity of a material may be made from this graph by first calculating Arb, and
then reading off a value of Re mf and from this estimating Umf .
The foregoing analysis is a general one, endeavouring to cover the whole
range of flow behaviour from laminar through transitional to turbulent.
However, at normal atmospheric pressures and temperature the fluid flow
through a bed of solid particles tends to be laminar for particles having
diameters less than about 500,um. For such relatively fine particles, viscous
effects predominate and the expressions for minimum fluidizing velocity can
therefore be simplified by ignoring the kinetic energy term.
Thus, for example equation (3.47) reduces to
1- effi r) 2 1
Apb = 150 ( -----:i:d -3-· ,uUmr H mr (3.58)
'Vs v emr
(3.61)
(3.62)
which is derived by combining equations (3.29), (3.36), (3.39) and (3.40), noting
that Ar = iCDRe;.
Although it may happen that entrainment of particles from the bed surface
does not become significant until the bed is fluidized at velocities well in excess
of the terminal velocity of a single particle, at higher velocities the quantity of
material entrained can increase rapidly.
particularly with regard to the material from which it is constructed and the
pressure-drop across it, can vary over a wide range. For example, some
applications are suited to the use of metal plates perforated with a small
number of relatively large holes across which the pressure-drop would be very
small, whilst at the other end ofthe scale (that is, high pressure-drop) would be
found porous distributors such as ceramics, sintered metal and plastics, and
woven cotton and polyester materials.
Considerable interest surrounds the influence of the pressure-drop across
the distributor, or more specifically, the ratio of this pressure-drop to that
across the fluidized bed, on the 'quality' of fluidization. Clearly the stability of
the fluid bed system is an important criterion, and it is worth considering how
this might be defined and how it depends upon the ratio of the distributor
resistance to the bed resistance.
Suppose that a disturbance occurs, in the nature of a localized increase in
gas velocity, in (l uniform bed of dry particles in a condition of incipient
fluidization. This disturbance will cause the bed in this region to expand,
resulting in a fall in the local pressure-drop through the bed, and consequent
rise in pressure-drop through the distributor as more gas tries to force its way
through the potential 'channel'. The system is stable if the combined pressure-
drop across the bed and distributor rises with an increase in the local gas
velocity in the bed. However, if this combined pressure-drop were to fall, there
would be a further increase in the local gas velocity, tending to establish a
channel through which most of the fluidizing gas could flow, causing the rest of
the bed to defluidize. In general it may be said that the resistance to gas flow
offered by the distributor should be great enough to ensure stability of the
fluidized bed system without being so high that blower power becomes
excessive. Although there appears to be some disagreement as to how the
optimum pressure-drop should be determined, the consensus suggests that the
pressure-drop through the distributor should be at least 15% of that across the
particle bed. In fact the stability of the fluidized bed may also be influenced by
the size and density of the particles in it, and, although very little experimental
data is available, Figure 3.12 gives an indication of the way in which the
minimum required distributor pressure-drop would vary with these
properties.
'0
Q)
D
V>
~24 r--------i--------~---------}--------4-____~~
(;
It!
Co
o
U
Q,
~20 1---------i--------~------~~~~~~~~~~~
V>
Q)
C.
'0
~16 r-------~ ~~~~~~~__~~~~______+-______~
C
Q)
o
(j;
Co
:12 r-------~--------_4--------_+_
CO
o
~
~ 8 r--------i---------i---------+--------4-------~
V>
V>
o
(;
CO
Q
uo 4 ,...---------r--------~--------+_------~~------~
~
::J
V>
V>
CI>
C.
500
mean particle diameter d v (I'm)
Figure 3.12 Minimum pressure drop required across distributor for bed of spheroidal particles
fluidized with air at a condition close to normal ambient, based on an equation by Siegel [II].
defined by
(3.67)
where da is the particle size from sieve analysis and x is the mass fraction of
particles of that size, tends to under-emphasize the influence of the fine
particles, which may in fact have a pronounced effect on the particle surface
area per unit volume of the bed, and therefore on its fluidization behaviour. A
more relevant size is the volume surface mean diameter, which is conveniently
(though not exactly) expressed as
Probably the most useful recent work dealing with fluidization characteristics
of different types of particulate bulk solids has been that of Geldart [12] who
112 BULK SOLIDS HANDLING
bed when the flow of the fluidizing medium is shut off. At velocities above U mb
the bed bubbles freely and at higher velocities axisymmetric slugging tends to
occur. At velocities higher still, the slugging movement is continually
collapsing so that the upward flowing fluid is forced to track upwards through
angled crevices to the top surface of the vigorously turbulent bed.
Group B. Including most materials in the mean particle size and density
ranges 40-500,um and 1400-4000 kg/m 3 , this group would typify the
generally accepted model of fluidized bed behaviour. At fluid velocities above
U mf the expansion of the bed is small and bubbling occurs at or just above this
minimum fluidizing velocity. Collapse of the bed is rapid when the fluid flow is
shut off. As the velocity is increased the bed bubbles freely, and eventually
tends to a form of asymmetric slug flow.
Group C. This includes cohesive powders that are difficult to fluidize satis-
factorily because of high interparticle forces resulting from very small particle
size, electrostatic effects or high moisture content. Attempts to fluidize such
materials usually result in the formation of stable channels or in the whole bed
rising as a plug, although some success may be achieved with the aid of
mechanical vibrators or stirrers.
Group D. Including materials having large mean particle size and/or high
particle density. Fluidization behaviour is in some respects similar to powders
in Group B, but beds of Group D materials can generally be made to exhibit
the phenomenon known as 'spouting' (see section 3.5) if the gas is admitted
centrally.
~ Iii '~
D
2000 -~\ 1'\
B '\
(')
~
.t l-
I ~\
,
'"~
(J)
r--~\
23,
1000 r--
~
0:- I-
-
\~ A
\\,
I
I-
a. -
"~
Q
'\
ill
<.)
500
":',
"~\"
C -
ill
~,
~
Ie
-
'6
~ 200 \.~
iii
~ '~
i ~,
I"
c
ill
U
100 I
20 50 100 500 1000 5000
mean particle diameter (I'm)
Figure 3.13 Geldart's classification of fluidization behaviour according to size and density of the
particulate material: for fluidization with ambient air [12].
fountain
_ fevef of natural
free surtace
';ga~~t--
~
spout velocity)
(t1igh
conical base
gas inlet
"'0
1:
'"'"o /' - ....... , incipient spouting
----, \
-
<> varying degrees Of
<'II
initial compaction
a.
o ////
is
e
:::l .",
/
//
\ \_-~
\
'"'"CD ~
a /. / '
/ / . / .",""
/
.",...
.",...""'" minimum spouting /
steady-state spouting
~.", .",...-
:;.-'/ .",...
9'/ ".,.,...
~-
superficial air velocity
Figure 3.15 Typical relationship between pressure-drop and air flow rate for a spouted bed.
DYNAMICS OF FLUID/SOLIDS SYSTEMS 115
provides an alternative to fluidization for contacting fluids with a coarse
granular material.
Various applications of the spouting phenomenon occur in industry, the
commonest involving the drying of granular bulk solids such as grain and
wood chips. As with fluidization, the most important single factor in the design
of a spouted bed system is ensuring that the flow rate of fluid supplied to the
bed is correct. Various correlations for minimum spouting velocity have been
proposed and some of these are introduced here. Other important design
considerations relate to the geometry of the spouting vessel, the pressure-drop
across the bed, and so on, and for further information on these aspects the
interested reader is referred first to the work of Mathur and Epstein [13,14].
Figure 3.15 shows the typical form of relationship between the pressure-
drop and air flow rate for a spouted bed as the flow rate is increased from zero
to the condition of steady-state spouting. As with a conventional fluidized bed
the system initially corresponds to flow through a bed of fixed particles and the
pressure-drop is nearly proportional to the flow rate. Eventually a point will
be reached at which the particles at the apex of the conical base of the vessel
(where the velocity is greatest) begin to rise. Further increase of the air flow rate
will cause the channel or spout formed at the bottom of the vessel to extend
upward into the bed and, since the concentration of particles in this spout is
much lower than in the rest of the bed, there will be a decrease in the overall
pressure-drop. Continuing to increase the air flow rate will result in further
upward extension of the internal spout although, because of the increase in the
depth of the bed caused by displacement of particles from the central region,
the fall in overall pressure-drop could be less marked. When the air flow rate is
sufficient to cause the spout to break through the surface of the bed there will
be a sudden decrease in the overall pressure-drop to the value corresponding
to steady-state spouting and this value will be more or less unaffected by
further increases in airflow.
It should be noted that the peak value of pressure-drop reached will be
largely dependent upon the packing of the granular bed so that for the most
loosely packed bed there may be virtually no observable peak at all in the plot
of /1p against air flow rate.
The usually accepted correlation for the prediction of minimum spouting
velocity urns is an empirical equation involving the densities ofthe flowing fluid
and the particles, together with relevant dimensions of the spouting vessel:
where d is the effective diameter of the granules, Dj and Do are the diameters of
the inlet and the main vessel, H is the height of the bed surface above the inlet,
and Pp, Pc are respectively the densities of the granules and the fluid. Leva [15]
gives the following values of the index n: for Do = 150 mm, n = 0.33
(independent of cone angle); for Do = 600 mm, n = 0.23 (for 45° cone) n = 0.13
(for 85° cone).
116 BULK SOLIDS HANDLING
3.6.1 Introduction
(i) When the solid particles are conveyed in a uniformly dispersed phase.
(ii) When the conveyed material mainly occupies the lower part of the
conveying line and assumes the form of a moving layer, or moving 'dunes'
of solid particles.
(iii) When the density of the flowing suspension approaches the bulk density of
the conveyed material. This would represent a true 'mass-flow' situation
somewhat reminiscent of the 'extruded flow' of a soft plastic material.
The transition from (i) to (ii) and from (ii) to (iii) occurs as the gas velocity is
decreased or the solids flow rate is increased, and is due to the continued
deposition of solid particles from the flowing suspension. Actual values of the
solids loading ratio for these three categories of stable flow cannot, of course,
be exactly specified since they are influenced by a number of other factors, but
dispersed- or dilute-phase flow would typically be observed with solids
loading ratios of less than five whilst the characteristics of dense-phase flow
would tend to be seen when the solids loading ratio ranges from about 25 up to
a value of several hundreds.
Methods of prediction of pressure-drop will be discussed in a later section,
but it may be emphasized at this stage that the tendency for the solid material
to be concentrated in the lower part of a horizontal pipeline makes it unwise to
compare pressure-drop data for suspension flow in horizontal pipes with
corresponding data obtained in vertical flow, except perhaps at very high
conveying velocities where the particles would be widely dispersed. Also,
pressure-drop correlations proposed by various investigators must be used
with caution and only for the limited region of the experimental programme
upon which the correlation is based. If extrapolation is absolutely necessary,
careful analysis ofthe actual flow conditions to be encountered must be carried
out.
It should, at this stage, be understood that the different flow patterns
E
118 BULK SOLIDS HANDLING
10
flow direction
illustrated in Figure 3.16 may be observed at different points along the same
pipeline. Changes in the cross-sectional area of the pipe will affect the velocity
and therefore may change the flow pattern. However, even in a pipe of uniform
cross-section, the decreasing pressure of the conveying gas will cause its
velocity to increase so that, in an extreme case, the flow could change from
dense-phase (at low velocity) at the entry to the pipe, to a very dilute phase,
with widely dispersed particles travelling at high velocity at the outlet end.
A useful qualitative presentation of dilute-phase gas/solids flow in a
horizontal pipeline has been given by Zenz and Othmer [17J in the form of a
so-called 'phase-diagram' which is a log-log plot of the average pressure
gradient along the pipe against the superficial gas velocity (based on the total
DYNAMICS OF FLUID/SOLIDS SYSTEMS 119
...J
J::
0>
c
.,
~
0.
00.
oS
0.
o
-0
'en5"
.,en
0.
saltation
velocity Us
for solids
flow rate rTlPl
concerned, and thus represent two boundaries of the area within which any
actual flow condition of the product must lie. It should be noted, however, that
this does not imply that the area defines flow conditions that could actually be
achieved, as whether a certain flow condition is possible or not depends upon
the properties of the bulk solid in a manner that is not easily modelled or
predicted.
The two lines denoted mp = 0 therefore represent the flow of gas alone,
whilst m p1 , m p2 , ' " represent increasing solids mass flow rates. Thus, for
example, suppose the solid particles are introduced at a rate m p1 into a gas
flowing along a pipeline at a superficial velocity UB' The increase in frictional
resistance due to the particles causes the pressure-drop per unit length to
increase from point B to point C l ' If the superficial gas velocity is now reduced
(effectively increasing the solids loading ratio) the concentration of particles
per unit length of the pipe will increase until eventually a point will be reached
(D 1) where the particles begin to settle out at the bottom of the pipe. This
phenomenon is known as 'saltation' and the value of the superficial gas
velocity at this point (us) is known as the 'saltation velocity'. Note, however,
that this saltation velocity may be a function of the mass flow rate of solids, so
that points D2 , D3 ... correspond to saltation velocities for solids mass flow
rates m p2 ' mp3 '" Further reduction of the gas velocity will cause more solid
material to settle out until a substantial non-moving layer develops on the
bottom of the pipe. Transport will continue above this deposited layer, with
the actual gas velocity significantly greater than the superficial velocity
because of the reduced area, but there will be a sharp increase in the pressure-
drop (from D to E). After passing through the various intermediate stages
illustrated in Figure 3.16 as the amount of deposited material increases, the
pipe eventually becomes full of particles and a condition of true mass flow may
be attained, with the pressure-drop approaching that corresponding to the
value for packed-bed flow.
The actual mechanism of two-phase gas/solids flow at high solids loading
ratios and low velocities (i.e. below the saltation velocity) is still far from being
fully understood, although recently reported experimental investigations,
particularly at Thames Polytechnic in the UK [18-20] have done much to
improve this situation.
The proposal of Geldart [12] for characterizing the fluidization behaviour
of bulk solids, which was described in section 3.4.5, is now well established and
it is hardly surprising that various research workers, notably Dixon [21,22],
remarking on certain similarities between gas fluidization and dense-phase
gas/solids flow, have attempted a similar classification for pneumatically
conveyed materials. Although originally based on empirical formulae relating
to flow in vertical pipes, Dixon's so-called 'slugging diagrams' may well have
relevance to non-suspension gas/solids flow generally. Figure 3.18 shows the
slugging diagram for flow in a 2-inch (50,um) diameter pipe. Group A
materials (powders) and Group D materials (granules) both tend to convey
pressure (bars)
4
. \
\\ \\
\\ B D
:/. \ \
\\\ \ strong
5000 I- ~ \ \ weak asymmetric \\ axisymmetric slugs
/. \ \ slugs (dunes) \\
(') ~ \\ ~ t::I
E /. \\ \\
Ci / \\ ,\ ~
"" >
~ \\ \\ f:5
1"2000 \ \ (")
(J'l
~ A \\
h /. \ \
\\ \\
Q. ~
~ ~ no slugging \ \ \ \
Q)
"'1
/ \ \ \ \ t""
g 1000
Q) ~ \ \ \ \ @
/ \ \ \ \
~
"0 C 'l/ \\ \ \ ~
t""
~ ~ \\ \ \
·iii 500 // \\ \ \ 8
(J'l
c
Q) // \ \ \ (J'l
"0 // \ \ \ -<
(J'l
/ \
, \ @
// \\ \
// \ \ 15::
(J'l
200 I- ~ \\ \
,,
\ \ \
\\
\\
, ,, \
\
\\ \ \
20 50 100 500 1000
mean particle size d (/Lm)
Figure 3.18 Slugging diagram for 50-mm (2-inch) pipe. .....
IV
.....
122 BULK SOLIDS HANDLING
well in dense-phase, but their mode of flow is very different. The significant
feature of Group A materials is that they have the capability of retaining air in
the void spaces for some time after the supply of air has been discontinued.
This means that, once aerated, these products have a persisting fluid-like
quality which enables them to 'flow' very readily along a pipeline without
slugging. The granular bulk solids of Group D usually exhibit a natural
tendency to form slugs of up to a metre or so in length which travel along the
conveying line shedding material from the back of the slug and picking up
material at the front. Materials falling into Group B do not retain air and in
general can only be conveyed in dense phase at relatively high velocities if
unstable slugging behaviour is to be avoided. Finally, there are the Group C
powders to be considered: these are likely to be cohesive and therefore
unsuitable for simple dense-phase conveying, although it may be possible to
transport such materials in special systems which are designed to provide
additional air at successive points along the conveying line. For descriptions of
various types of pneumatic conveying systems with 'air addition' see
Chapter 12.
,,
,,
,,
Q)
, E2
iii
o c,
'"
g0>
--'
.c
c;,
c:
oS!
Q)
Q
'0.
,S
Q
o
-6
~
:::>
'"'"
Q)
0.
y'OW""
choking velocity for
Pressure-drop in a gas flowing along a pipe. As a gas flows along a pipeline, the
decreasing pressure resulting from the frictional resistance to the flow causes
the gas to expand. That is, the density of the gas decreases, and consequently
the average velocity of the gas across a section of the pipe must increase in the
direction of flow. These changes of density and velocity may not be very great
and, if the velocity at the upstream end of the pipe is not high and the pipe is
relatively short, it is usually safe to determine the pressure-drop by treating the
flow as one of constant density.
Thus, using the familiar Darcy formula, the pressure-drop I1pg in a gas of
density Pg flowing along a pipeline of diameter D and length L would be given
by
where ug is the average velocity of the flowing gas and I is the 'pipe friction
factor'.
A more reliable prediction of the pressure-drop, and a useful indication of
the variation in velocity along the pipeline, may be obtained by using one of
several possible analytical models that take account of the varying density.
The most convenient of these is perhaps the isothermal model in which the
pressure gradient along the pipe is expressed as
dpg 321m; RT
dL = n 2 ' D 5 . P; (3.72)
DYNAMICS OF FLUID/SOLIDS SYSTEMS 127
where mg is the gas mass flow rate, T is the (constant) temperature of the gas
and R is the characteristic gas constant.
Provided that the velocity of the gas remains well below the sonic velocity
(so that variation of kinetic energy is insignificant), integration of
equation (3.72) allows a reliable value of the pressure-drop (P g 1 - Pg 2) over
pipe length L to be determined from
_ [ 2 _ 64/m;RTLJ1 /2 (3.73)
Pg 2 - Pg 1 7[2 D5
(3.74)
and rearranging
1
P [1 _4fL.
g1 = U;2 ] 1/2
(3.75)
D RT
Thus, in a situation where the downstream pressure is known and the
velocity at the upstream end of the pipe (pick-up velocity) is specified, this
expression allows the pressure required at the upstream end, for gas alone, to
be estimated.
Note that the value of the pipe friction factor f may be taken to be 0.005 for a
preliminary calculation, but should then be checked from the Moody chart
(Figure 3.20) using an appropriate value of the pipe roughness e and the value
of Reynolds number at the upstream end of the pipe, calculated from
(3.76)
1
.jj= - l.7210g e 3.71
(e/D + Re.jj
1.255 ) (3.77)
\ laminar flow (critical) turbulent flow .....
I tv
00
0.02
0
1\ ~
(f)
OJ
'"
laminar 1\ c
.c
OJ
flow, \ ::J
2
0.012 f =16/Re OJ
, >
.~
I~ t--. t--."
0.01 ~
\ " "t-..: F:::~ 1"- t:Il
\ f"'t-- ~ t-- r- r- C
c5 t t""'
/ 0.005 i"i
0 Recrit
~ \ 1'-1'.... . . . ~ t--.....
c
'"
0
\ t""'
Q \
I-- t- S
0 0.002
RtS: t:-- t--.r-.
E '"
::r:
r-- r- !--- :>-
0.001 Z
'~ ~ ~~ I--""t-
0.005
t:I
t""'
r--I' l- t-- I--
~ 0.0005 Z
0.004 ~~ t- t--.. 0
.........
~ 0.0002
Approximate roughness of internal ~ ......... f:::: r--
- -
surfaces of pipes, dmml ~ f:::::::: 0.0001
0.003 f-- Cast iron 0.25
::::::: - 0.00005
Commercial steel 0.045 '~ :::::::: 0.00001
Drawn tubing 0.0015 smooth
f--
0.002I I I - I
10 3 10 4 10 5 10 6
Reynolds number, Re
Figure 3.20 Moody chart for the determination offriction factors for the flow of fluids in pipes of
circular cross-section.
DYNAMICS OF FLUID/SOLIDS SYSTEMS 129
[(
8 )12 1 J1 /12 (3.78)
f = Re + (A + B)1.5
where
1000
Butterfly valve,8=200
Bend, 180 0 close return 50 600
500
30
400
Gate valve, 314 open 20
20
0.05
Figure 3.21
has been the subject of considerable research effort. Most authors seem to
agree that rt will be directly proportional to the solids loading ratio cp, but there
is clearly some substantial inconsistency in the suggestions concerning the
influence of particle characteristics such as size, shape and density.
Clearly, any correlation involving the large number of relevant variables
will be complex, However, test results reported for a large number of different
products demonstrate the general trend illustrated in Figure 3.22; that is, the
frictional pressure-drop attributable to the presence of solid particles in the gas
stream increases as solids loading increases, and also as the conveying velocity
is decreased, The very sharp rise in frictional pressure-drop that is seen in
100
r
~
~\.
50 \.\.\.'\.
~,~
~
~~ ~ 1::1
2
<.l
~
~ 20 ~~ 20
~
18 -G- n
.Q 16 6
'"'"
CD
'."'~
\ \." ~'" ::::=::::- 14 ~
'"0
'!j
5 ~ 12 ;;, '!j
'"'"~ 10 0 ........ '" 10 o§
Co ........ Cll @
" 8 .Q
....... --- :2
'" ---
5
'"" ........... --
r---..... 6 (5
'"
1St"'
S
'"
-- 4 '"><
'">-lttl
is:
'"
2
10 20 30 40 50
conveying velocity Cm/s)
Figure 3.22 Approximate values of the solids pressure-loss factor in equation (3.80). t-
V)
t-
132 BULK SOLIDS HANDLING
IX =~.&(pp)1/2'</J (3.81 )
8fg Pg
where fg and fp are respectively pipe friction factors for the flow of gas alone
and for the flow of solids, Pg and Pp are the densities of the gas and the solid
particles and </J is the solids loading ratio. Information given by Rose and
Barnacle suggests that an acceptable value of fp would be given by
for 1.104 < Re < 5.104 , where Re is the Reynolds number for the gas phase.
If the friction factor for gas is now expressed in terms of Reynolds number by
the Blasius formula
fg = 0.08 Re- O . 25
equation (3.81) can be simplified to
IX = K 1(p P/p g )1/2</J (3.82)
where K 1 = (0.325 Re - 0.60) + (0.0425 Re - 0.35).
A very similar correlation, having IX a function of slip ratio instead of density
ratio, has been proposed by Hinkle and referred to subsequently by several
authors, for example, Leva [15] and Dixon [22]. This correlation can be
expressed as
f, U
IX=~·-.J'.·</J (3.83)
fg ug
where up is the solids velocity and ug is the gas velocity.
The use of an empirical 'solids friction factor' fp in this and the previous
DYNAMICS OF FLUID/SOLIDS SYSTEMS 133
correlations is interesting. That of Rose and Barnacle is said to be a function of
the gas-phase Reynolds number, whereas Leva gives an expression for the
solids friction factor as
(3.84)
in which CD is the drag coefficient for a particle and is a function of the particle
Reynolds number, Rep = dpgut/Jl, as shown in Figure 3.3.
Another somewhat similar correlation is that of Richardson and McLeman
who suggested [28]
(3.85)
where tit is the terminal velocity of the solids particles (in free fall) and K 2 is a
factor that depends on the diameter of the conveying pipe.
Yet another correlation, quoted by Boothroyd [29], is that of Vogt and
White who give
IX = K3.!L(~)2 Pp (3.86)
Re d Pg
where diD is the ratio of particle size to pipe size, Re is the gas-phase Reynolds
number and K3 is a constant.
There are many such correlations, often unfortunately showing significant
lack of agreement. A useful summary of the influence of different variables,
such as solids loading ratio, Reynolds number, particle and conveying-pipe
size and particle/gas density ratio, has been given by Boothroyd [29]. He
follows this with a theoretical discussion which leads to the result that
(3.87)
where K4 is a constant, and this agrees quite closely with some of the empirical
correlations, notably that of Richardson and McLeman, equation (3.85).
There appears to be fairly general agreement that the pressure loss factor IX is
likely to be proportional to the solids loading ratio <p and the conveying-pipe
diameter D, and inversely proportional to the solids velocity up. The particle
size ofthe conveyed solids also has an influence on IX and this may be taken into
account by including in the correlation the particle diameter d, the terminal
velocity Ut or the drag coefficient CD'
For most of the above approaches it is necessary to know the actual
conveying velocity of the solid particles and their terminal velocity in free fall.
Again, various correlations have been proposed for these quantities. For
example, Arastoopour et ai. [26] give for the particle velocity
(3.88)
134 BULK SOLIDS HANDLING
1.0r---,-------------,---------,---------,------------.
-
0.9
Ol
:::l
a.
:::l
Ui
'"
Ol
'0 0.8
i'::
'0
0
Qi
<-
Q) particle density 1000
(3
:;::; (kg/m 3 )
~
a. 0.7
3000
'0
i'::
'0
0 5000
Qi
>
J1
0
0.6
~
.Q-
Ui
0.5
Figure 3.23 Correlation of slip ratio (up/ug) with particle size and particle density. Based on
equation (3.88) [26].
where d is the particle diameter in f.1m and Pp is its density in kg/m3. This
correlation is shown plotted as Figure 3.23 and gives a convenient indication
of the relationship between the velocities of the conveying gas stream and of
the solid particles entrained in it.
Many correlations are also available for the terminal velocity in free-fall of
particles of specified size and density, and some methods of predicting the
terminal velocity have been discussed in section 3.3.
The majority of the previously mentioned correlations for pressure-drop in
two-phase gas/solids flow relate to flow in horizontal pipes, and where vertical
flow is involved it is necessary to incorporate an additional term to account for
the solids head.
DYNAMICS OF FLUID/SOLIDS SYSTEMS 135
Thus, for example, we could write
I1ps = I1pg (1 + a) + I1Ph (3.89)
where
(3.90)
(3.91 )
for a horizontal line, where A is the pipe cross-sectional area. The prediction of
additional pressure-drop resulting from a pick-up in a vertical riser would be
somewhat more difficult due to the added effect of solids hold-up in the
accelerating length.
The flow of gas/solids suspensions around pipe bends has been discussed
elsewhere (section 3.6.4) and from that discussion it was evident that the
peculiar sliding/bouncing motion of the particles through the bend must
render the reliable prediction of pressure-drop all but impossible. A reason-
able approach to the estimation of the bend pressure-drops would be through
the use of 'equivalent lengths' of pipe, using factors derived from experimental
work, or based on past experience. Thus, if the pressure-drop in a bend is
expressed as
2
A _ k Psu g (3.92)
U.Pb - b
2
where Ps is the density of the gas/solids suspension and kb is a coefficient,
comparison with the Darcy formula equation (3.71), shows that the equivalent
length of straight pipe would be given by
L _kb.~.Ps
b - 4 f Pg
136 BULK SOLIDS HANDLING
4 1.50
8 0.75
12 0.50
or
kb D
Lb =4"7(1 + ¢) (3.93)
Values of kb in equations (3.92) and (3.93) [31] are given in Table 3.1.
where d is the average particle diameter, up is the particle velocity and Pds is the
dispersed solids density (defined as the mass of solids trapped in a short length
DYNAMICS OF FLUID/SOLIDS SYSTEMS 137
of conveying line by the instantaneous closure of two valves, divided by the
volume of the line between the two valves).
The work of Muschelknautz and Krambrock [33] yielded different
correlating expressions according to whether the mode of the dense-phase flow
was 'stratified' or 'dune/slug'. The analysis leading to these expressions is
interesting, but quite complex, and the reader is directed to [33] for full details.
For stratified flow, the form of the expression for pressure-drop in a pipe of
length Lis
(3.95)
where rc is the steady-state cross-section ratio, Ps is the bulk density of the
stratified flow and fd is a frictional coefficient for the sliding and rolling
product.
In general, if stratified flow is to be maintained the ratio of the cross-
sectional area of the suspension flow should be at least 40 percent of the total
flow cross-section, and this is likely to correspond to a solids loading ratio of
10-100 with gas-phase velocity of 6-20m/s and solids velocity of 0.1 to 0.3
times the gas velocity. The frictional coefficient fd would be typically around
0.6 to 0.8.
Dune and plug conveyance can occur over much the same range of solids
loading ratios as stratified flow but the gas velocity is likely to be slightly lower
and the solids velocity slightly higher. The form of the Muschelknautz and
Krambrock equation for this mode of dense-phase flow, which is also
discussed by Dixon [22], is
(3.96)
u
fdCPL g
Z=-_·- (3.97)
RT up
The probable value of the friction coefficient fd is in this case 0.4 to 0.8. The
velocity ratio, up/u g, would normally be in the range 0.3 to 1.0, with high
loadings of fine products giving the higher values of velocity ratio.
It is clear that, especially for dense-phase flow, the techniques available for
the prediction of pressure-drops in two-phase gas/solids flows is not suffi-
ciently reliable for the engineer to design, with confidence, systems for the
pneumatic transport of bulk solids. The use of test results from suitable pilot
plant is essential, but the models and correlations discussed in this chapter can
be invaluable in scaling and otherwise manipulating such results in order to
understand fully the behaviour of the bulk solid concerned, when it is
pneumatically conveyed. Detailed descriptions of pneumatic conveying
systems and full recommended design methods are given in Chapters 12-14.
138 BULK SOLIDS HANDLING
(3.98)
where '0 is the shear stress existing at the pipe wall, L is the pipe length over
which /'ip occurs and D is the diameter of the pipe. Naturally, if there is a
change of elevation this will also have to be taken into account in order to
determine pumping requirements.
In the familiar case of Newtonian fluid behaviour the local shear stress is
given by
du (3.99)
'=11-
dr
where 11 is the coefficient of (dynamic) viscosity and du/dr is the velocity
gradient.
More generally, however, the local shear stress, could be regarded as a
function of the rate of shear y and the time t, and a considerable number of
non-Newtonian fluid models have been proposed, described variously as
'time-independent', 'time-dependent' and 'visco-elastic'. Although some slur-
ries may exhibit time-dependent behaviour, this is relatively uncommon, and
in this book only the first group of models- those in which the shear stress is a
function only of the shear rate-will be considered.
The time-independent fluid models are defined by the relationship
, = function [Y]
140 BULK SOLIDS HANDLING
- Herschel-Bulkley
- - Bingham plastic
_ Newtonian
_dilatant
shear rate, 1-
Figure 3.24 Models of time-independent non-Newtonian fluids.
and it may be noted that the Newtonian fluid is merely a special case of this
general model in which the function is a linear one.
Since for this model of time-independent fluid there is a unique relationship
between rand y, the function may be plotted as a single line on a graph of shear
stress against shear rate. Various types of behaviour have been observed and
the most important of these are represented in Figure 3.24.
C])
Ol
.2
~~_--n<1 (pseudoplastic)
/ . - - n=1 (Newtonian)
10g e 1
Figure 3.25 Power law models of non-Newtonian fluids.
number has a certain characteristic (or 'critical') value. Thus, for a Newtonian
fluid flowing in a pipe of circular cross-section, the mode of flow is likely to be
laminar if
(3.107)
_ DAp
f.1- 4L
/8UD av
(3.109)
2600
Q;
.c
E
::J
~ 2400
"0
)~ ...........
"0 ........
,.,
co
Q)
Combining equations (3.107) and (3.110) it is seen that for a power-law fluid
the effective viscosity is given by
"\
i\ f=16/Re
'< -- ----.. ..
0.02
i'
-
... J ... ,
·~ I ~ I ~
~ ' ~ ......
- --....
0
0.01
"'"
I
",Jf
~
.. ...
U J ~ 2.0
.!'! V -~ r-- ~
c
..... r-- -r- ~ 1.4
.2 0.005
-r-
::",
" , , i'- 1.0
U
, r-- ....
... ... ...
..
c
:E 0.8 ,;:
-r---_ ...
Q)
....... ... , ... 0.6 "0
0.
.0. . ~
-----
experimental regions
,, ... ........
0.3
g
I III
ex trapolated regions
I I I II I
,, 0.2
0.001
10 3 10 4
generalized Reynolds number. Re"
Figure 3.27 Friction factor design chart (power law fluids) from [35].
slope = I'p
(coefficient of rigidity
or plastic viscosity)
t
yield stress. T y
I
shear rate. 'Y
Figure 3.28 Bingham plastic and Herschel-Bulkley models of non-Newtonian fluid flow.
DYNAMICS OF FLUID/SOLIDS SYSTEMS 145
value of the pipe friction factor can be estimated which allows the pressure-
drop to be calculated in the usual way.
and it is also possible to define an 'apparent viscosity' in the same way as for
the power law models, i.e.
(3.114)
The Bingham plastic model is found to be quite reliable for the prediction of
flow behaviour of a wide range of liquid/solid suspensions such as drilling
muds, thick mineral slurries, sewage sludge, and polymer solutions.
As with other models of fluid flow, it is necessary to be able to predict the
transition from laminar to turbulent behaviour. For Bingham plastics a useful
dimensionless parameter, from which the transition can be predicted with
reasonable confidence, is the Hedstrom number, defined as
He = PsTyD2
(3.115)
f.1;
~I--
V
~r-
.- --
~
~
10 5
Hedstrom number. He
Figure 3.29 Relationship between critical Reynolds number and Hedstrom number for
Bingham plastics [34].
flow
~
-- -- .......
~
t
plug zone
(T < Ty)
~
flow zo ne
(T>Ty )
--- ----
~
~
Figure 3.30 Velocity distribution in a flowing Bingham plastic.
the shear stress in the flowing fluid decreases from a maximum at the pipe wall
towards the centre, there will be a point at which it becomes equal to the yield
stress 'y. Between this radial position and the pipe centre-line the fluid shear
stress does not exceed the yield value and therefore there is a central core of
fluid which moves at a uniform velocity, effectively as a solid cylindrical 'plug'
(Figure 3.30).
Analysis of this model yields the following expression for the mean velocity
of the flow of a Bingham plastic in terms of the plastic viscosity flp' the yield
'y
stress and the shear stress at the pipe wall '0:
Hedstrom number, He
1.0
10 4 10 5 10 6 10 7 10 8 10 9 10 10
~03 \ \ \
\
\
c5 0.1
r'\.\ 1'\ \
1\
\
\ 1\ \ \
o
~
c \
o \.
1\ 1\ \
.~
f-- f=16/Re \
:E
Q)
6: 0.01 I
~\
'- \ 1\
\ \
n-
~urbule~t flow of
Newtonian fluids
0.001 II11111 I I I II
10 4
Reynolds number, Re
Figure 3.31 Friction factor design chart (Bingham plastics) from [36].
pseudo-heterogeneous
saltation regime heterogeneous regime regime
<J)
Ol
.2
c: c:
0 0
"(jj "(jj
c: c:
<J) <J)
"'.
"C C. C.
'"
"C <J)
,.,
<J) .0 "C ::l
::l
'"
<J)
'"
Ol
Ol .0
()
::l ~
c. Ol ()
";:; ";:;
c: c:
<J) 0 "; I Qi Qi
c. ~ 0 I E E
"Ci
en E I ,.,
E E,.,
:/U dC '"ttl '"
loge u av
Figure 3.32 Modes of flow occurring in heterogeneous slurries"
diagram (Figure 3.20) for the determination of the pipe friction factor f, but
with the Reynolds number defined in terms of the plastic viscosity Jlp • For a
discussion of the error incurred in this approach the reader is referred to [34].
where Pp' Pc are the densities of the solid particles and the liquid respectively.
It is found that F L is a function of the particle size and of the concentration
of solids in the suspension. Wasp [34] has extended the correlation to include
the influence of particle size, suggesting the expression
F
150 BULK SOLIDS HANDLING
where K is a constant having a value in the range 80~ 150. A detailed discussion
and examples of the use of this correlation may be found in [34].
3.8 Notation
A Cross-sectional area of a bed of particles
Ae Average effective cross-sectional flow area of voids
Ap Projected area of particle
Ar Archimedes number
CD Drag coefficient
C y Volumetric concentration of solids in a suspension
D Diameter of pipe
d Diameter of a spherical particle
da Sieve aperture size
dy Volume diameter of a particle
dysm Volume-surface mean diameter of a particle
dwm Median size of particles in a bulk solid
e Pipe roughness
FD Drag force on particle
FG Gravitational force on particle
Fu Buoyancy force on particle
I Pipe friction factor (Darcy)
Id Friction factor for dense-phase flow
If Pipe friction factor for a liquid
Ig Pipe friction factor (gas phase)
Ip Pipe friction factor (solids phase)
Is Pipe friction factor for a suspension of particles in a liquid
H Depth of bed
Hmf Depth of bed at condition of incipient fluidization
Kl Constant in equation (3.82)
K2 Constant in equation (3.85)
K3 Constant in equation (3.86)
Kt Multiplying factor in equation (3.38)
k Constant in equation (3.3); consistency constant for power-law
fluid
k', k" Coefficients in Carman~Kozeny/Ergun equations
kb Bend pressure loss factor
kf Friction coefficient for particulate bed
L Length of pipe
Ie Effective length of fluid path through bed
mp Mass of particle
rhg Gas mass flow rate
rhp Solids mass flow rate
n Index in equation (3.43); index in equation (3.69); flow index for
power-law fluid
DYNAMICS OF FLUID/SOLIDS SYSTEMS 151
Pg Pressure of gas
R Characteristic gas constant
Rb Flow resistance of particulate bed per unit area of free surface
Reb Reynolds number for flow in a particulate bed
Re* Generalized Reynolds number, equation (3.112)
r Radial position
rc For stratified dense-phase gas/solids flow, the ratio of the
effective cross-section of the gas phase to that of the empty pipe
Sb Specific surface of a particulate bed
Sp Specific surface of particles within a bed
T Absolute temperature
Time
U Mean approach velocity of fluid (superficial velocity)
Uav Mean velocity (over cross-section of flow)
Uch Choking velocity
Udc Deposition critical velocity for heterogeneous slurry
Ue Effective mean axial component of velocity in voids (interstitial
velocity)
u~ Corrected interstitial velocity
Ufs Minimum velocity at which fluidized bed is 'fully supported'
ug Velocity of gas
Umb Minimum bubbling velocity of fluidized bed
Umf Minimum fluidizing velocity
Ums Minimum spouting velocity of granular bed
up Velocity of solid particles
Us Saltation velocity
Ut Terminal velocity of a particle
Vb Volume of particulate bed
V Volume flow rate
Wb Total gravity force on bed of particles
x Mass fraction
rJ. 'Pressure loss factor,' equation (3.80)
y Shear rate
f:t.p Pressure drop
f:t.Pac Acceleration pressure-drop
f:t.Pb Pressure-drop across bed of particles; pressure-drop across pipe
bend
f:t.P g Pressure-drop for gas
emf Voidage of bed at condition of incipient fluidization
eo Voidage of a particulate bed
es Voidage of a suspension of particles in a fluid
A Hydraulic radius
/l Dynamic viscosity
/lapp Apparent viscosity
/le Effective viscosity of non-Newtonian fluid
152 BULK SOLIDS HANDLING
References
1. Carman, P.e. (1937) Fluid flow through granular beds. Trans.lnstn. Chern. Engrs. (London)
51 (1) 150-166.
2. Ergun, S. (1952) Fluid flow through packed columns. Chern. Engg. Progr. 48, 89-94.
3. Pettyjohn, E.S. and Christiansen, E.B. (1948) Effect of particle shape on free-settling rates of
isometric particles. Chern. Engg. Progr. 44 (2) 157-172.
4. Hawksley, P.G.W. (1951) The physics of particle size measurement. BCURA Bull. 15(4)
105-146.
5. Allen, T. (1981) Particle Size Measurement. 3rd edn., Chapman and Hall, London.
6. Richardson, IF. and Zaki, W.N. (1954) Sedimentation and fluidisation: Part 1. Trans.lnstn.
Chern. Engrs. 32, 35-53.
7. Kunii, D. and Levenspiel, O. (1969) Fluidization Engineering. John Wiley, New York.
8. Wen, e.- Y. and Yu, Y.H. (1966) Mechanics of fluidization. Chern. Engg. Progr. Symp. Ser. 62
(62) 100-111.
9. Richardson, J.F. (1971) Incipient fluidization and particulate systems, in Fluidization, eds.
IF. Davidson and D. Harrison, Academic Press, New York, 25-64.
10 Baeyens, land Ge\dart, D. Predictive calculations of flow parameters in gas fluidized beds
and fluidization behaviour of various powders, in Proc. Conf, La Fluidization et ses
Applications, Toulouse, October 1973, 263-273.
11. Siegel, R. (1976) Effect of distributor plate-to-bed resistance ratio on onset of fluidized bed
channelling. AIChE J, 22 (3) 590-592.
12. Ge\dart, D. (1973) Types of gas fluidization. Powder Technol. 7, 285-292.
13. Mathur, K.B. and Epstein, N. (1974) Spouted Beds. Academic Press, New York.
14. Epstein, N., Lim. C.I. and Mathur, K.B. (1978) Data and models for flow distribution and
pressure drop in spouted beds. Can. J. Chern. Engg. 56, 436-447.
15. Leva, M. (1959) Fluidization. McGraw-Hill, New York.
16. Wen, e.-y. (1971) Dilute and dense-phase pneumatic transport, in Bulk Materials Handling,
ed. M.e. Hawk, Vol. 1, Univ. Pittsburg School of Mech. Engg., 258-287.
17. Zenz, F.A. and Othmer, D.F. (1960) Fluidization and Fluid Particle Systems. Reinhold, New
York.
18. Hitt, R.I., Reed, A.R. and Mason, lS. An investigation into modes of slugging in horizontal
dense-phase pneumatic conveying, in Proc. Pneuma tech 1 Con!, May 1982, Stratford-upon-
Avon, UK.
19. Hitt, R.I. (1984) An investigation into the low velocity pneumatic conveying of bulk solids.
PhD Thesis, Thames Polytechnic, London.
DYNAMICS OF FLUID/SOLIDS SYSTEMS 153
20. Mainwaring, N.J. and Reed, A.R. Mechanisms of gas-solids flows at low velocity in pneumatic
conveying pipelines, in Proc. 11th Powder and Bulk Solids Con!, Chicago, May 1986.
21. Dixon, G. The impact of powder properties on dense-phase flow, in Proc. Int. Conf on
Pneumatic Conveying, Cafe Royal, London, January 1979.
22. Dixon, G. (1981) Pneumatic conveying. In Plastics Pneumatic Conveying and Bulk Storage,
ed. G. Butters, Applied Science Publishers, Barking.
23. Mason, 1.S. (1972) Pressure drop and flow characteristics for the pneumatic transport of fine
particles through curved and straight circular pipes. PhD Thesis, Liverpool Polytechnic.
24. Churchill, S.W. (1977) Friction factor equation spans all fluid-flow regimes. Chem. Engg., 7th
November, 91-92.
25. Marcus, RD. A review of drag reduction and reduction in power consumption in pneumatic
conveying systems with special reference to actual experimental observations, in Proc. Int.
Powder and Bulk Solids Handling and Processing Conf, Philadelphia, May 1979,315-326.
26. Arastoopour, H., Modi, M.V., Punwani, D.V. and Talwalkar, A.T. A review of design
equations for dilute-phase gas-solids horizontal conveying systems for coal and related
materials, in Proc.lnt. Powder and Bulk Solids Handling and Processing Con!, Philadelphia,
May 1979,339-355.
27. Rose, H.E. and Barnacle, H.E. (1957) Flow of suspensions of non-cohesive spherical particles
in pipes. The Engineer 203 (5290) 898-901, 939-941.
28. Richardson, J.F. and McLeman, M. (1960) Pneumatic Conveying: Part II. Solids velocities
and pressure gradients in a one-inch horizontal pipe. Trans.lnstn. Chem. Engrs. 38, 257-266.
29. Boothroyd, RG. (1971) Flowing Gas-Solids Suspensions. Chapman and Hall, London.
30. Scott, A.W. Pneumatic conveyor design-art or science, in Proc. 4th Int. Powder Tech. and
Bulk Solids Con!, Harrogate, February 1977, Heyden, Philadelphia, 10-17.
31. EEUA Handbook No. 15, Pneumatic Handling of Powdered Materials. Constable, London
(1963).
32. Wen, c.-Y. and Simons, H.P. (1959) Flow characteristics in horizontal fluidised solids
transport. AIChE J. 5 (2),263-267.
33. Muschelknautz, E. and Krambrock, W. (1969) Vereinfachte Berechnung horizontaler
pneumatischer Fiirderleitungen bei hoher Gutbeladung mit feinkiirnigen Produkten (Simpli-
fied calculations for horizontal pneumatic systems conveying fine products at high loadings)
Chemie Ing. Tech. 41 (21),1164-1172. [In German.]
34. Wasp, E.J., Kenny, J.P. and Gandhi, RL. (1979) Solid-Liquid Flow Slurry Pipeline
Transportation. Gulf Publishing Co., Houston.
35. Dodge, D.W. and Metzner, A.B. (1959) Turbulent flow of non-Newtonian systems. AIChE J.
5 (2), 189-204.
36. Baker, P.J. and Jacobs, B.E.A. (1979) A Guide to Slurry Pipeline Systems, BHRA Fluid
Engineering.
37. Durand, R. (1952) The hydraulic transportation of coal and other material in pipes, Colloq.
National Coal Board, London.
of some form of discharge aid is necessary. Examples of such discharge aids for
'awkward' products range from simple impact devices that are little better
than continuously beating the hopper wall with a hammer, to quite
sophisticated vibrating mechanisms that fit inside the hopper, and in the final
part of this chapter a selection of these will be described.
4.2.1 Shape
It is convenient to make a general classification of storage hoppers or bins as
'mass-flow', 'core-flow' or 'composite', although the actual pattern of flow
within the container may depend upon the nature of the bulk solid concerned
as well as on the shape of the hopper.
Typical mass-flow bins are shown in Figure 4.1. The two basic shapes are
conical and plane-flow, as illustrated in Figures 4.1a and 4.1b respectively. As
explained in Chapter 2, mass-flow hoppers are characterized by a shallow
angle of the converging section. For a given product, the hopper half-angle flc
(d) Chisel.
(f) Square opening
plane-flow hopper
(e) Pyramid hopper
Figure 4.1 Mass-flow hoppers.
THE DESIGN OF STORAGE BINS AND HOPPERS 157
Dc
(b) Cylindrical.
(a) Pyramid. flat-bottomed. (c) Conical (d) Cylindrical.
square opening slot opening flat-bottomed.
circular opening
Figure 4.2 Core flow hoppers.
will normally be smaller for a conical hopper than the half-angle {3p for a
corresponding wedge, plane-flow hopper. In addition the opening size or
diameter Dc for a conical hopper is typically twice as large as the minimum slot
width Dp for a wedge hopper. Thus it is clear that a plane-flow hopper is more
efficient in terms of headroom required when a given quantity of material is to
be stored. The disadvantage of the plane-flow hopper is the need for the slot
length to be equal to the hopper width L; this makes for a long narrow
opening. The limiting (minimum) length of slot for plane-flow is L = 3D p •
There are several alternative shapes for mass-flow hoppers, as illustrated in
Figures 4.1c-f. The transition hopper has plane-flow sides and conical ends.
The chisel shape is simple and effective but has the disadvantage of in-flowing
valleys. The same is true of the pyramidal shape with a square opening.
Typical core-flow hoppers are shown in Figure 4.2. Such hoppers may have
flat or tapered bottoms, but in the case of the latter the inclusive angles are
larger than for mass-flow hoppers. Core-flow hoppers therefore tend to be of
more squat proportions than the mass-flow type, and may be used to good
effect in situations where headroom is limited. The outlet dimension of a core-
",.oj~-Iive (effective)
storage
dead storage
Figure 4.3 Reduction of the effective storage capacity of a core-flow hopper as a result of
'topping-up'.
158 BULK SOLIDS HANDLING
flow hopper is larger for a given product than that of a mass-flow hopper.
Although a core-flow hopper will maximize the storage volume for a given
headroom, it will do so only if the contents are completely emptied on a
batchwise basis. If the hopper is continually 'topped-up', the first-in last-out
sequence of a core-flow hopper will mean that the effective storage volume can
be significantly less than the potential capacity, as illustrated in Figure 4.3.
Composite hoppers are a combination of both core- and mass-flow
patterns: the upper section is designed for core-flow whilst the lower section is
designed for mass flow (Figure 4.4a). This is a useful way of increasing the
storage capacity whilst still maintaining mass flow, and therefore a greater
:: .... 0
H
. '. '
..
:: >:::;) ...... .
' ..
or, in general
stored volume of conical
volume section
volume of
+ parallel section
+ volume resulting
from surcharge on
(4.1)
filling
In order to illustrate this approach a bin of cylindrical cross-section will be
considered. In this case the stored volume can be simply determined from the
geometry, so that
(4.2)
where D is the diameter of the bin, Dc is the diameter of the outlet, H is the
e
height of the cylindrical section, f3 is the half-angle of the conical section and
is the surcharge angle of the 'free surface' of material in the hopper (which
corresponds to the poured angle of repose).
Suppose that, in order to estimate H for a given volume of stored material, f3
e
and are both given a value of 30° and the volume of the space between the
outlet and the vertex of the conical section is neglected. Equation (4.2) can then
be rearranged to give
While it must be acknowledged that this equation strictly is valid only for
the chosen values of f3 and e, the error resulting from moderate changes in
these angles will be small. Similar equations can be developed for other shapes
of bin.
Often the specification for a bin or hopper requires that it should store a
given mass of product. Writing the volume V in terms of the mass m and bulk
density Pb' equation (4.3) becomes
1.274m
H = - - - 0.385D (4.4)
D2Pb
Clearly the accuracy of this expression depends upon the value of the bulk
density used, which itself depends upon the condition of the product.
Therefore it is evident that the value used should represent as closely as
possible the condition that will exist in the hopper.
It is useful to represent equation (4.3) in the form of a chart (Figure 4.6)
which yields a rapid, albeit approximate, indication of the relationship
THE DESIGN OF STORAGE BINS AND HOPPERS 161
volume, V (m 3 )
20 ,
60 100 200 300
, J
500
18
/. .-l- H-4D
~
~
r--- limits 01 -
16
/ \ recommended
range 01 hopper _
\ \ proporflons
,
§
x 14
40 / \1 ~ \
:p
20 / \ 1\
\ \
,
0. 0
0.
0 12 ~
~ \ \
~
'0
c
.g 5
\ \ \ \
..
t)
lSI
10
\ \, \, \ i\ Y
:!
~tel 8
1 \~ \ \ """ /'"
0.
\ '\ \ \ \ l.->\ ~H -0
\ ~ \'
\ ):' \ \
'0
.: 6
/
.;co
\\ 1\ /-\ \ \ \
'
~
\ \
~.
\ i\ ~ \.,
l! \ \ \ ~/" \\ \ \. \. \.
4
A \ ~X \ 1\ \1\ \ ~ ~'
\ /~ \ '~ ~\ l\.'
"
2
'\ ~
1
&/ \ ~ f" " "
2 4
"
diameter, 0 (m)
6 8 10
Figure 4.6 Recommended proportions of cylindrical mass-flow hoppers to store a given volume
of bulk solid.
between the height H and diameter D for a mass-flow hopper of fixed volume
V. Hoppers are generally manufactured to have a height H (of the parallel)
between one and four times the diameter; i.e.
D<H <4D (4.5)
This range plotted on Figure 4.6 shows that for a hopper of given volume V
162 BULK SOLIDS HANDLING
there is a lower limit (Dd and an upper limit (D 2 ) of diameter which, because of
the steepness of the constant volume lines, are not very different in magnitude.
The selection of an appropriate value of D is made considerably easier by the
fact that an increasing number of manufacturers are making bins and hoppers
in 'standard' diameters. Selection is then simply from the available diameter(s)
within the range D 1 < D < D 2 , and a bin of the required volume can be easily
fabricated. The only part of the bin that needs to be manufactured to suit the
product is the converging section, and methods of determining the critical
dimensions of this item will be discussed in the following pages.
It may be noted in passing that, for the example being considered (i.e. a bin
filled with material such that 8 = f3 = 30°), the overall height Htotal' which
includes both the conical section and the surcharge space at the top, can be
expressed approximately as
Htotal = H + 1.15D (4.6)
or
Htotal = -----vz
1.274 V
+ 0.765D (4.7)
o
c
g
.;;;
o
Co
flowing .
:n
Co
element foI a1 Co
o
01 solid I .c
c:
£
.j
c:
g
to
(.)
o
\/
consolidating stress
(or pressure), (11
(b) Variation of consolidating stress within a bulk solid
discharging from a hopper
Figure 4.7 Stress variation within a bulk solid in a hopper.
strength O"c which it develops is less than the stress O"a which would exist in a
stable obstruction to flow'.
In order to determine the variation of O"c within the bulk solid it is necessary
first to understand the distribution of the consolidating stress 0" 1. The bulk
material is unconsolidated when it is fed into the bin but becomes consolidated
as the fiJling process continues. In Chapter 2 it was explained how the change
164 BULK SOLIDS HANDLING
from a static to a dynamic stress field occurs as the hopper outlet is opened. In
the flowing condition, illustrated in Figure 4.7b, the consolidating stress (Jl
varies within the 'static' stress field from zero in the top layer of the bulk solid
towards a maximum near the junction of the cylindrical and conical hopper
sections. There is then an abrupt increase in stress to a peak value at the point
where the transition from the 'static' to the 'dynamic' stress field occurs (the
'switch'). Within the dynamic stress field, (J 1 decreases linearly towards zero at
the virtual apex of the conical section.
As explained in Chapter 1, the flow behaviour of a cohesive bulk solid can
be conveniently illustrated by a plot of unconfined yield stress (Jc against the
major consolidating (normal) stress. This plot, termed the 'Flow Function'
(F F) ofthe material, can be determined by shear cell tests ofthe type described
in section 1.9.3.
Figure 4.8 illustrates the manner in which the unconfined yield stress (Jc,
generated by the consolidating stress (J 1, follows the same type of profile as (J l'
Also on this diagram is re-plotted the stress (J. that would exist in a stable arch,
and it is evident that the point of intersection (P) of these lines represents a
critical condition between 'flow' and 'no flow'. Above this point P ,(J. > (Jc, the
flow condition is satisfied and the product will flow. Below P, however, (Jc > (J.
indicating that the bulk solid has enough strength to support a stable arch and
therefore may not flow without some form of discharge aid of the type
described in section 4.10. The dimension D min corresponding to the position in
the hopper where (J. = (Jc is thus the 'critical outlet dimension' which has to be
exceeded if no arching is to occur.
I
flow i ng
element a,
of solid I
D . = aerit]
(4.8)
mID
Pbg
where Pb is the bulk density of the stored material, g is the gravitational
acceleration and J is an empirical dimensionless factor which depends upon
consolidating stress, (] i
Figure 4.9 Bulk solid Flow Function FF and hopper flow factor jJ.
166 BULK SOLIDS HANDLING
3.0
.. ..
.--- --- -
- ~'J-
circular
2.5 section ~
I =
.....- "-- ---
i""'"
,.....
<I)
<I)
CD ,--
,,- - ' ~ I =
1~ =
---- ---
'E 2.0
0
.;;; '~Quare
E
'0
c:
CD
section
I -
-
.....
-
rectangular
.., 1.5 section
(l;;t 3Dp) ~
1.0 I I 1
o 10 20 30 40 50 60
hopper half angle ~ (degrees)
Figure 4.10 Values of the empirical factor J in equation (4.8).
the shape of the hopper and the angle of the converging section (Figure 4.10).
Note that for a rectangular hopper having L < 3Dmin the value of J should be
interpolated between the curves on Figure 4.10 for square and rectangular
shapes.
When designing for core flow, it is necessary to ensure that the outlet is large
enough to prevent the occurrence of rat-holing. The design procedure is
similar to that outlined above, except that a different flow factor jJ would be
used, and the empirical factor J replaced by a term G which depends upon the
static angle of internal friction of the bulk solid. Typically, for the same
product, the outlet size for core flow will be two to three times that required for
mass flow.
g
~ 20
OJ
~
'0
Q)
0.
c
'"
~
"$-
C
.2
"0
E
OJ
~
'0
Q)
0. 10
c
'"
0
10
hopper half angle (3p (degrees)
Flow factor charts for various designs of hopper are presented in detail
elsewhere [1J, [3J but, as an illustration, two typical charts are shown here
(Figure 4.11). These charts, for a product having an angle of internal friction ¢
of 50° in a conical hopper (Figure 4.11a) and in a plane-flow hopper
(Figure 4. 11 b), show the manner in which the flow factor ff varies with the
angle of wall friction ¢w and the hopper half-angle p.
In the case of a conical hopper the transition from mass flow to core flow is
168 BULK SOLIDS HANDLING
quite distinct and is indicated by the 'critical line'. When designing for mass
flow in conical hoppers, it is usual to select a value of Pc some 4 0 to the left of the
critical line. In plane-flow hoppers the region for mass flow is much wider, and
experience suggests that it is better for Pp to be selected either on or very close
to the broken line marking the 'suggested limit for mass flow'. Thus, for a given
value of wall friction ¢w, the flow factor ff and hopper half-angle Pcan be
predicted. The value of ff enables a line to be drawn to intersect the Flow
Function FF, giving <T eri !, which can be substituted in equation (4.8), together
with the values of J (from Figure 4.10) and p, to yield the critical outlet
dimension D mio ' A similar procedure would be followed, using appropriate
charts for ff and G, when designing for core flow.
It is recommended that, in order to avoid instabilities of flow patterns, the
actual hopper outlet dimension should be about 20% greater than the
minimum determined for equation (4.8) [2].
FF t - Row Function
ff / resulting from specified
.c 'y period of storage
'& Ucrit based on FF t /
1_.___- //
c
~
iii
..t.::.:/:.----\-:-:_
G)
.~~c. - - -~
-/'n / \
_ ~ FF - Flow FlJ1Ction
E X resulting from
8 / Ucrit based on FF Instantaneous discharge
/
consolidating stress
t
storage time ~
Figure 4.13 The effect of storage time on the minimum outlet dimension.
period of storage, and it is clear that, although the strength of the material and
hence Dmin are increasing with time, the rate of increase is diminishing.
Ultimately a stage is reached where further increases in the period of storage
have little or no effect on Dmin and the product is then considered to have
acquired maximum strength. This observation is significant and is put to use
when testing for consolidation effects.
4.4.1 Caking
It must be remembered that under normal circumstances an increase in
strength due to de-aeration and re-orientation of the constituent particles is a
reversible situation and thus, given space into which it can dilate or expand,
the bulk will revert to a weaker state. However, with some products, changes in
moisture level or chemical reactions can cause 'caking'. In this situation
particles are not just attached to adjacent particles by electrical or surface
170 BULK SOLIDS HANDLING
time ,.
Figure 4.14 Typical relationship between shear strength and time (for constant normal load)
THE DESIGN OF STORAGE BINS AND HOPPERS 171
=
01
c:
...
G)
iii
...
<G
G)
.t:
til
time ...
Figure 4.15 Typical relationship between shear strength and time for a product exhibiting
caking tendencies
strength and time exhibits a significant upward turn, as shown in Figure 4.15.
Having estimated the percentage increase in shear strength resulting from
the required period of undisturbed storage over that for the 'instantaneous'
value, the instantaneous yield loci for the product are increased by the same
percentage. This then permits a new Flow Function, F F I , corresponding to the
required storage period to be plotted (Figure 4.12). When the appropriate flow
factor, jJ, is superimposed on this figure, the intersection denotes (Jeril'
Substituting this value into equation (4.8) then yields the minimum outlet
dimension, Dmin , necessary to achieve gravity discharge after the specified
period of storage. It is not uncommon for the outlet dimension based on the
time consolidated Flow Function, FF I , to be as much as twice that of the
instantaneous value.
the material concerned. As discussed in the previous section, the period of sto-
rage can have a significant effect on O"eri! and hence on Dmin . With many bulk
solids the moisture content of the material can also have a significant effect on
its flow behaviour. Any water present on the outer surfaces of the constituent
particles of the bulk (i.e. 'free moisture') can result in surface tension effects
which inhibit their movement relative to one another, rendering the bulk more
cohesive and, therefore, less free-flowing. The consequence of this is that a
hopper will generally require a larger value of minimum outlet dimension Dmin
if surface tension effects are present than for the same product free from
moisture. The effect that moisture has on the required minimum outlet
dimension can be quantified by determining the Flow Functions FF of the
material at different levels of moisture. Figure 4.16 illustrates, as an example,
the outcome of such tests for copper concentrate, and it is evident that, with this
particular product, moisture has a significant effect on the hopper design. The
form of Figure 4.16 is typical of the effect of moisture on outlet size, although
the actual values will obviously depend upon the material and the particle size
distribution. It should be noted that at moisture levels in excess of the
saturation value the product takes on slurry-like characteristics and therefore
can no longer be considered as a bulk solid. If moisture is a potential problem
information in the form of Figure 4.16 is useful since it permits the engineer to
balance the cost of a drier or filter, to render the product more free-flowing,
against that ofthe size offeeder necessary to handle the undried product from a
large outlet. Naturally, design should be based on the Flow Function F F ofthe
product at the highest moisture level that is expected in practice.
3.6 ,J ~
3. 2
·
......
! 2. 8
i·
i
.5c:
c
·e 2. 4
c:o conical flow
·in hopper.~
I
1/, ·
i 2.0 ........
\,
E
'6
'"'"
i
g 1.6
E
~
E
·c V '\ ~
:/ / '\
'e 1.2
\
plane flow
hopper ' "
0.8
~ I ,
V
c:
~
o II)
~~
0.4
",
.JIll'
100""" ...
~ .-0'" - f--
----
-
~ ~iE
4 6 8 10 12 14
% moisture content
Figure 4.16 Relationship between minimum outlet dimension and moisture content for copper
concentrate.
10r---,----r---r----r---,----r---,----r---,---~
8r---+----r---+----~--+_--~--_+----~.-+_--~
C\J
E
Z 6r---~--~----4_---+----+----+~~~--~--=-~--~
.::s
(f)
(f)
~ 4r----r----t----+--~~~-+--~~~~----~----~--~
u;
20
normal stress (kN/m2)
Figure 4.17 Frictional characteristics of brown flour against epoxy-coated mild steel and
stainless steel linings.
Conical channel
Effective angle of
internal friction cf> = 50 0
'0
Q)
C>
c
'"
50
hopper half angle {3 c (degrees)
Figure 4.18 The effect of decreasing rpw on hopper half angle p, and flow factor ff.
Figure 4.17 there is a significant difference between the wall friction angle for a
grade of brown flour on epoxy-coated mild steel compared with that for the
stainless steel. If this information is translated to the appropriate flow factor
(if) contours, it will result in an increased hopper half-angle for the lower
friction wall material but a correspondingly higher value of if. Figure 4.18
illustrates this point. This in turn means that although the included angle of
the hopper is increased, thereby increasing the storage capacity, the corre-
sponding value of O"eri! and hence outlet dimension Dmin are also increased.
THE DESIGN OF STORAGE BINS AND HOPPERS 175
4.6.2 Changing hopper shape
A relatively simple but effective way of increasing the storage volume of a
mass-flow hopper where headroom is a limitation is to change from a conical
to a pyramidal, square-outlet hopper. This will result in a slightly smaller
outlet dimension, that is, the length of the side of the square outlet will be less
than the diameter of the outlet of a circular hopper. However, it should be
remembered that the major consideration with this type of hopper is that to
ensure a mass-flow discharge pattern, the valley angles must conform to the
minimum angle for mass flow. This results in the walls being steeper than for
the corresponding circular hopper. The nomograph shown in Figure 4.19 will
assist in determining the relationship between the valley and wall angles and
can be used to determine the wall angles for hoppers with either square or
rectangular outlet openings.
Another approach to utilizing space more effectively is to use a wedge-
shaped hopper. The reasoning behind this is based on the observation that if
the same basic data resulting from shear and wall friction tests is used to design
conical and plane mass-flow hoppers, it will be found that the latter has a
larger included angle and smaller outlet dimension. Both the increased
included angle and the more efficient utilization of floor area result in a
o (vertical)
10
20
30
valley
wall angle angle
(jp, {jv
40
wall angle
{jP2
50
Figure 4.19 Nomograph relating wall and valley angles for hoppers of square and rectangular
section.
176 BULK SOLIDS HANDLING
considerably larger storage volume. The width of the slot outlet is typically
half that of the diameter of a conical hopper for the same product. However, it
should be remembered that the length of the slot outlet must be at least three
times greater than the width in order to achieve mass flow.
A more drastic step in attempting to increase capacity is to move from a
mass-flow to a core-flow hopper. The larger included angle of such a hopper
maximizes the storage volume for a given headroom. However, the disadvan-
tage of this type of hopper is a non-uniform feed of material through the outlet.
If this is an important criterion, a composite hopper (Figure 4.4a) combining
both core-flow and mass-flow patterns may be more appropriate. As already
explained, such a hopper is designed for core flow in the upper section and
mass flow in the lower section. The dimension of the transition from core
flow to mass flow corresponds to D min for a core-flow hopper. This
approach has provided a useful way of increasing storage capacity while still
maintaining mass flow, and therefore a greater uniformity of feed, at the outlet.
new British code of practice has very recently been published, in draft form,
under the auspices of the British Materials Handling Board [2]. Even more
recent is the code prepared by the Institution of Engineers, Australia [11].
There is a great deal of detail in these codes, and the reader wishing to
undertake a serious exploration of the tortuous routes leading to the reliable
structural design of storage bins and silos is recommended to begin with [2J
and [11].
It would not be right to terminate this brief comment on structural design
without mentioning the recent advances in the computer-aided design of bins
and silos, especially the finite-element method, which can enable a complete
silo system to be analysed in a relatively short time. In the finite-element
method the 'system' of the silo material and the silo wall are treated as a
continuum discretized by a number of finite elements. Ideally this should be
done in three dimensions, although all of the studies to date have confined
themselves to a 2-D analysis.
A recent study of the silo/materials interaction for powdered coal shows the
potential of the finite element method [12]. The silo in question was a 30 m
diameter self-cleaning coal silo having seven draw-off points. On unloading,
pressures were generated due to eccentric draw-off. This is an area where the
a vailable codes of practice provided little information. The flow channels were
established from functional design, the flowing and non-flowing regions
having different internal pressures (Figure 4.20a). Figure 4.20b shows a
quarter-section of the silo divided into finite elements and Figure 4.20c the
deformed shape ofthe silo due to the pressure exerted by the flowing material.
The advantages of this approach are, first, that eccentric loading conditions
can be simulated, and second, that the material and silo can be treated as a
single system.
/ \ l.flOW channels
E ~
t:I
'"'"
~
~
en
L. u.-- 7 draw-off hopper "\,
\
\ ~
\ Q
>
\ tTl
30.4m dia.
, \ ~
,\ \
~
I 52
en
,\
,I
slatic material ~
pressure 22 kN/m 2 t:I
6
"d
"d
\\ _ flowing material ~
en
pressure 31 kN/m 2
(c) Displaced shape
of silo (shown In
broken lines)
(a) geometry and flow reg ime
storage
hopper
to process
feed rate solids
controller flowmeter
feedback
flow rate to the desired rate. It follows, of course, that for accurate control it is
necessary to measure the flow rate either continuously or at suitable intervals
in order to provide the feedback signal to the flow control device. The problem
can be represented diagrammatically, as in Figure 4.21.
There are various methods of measuring solids flow rate, but probably the
commonest device used in this type of application is the belt weigher which can
be installed either on a main conveying belt or alternatively on a belt feeder.
Where the highest accuracy is not required, and provided that the physical
characteristics (especially bulk density) of the product do not vary, it may be
acceptable to rely on calibration of the feeder to give flow control over the
desired range. In the case of the screw feeder, for example, the solids mass flow
rate is approximately proportional to the rotational speed of the screw so that,
once calibrated, the device can provide a reasonably reliable control of the
flow. It must be remembered, however, that with products that do not flow
readily the problem is to ensure that a continuous feed is maintained to the
feed rate controller!
In the following pages are described a selection of different types of feeder,
but in the cases of belt, screw and vibratory feeders, which are obviously
similar to the corresponding conveyors, further information may be obtained
from Chapters 7, 8 and 9. Some additional information on feeders (notably
rotary valves) specifically applying to pneumatic conveying systems is to be
found in Chapter 13.
4.9 Feeders
4.9.1 Introduction
It has been explained previously that to ensure reliable operation of a
continuous weighing device it is usually necessary to provide a consistent
THE DESIGN OF STORAGE BINS AND HOPPERS 181
supply of the bulk solid concerned. Thus, for example, when a bulk solid is
required to be discharged from a hopper to a process at a controlled and
measured rate, a feeder of some kind would normally be installed at the hopper
outlet. It is essential to appreciate that a feeder used in this way can only
operate satisfactorily if the bulk material flows steadily and continuously into
it under gravity. The function of a feeder as a means of controlling the
discharge of bulk solids from bins or hoppers should not be confused with that
of a discharge aid which is specifically to prevent the flow being obstructed as a
result of the formation of arches or rat-holes. Feeders, and indeed discharge
aids, must be considered as an integral part of the complete storage and feed
system. There is little point, for instance, in attempting to select a feeder for a
system unless the hopper has been properly designed to prevent arching and
rat-holing and to provide the maximum discharge rate required.
The importance of the hopper-feeder interface cannot be over-emphasized,
and it is probably fair to say that more discharge problems arise through the
failure of the designer to understand the flow conditions existing in this region
than for any other reason.
It is necessary also to consider the vertical load exerted on a feeder mounted
directly beneath the opening of a hopper. Whilst this load would normally be
less than the 'hydrostatic head' of material in the hopper, it may become very
high during filling. However, various techniques may be used to ensure that
the feeder load does not become excessive, the most obvious being to locate the
feeder in an offset position from the hopper opening. Another approach is to
ensure that the bin is not completely emptied, but that a two- or three-metre
depth of product is still present when it is refilled, thus avoiding the impact of
fresh material directly over the bin opening. For a further discussion of this
aspect of feeder design see, for example, [13], [14].
G
182 BULK SOLIDS HANDLING
constant speed
II~-II-J-J-J------------------~:Tn~~
I--
I
I variable
1 speed drive
load
cell
f to feeder
I
I
------,
L-----1
I feed rate
I
I
I metering
I
I
I t (h",,,,,,,,
I
I feed rate set feed rate feed rate
,------~---- controller indicator
spiral
collar
hopper
outlet
~~;:'t7''--- plough
The device consists basically of a horizontal circular table concentric with, and
just below the hopper opening (Figure 4.26). The diameter of the table is some
50% greater than the hopper outlet diameter. While the table rotates (typically
at 2-10 rev/min) a fixed blade ploughs off material from the column emerging
from the hopper outlet, the fixed spiral collar helping to ensure a uniform rate
of flow. It should be noted that most of the shearing resistance to the rotation
of the table results from the 'dead' conical mass of product in the centre
occupying a cross-sectional area of 40-50% of the hopper outlet and extending
to a height of around half the outlet diameter [13].
'dead' region
'dead' regions
/
4.10.1 Introduction
It is worth re-emphasizing the comments made previously concerning the need
to regard discharge aids as an integral part of the complete storage and feed
system. Too frequently these useful devices are treated simply as a solution to
flow problems caused by poor design or incorrect use of a hopper. Whilst it is
certainly true that the installation of an appropriate discharge aid can provide
a satisfactory solution to the problem of a poorly-flowing hopper, it should
also be understood that the selection of an unsuitable device may have the
reverse effect and create more problems than it solves. In short, discharge aids
should not be used as a substitute for good design but should be selected, at the
design stage, ifit becomes apparent that a simple gravity-flow hopper will not
188 BULK SOLIDS HANDLING
be suitable because ofthe nature of the product or other constraints within the
overall system.
The first step in the design of a storage/feed system for a bulk solid should
normally be concerned with the size and proportions of a hopper for gravity
flow. This should involve laboratory tests on a representative sample of the
bulk solid, as described in Chapter 1.
It may happen that the 'ideal' dimensions of a hopper of the required volume
that can be relied upon to discharge its contents without obstructions
developing render it impractical for the intended application. For example,
mass-flow hoppers are generally tall, and there may be insufficient headroom
to accommodate the required storage volume. Another common difficulty
with mass-flow hoppers, particularly where cohesive products are involved, is
that the outlet opening is generally large. The discharge rate is then likely to be
high and may prove to be incompatible with the feeder or with other
downstream plant components. It could be possible to overcome these
problems by modifying the hopper geometry, for example, by fitting stationary
conical inserts or providing a long slot outlet, but where such approaches are
impractical or insufficient it becomes necessary to adopt a more positive
method of assisting the flow of material from the hopper-the so-called
'discharge aid'.
Commercially available discharge aids have generally developed from
primitive practices such as beating the sides of the hopper with a convenient
'blunt instrument' and stirring or poking the material in the hopper with some
kind of rod. It is helpful to classify modern discharge aids as (i) pneumatic-
relying on the application of air (or other gas) to the product; (ii) vibrational-
relying on mechanical vibration of the hopper and/or the product; and
(iii) mechanical-physically extracting the product from the hopper. The
advantages and limitations of a selection of devices from each of these groups
will now be considered.
forces and the particle-wall effects, thus rendering the product more free-
flowing. However, this can itself cause problems as the product can become
excessively fluid, with the result that it 'floods' uncontrollably from the hopper
outlet. It has been suggested that if the air is introduced continuously at a very
low rate throughout the duration of storage, the problem of flooding should
not occur. The explanation is that the air that is lost by slow diffusion as the
product settles is continuously replaced so as to maintain the initial 'weak'
state of the product. Air flow rates of as little as 0.1 m 3 jmin per m 2 of hopper
cross-section (0.3 ft3 jmin per ft2) may be sufficient for this purpose, but it
should be noted that this is unlikely to be enough to restore the 'weak'
condition of the product and promote flow if the air has previOl.jsly been shut
off for any length of time.
Whether the air is supplied continuously or just during discharge, the key to
success is to ensure uniform distribution throughout the product. Introducing
the air through some kind of high-resistance porous surface, such as sintered
metal, plastic or ceramic tile, or woven steel laminate, is commonly used
(Figure 4.30) but an alternative method is to use an internal distributor such as
the perforated ring device shown in Figure 4.31.
Continuous aeration is likely to be effective for fine dry powders of around
1-70.um in size. For sub-micron powders the air flow would probably be
insufficient to reduce the high interparticle force. Materials coarser than about
70.um settle quite rapidly, and the air flow necessary to maintain the 'weak'
condition approaches that required for 'fluidized' discharge. For these
materials (up to about 300.um), aeration during discharge is likely to be
effective.
As an alternative to the introduction of air in a relatively gentle, uniform
flow, sudden bursts of air may be released into the hopper through one or more
jets (Figure 4.32). The pressure of air used may be up to 7 bar (100 lbfjin 2 ) and
190 BULK SOLIDS HANDLING
air
II
by introducing this air into regions where arching or rat-holing are most likely
to occur, the kinetic energy of the expanding jet(s) serves to dislodge the
material and so initiate flow. These devices may be used in various ways,
depending upon the nature of the product being handled and the type of flow
problem to be overcome. Thus in some cases it might be appropriate to
operate the air jets at regular intervals (which could be anything from once or
twice a day to several times a minute) and in others it could be more effective to
install an automatic system which triggers the air blast only when the flow
from the hopper is sensed to be sluggish.
The fact that air expansion devices are widely available under a number of
commercial names, such as 'Air Cannon', 'Air Gun', 'Blast Aerator' and 'Big
Blaster' is perhaps an indication of the frequency at which flow problems are
encountered. Nevertheless, it should be appreciated that this technique
represents a 'brute force' approach and is therefore to be used only as a last
resort. Furthermore, the user should be aware that air expansion devices can
cause problems, for example, dust generation resulting from the quantity of
expanding air and excessive stresses on the hopper walls if the stored material
fails to move.
Another method of using compressed air to promote discharge from
hoppers is by supplying it to inflatable cushions or pads mounted on the inside
of the hopper wall in the region where arching is likely to occur (Figure 4.33).
Typically each of these cushions would have a surface area of around 8000cm 2
(1240in2) and would be made of an elastic material some 12 mm (1 /2 in) thick.
Inflation of the cushions to 'half-balloon' shape results in a physical push on
the stationary product in the hopper which should cause any arch to collapse.
THE DESIGN OF STORAGE BINS AND HOPPERS 191
Figure 4.32 Air expansion methods. (Top) Air blasters fitted to an underground coal bunker.
(Bottom) A configuration of four air blasters fitted as an integral part of a materials flow system.
(Courtesy Linemann-Halflo Ltd.)
192 BULK SOLIDS HANDLING
'..-.
' 0 •
In practice, however, it may be found that, although working well for so-called
'brittle arches' (in products for which flow/no flow is marginal), the air
cushions can compact products in which a strong arch has developed, so
making the situation worse. As with air expansion devices, inflatable cushions
may be either continuously cycled at suitable intervals or automatically
controlled by flow sensors positioned in the hopper outlet.
Conical or
rectangular hoppers
rectangular bins ~
with hopper bottoms
6 "~+
t-'
underside.
near spout
dead
storage
..,/
:.:: ..,::~
other types and in spite of the disadvantages mentioned above, they have
achieved a reputation for successfully keeping difficult products on the move.
It is important that a device intended to vibrate the walls of a bin or hopper
should be correctly sited to achieve the optimum effect. The complexity of the
situation does not permit a mathematical analysis to predict the most suitable
point on the hopper wall to initiate a vibration which will be propagated
throughout the hopper. The best location(s) for vibrators are, in practice,
found by trial, but Figure 4.34 illustrates, for different shapes of hopper,
positions that are likely to prove suitable.
More recently there has been a trend towards devices which apply vibrations
directly to the bulk solid itself. The best known example in this category is the
well-established 'bin activator' (Figures 4.35,4.38). This consists essentially of
a steel dish flexibly supported beneath the hopper opening. A baffie plate,
typically in the form of an inverted cone fitted above the opening of the
activated section, supports the head load of the stored material and transmits
/ hopper bottom
suspension
links '"~~
. ~t=~=======~=~~~--i
vibrator
motor
flexible
seal
Vibrators off,
no flow
Vibrators on
.J'.:.i:~··~·~::f;v::~:::'f:·· __
.;: .....:.>:).:::~::. >...
Vibrators on,
maximum flow
with fine dry products. Materials in Group D (Table 4.1) which are likely to be
poor transmitters of vibration may also present problems.
Several varieties of bin activator are commercially available and offer
various features which are claimed to improve the discharge characteristics or
to offer some measure offlow control. These features include adjustment of the
vertical position of the cone and the width of the annular opening from outside
Table 4.1 Guidance for the selection of bin activators
Product Activator/bin
category Descriptions diameter ratio
air-operated
shaker
vibrating cage
universal joint
outlet section
motor and
gearbox
is free to work anywhere within the conical bin. Product is fed into the outlet
section by the rotation of the flights and the speed of the rotation does, in fact,
give some degree of control over the rate of discharge.
Various types of screw feeder may be used to mechanically extract difficult
products from storage containers. The essential features of screw feeders have
been described in section 4.9.5; the installation of these can be adapted for
handling awkward products by fitting multiple screws and extending them
right across the base of the bin or hopper so that the lower layers of product are
kept 'live'. Two examples are the 'Bowerhill-Parcey' and the 'Storall'.
The Bowerhill-Parcey system features a single rotating screw or sweep auger
which circles slowly around the base of the silo, cutting away the product and
discharging it through the central outlet (Figure 4.42). In the case of the Storall
(Figure 4.43), the screw operates in a fixed position but the base of the
200 BULK SOLIDS HANDLING
discharge screw
silo rotates in order to present the product to the screw. Although both of
these systems are expensive, it is claimed that they are capable of handling
products that are, for example, wet and sticky, and which could not be
satisfactorily discharged by other means. In order to match the operation of
the discharger to the flow characteristics of the stored bulk solid, devices such
as the sweep auger system may be fitted with separate motors for the rotation
of the auger screw and for the circular sweep, or at least have some means of
independently pre-setting these two movements.
4.11 Notation
D Diameter of cylindrical bin
D 1 ,D 2 Upper and lower limits for diameter of cylindrical bin
Da Span of arch
Dc Diameter of opening for circular-section hopper
D mio Limiting value of hopper outlet dimension
Dp Width of opening for plane-flow hopper
FF Bulk solid Flow Function
FF t Time-consolidated Flow Function
if Hopper flow factor
G Empirical hopper outlet factor for core flow
g Gravitational acceleration (specific gravitational force)
H Height of cylindrical section of bin
Htotal Overall height of storage bin
J Empirical hopper outlet factor for mass flow
L Length of opening for plane-flow hopper
m Mass of bulk solid stored in bin
V Total volume of bulk solid stored in bin
f3 Angle made by sloping hopper wall to vertical ( = half included
angle of hopper)
THE DESIGN OF STORAGE BINS AND HOPPERS 201
Wall angle for circular-section hopper
Wall angle for plane-flow hopper
Valley angle in plane-flow hopper
Surcharge angle offree-surface of bulk solid ( = poured angle of
repose)
Pb Bulk density of bulk solid stored in bin
eT 1 Consolidating stress
eTa Stress in stable arch
eTc Unconfined yield stress
(J erit Critical value of unconfined yield stress
¢ Angle of internal friction of bulk solid
¢w Angle of wall friction
References
1. Jenike, A.W. (1964) Storage and Flow of Solids. Bull. No. 123, Utah Engg. Exp. Station, Univ.
of Utah.
2. Draft Code of Practice for the Design of Silos. Bins, Bunkers and Hoppers. 2nd edn., British
Materials Handling Board (1985).
3. Arnold, P.e., McLean, A.G. and Roberts, A.W. (1979) Bulk Solids: Storage, Flow and
Handling. TUNRA Ltd., Univ. of Newcastle, New South Wales, Australia.
4. Janssen, H.A. (1895) Versuche tiber Getreidedruck in Silozellen (Tests on Grain Pressure in
Silos), Verein Deutscher Ingenieure, Zeitschr. 39 (35), 1045-1049 [in German].
5. Walker, D.M. (1966) An approximate theory for pressure and arching in hoppers, Chem. Eng.
Sci. 21, 975-997.
6. Proc. 1st Int. Conf on Design of Silos for Strength and Flow, Univ. of Lancaster, 2nd-4th
September 1980, Powder Advisory Centre, London.
7. Lastnahmenfor Bauen-Lasten in Silozellen (Design Loads for Buildings-Loads on Silo Bins),
DIN 1055, Part 6, (Draft) February 1984. [In German].
8. Regles de Conception et de Calcul des Silos en Beton, Syndicat National du Beton et des
Techniques Industrialisees. No. 189, 1975. [In French].
9. Recommended Practice for Design of Concrete Bins, Silos and Bunkers for Storing Granular
Materials (and Commentary), ACI 313, American Concrete Institute 1984.
10. Jenike, A.W. Effect of Solids Flow Properties and the Hopper Feeder Unit on Silo Loads, in
Int. Can[. on Design of Silos for Strength and Flow, University of Lancaster, September 1980.
11. Guidelines for the Assessment of Loads on Bulk Solids Containers. Institution of Engineers,
Australia (1986).
12. Ibrahim, A.G. and Dickenson, R.P. Finite element analysis of the stresses in powdered coal
stored in silos, in Proc. Int. Symp. on Recent Advances in Particulate Science and Technology,
lIT, Madras, India (1982).
13. Reisner, W. and Rothe, M. (1971) Bins and Bunkersfor Handling Bulk Materials. Trans Tech
Publications, Aedermannsdorf, Switzerland.
14. McLean, A.G. and Arnold, P.e. (1979) A simplified approach for the evaluation of feeder
loads for mass-flow bins. J. Powder Bulk Solids Techno/., 3 (3), 25-28.
15. Reed, A.R. and Duffell, e.H. Hopper discharge aids, in Proc. Solidex 80 Can[., Harrogate,
March/April 1980, Paper E3.
Arnold, P.c., McLean, A.G. and Roberts, A.W. (1979) Bulk Solids: Storage. Flow and Handling.
TUNRA Ltd., Univ. of Newcastle, New South Wales, Australia.
Reisner, W. and Rothe, M. (1971) Bins and Bunkers for Handling Bulk Materials. Trans Tech,
Cleveland,OH.
Reimbert, M. and Reimbert, A. (1976) Silos-Theory and Practice. Trans Tech, Cleveland, OH.
Gaylord, E.H. and Gaylord, C.N. (1984) Design of Steel Binsfor Storage of Bulk Solids. Prentice-
Hall International, Englewood Cliffs, NJ.
5 0 ust control
5.1 Introduction
One of the main problems arising from almost any process involving the
handling of bulk particulate materials is the generation and release of dust.
Designers and operators of bulk handling systems have recently become
increasingly aware of the hazards associated with the release of airborne dust
in significant quantities. Thus, whereas the principal incentive for the control
of dust emissions used to be an economic one (i.e. the more valuable the
product, the more trouble would be taken to ensure its total recovery) there are
now the additional factors of environment, health and safety to be given the
most serious consideration. Since the Health and Safety at Work Act (1974)
became law, the avoidance of excessive environmental pollution has become of
prime importance, and where the product concerned is potentially dangerous
(e.g. toxic or explosive) extreme measures must be taken to prevent its escape
from the plant in which it is being handled.
The handling of a powder or granular product in bulk may involve many
individual operations which could result in the generation of dust. Some
examples of cases where dust concentrations can be very high are grinding,
drying and pneumatic conveying, but other forms of bulk transport, and also
operations such as crushing, mixing and screening, can give rise to consider-
able dust.
In general, there are three types of hazard associated with the emission of
dust: (i) respiratory effects, (ii) skin and eye effects, and (iii) fire and explosion.
It is almost always the very fine particles of dust that pose the problem as it is
these that tend to remain suspended in the air for a significant period of time.
For example, the terminal velocity of a 1 pm particle of silica is about 1 mm in
30 seconds, whereas that of a 100 pm particle is about 300 mm per second.
(Figure 5.1 illustrates comparative size ranges of some familiar airborne
particles.) When suspended in air the smallest particle visible to the naked eye
is about 50-100 pm in diameter, but it is particles of 0.2-5 pm diameter that
are most dangerous for the lungs. Thus the existence of visible dust gives only
indirect evidence of danger, as finer invisible particles will almost certainly be
present too. The fact that no dust can be seen is no reliable indication that
dangerous invisible dust may not be present in the air.
There are many aspects to the problem of dust control, but this chapter
concentrates on the separation of the solid particles from the carrier gas in
some kind of 'disengaging device' such as a filter or cyclone. Firstly, however, it
is worth examining a little more closely the nature of the problem of dust as a
204 BULK SOLIDS HANDLING
carbon black
I
.1
viruses
I
oil smoke
I
tobacco ~moke
paint pigments
I
insecticide dusts
Iface powder
1
I I
industrial airborne dusts
I
bacteria
mille, flour
coal dust
fly ash
pollens
hazard to health. In the next chapter attention will be turned to the other
dangerous feature of airborne dust-the risk of explosion.
Table 5.1 Relative dangers of some common dusts. Based on information from [2]
N
o
-...I
208 BULK SOLIDS HANDLING
Clearly the best solution to the problem of dust is to stop making it! However,
it is often difficult to eliminate completely the generation of dust in
manufacturing processes and during the handling of particulate bulk solids.
An assessment of the magnitude of a potential dust problem can be made by
examining the bulk material being handled, paying special attention to the
fines content of that material. A test has been described [7] to determine the
'dustability' of a bulk particulate material; that is, the propensity of particles
DUST CONTROL 209
from within the bulk to become airborne when the bulk is subjected to
external forces. Where such a test, or previous experience with a product,
indicates that the generation of dust is likely to present a real problem, serious
consideration should be given to methods of modifying or treating the product
in order to reduce its 'dustability'.
The first step towards control of dust generation is to examine carefully the
various operations which may be a source of dust. Some examples of these are
falling streams of product (especially where air displacement is involved),
crushing and grinding processes, pneumatic conveying at high velocity, open
stockpiles subjected to winds, and so on. It may well be possible at least to
reduce the amount of dust generation by modifying the process or the method
of handling; for example, by handling the product wet instead of dry, by
agglomerating the particles (pelletizing), or by minimizing air flows which
might disturb the dry product. For a more detailed discussion of this aspect of
dust suppression see, for example, [3J and [7].
V=3.7Lux
V=2.8Lux
(e) Booth
V=uWH
(fJ Canopy
V=1.4PDu
where P is the perimeter of
the work space and D is the
height of the canopy above it
Figure 5.2 Forms of dust extraction hood, and formulae for calculating required air volume flow
rates [8]. Note: ]I = extraction air volume flow rate; u = centreline capture velocity.
required air flow rate may be estimated, once the capture velocity at a specified
distance from the hood has been selected. It should be noted that for a given air
flow rate the capture velocity, which may need to be anything from around
0.3 mls for very fine dust in still air to 10 ml s for coarse particles emitted at
high initial velocities, is inversely proportional to the square of the distance
from the entry plane of the hood. Thus the mean velocity at the entry plane
may need to be very high if the hood is to be effective over more than a short
distance and if the influence of draughts and convection currents is not to
cause an excessive reduction in its efficiency.
Dusty air collected from a booth, hood or other type of partial or total
enclosure must of course be cleaned before it can be released into the
DUST CONTROL 211
atmosphere, and the remainder of this chapter will examine some of the
commonly used types of air-cleaning system.
Methods of air cleaning fall broadly into three classes according to the
property of the solid particles on which the separation process depends. Thus
we have separation based upon (i) the mass of the particles, (ii) the size of the
particles, or (iii) the electrical properties of the particles. The selection of the air
cleaner to be used on any given application will be influenced by a number of
factors, notably the amount of bulk solid involved, the particle size range, the
collecting efficiency required and the capital/running costs. In general, the
finer the particles to be collected the higher will be the cost of a suitable
disengaging system.
Where the dust contains relatively large or heavy particles it would be usual
to select a cyclone separator in which a spin is imparted to the entering
gas/solid stream so that the solid particles are thrown outwards while the gas is
drawn off from the centre of the vortex. Where fine particles are involved,
especially if they are also of low density, separation in a cyclone may not be
fully effective and in this case the gas/solid stream may be vented through a
fabric filter. Many different types of fabric filter are in use and selection
depends mainly upon the nature of the solid particles being collected and the
proportion of solids in the gas stream. For materials containing extremely fine
particles or dust further refinements in the separation technique may be
necessary using, for example, wet washers or scrubbers, or electrostatic
precipitation.
Although a detailed consideration of dust collector selection procedures is
beyond the scope of this book, it must be emphasized that, in order to ensure
that the optimum choice is made, there are many factors to be taken into
account. Furthermore, it must not be overlooked that there is likely to be a
measure of interaction between the dust collecting device and other system
components, and therefore the dust collector should not be considered in
isolation. For a useful discussion of this topic the reader is referred to the
chapter on Plant Selection Procedure in [8], from which the information used
as the basis for Table 5.2 is taken.
Table 5.2 Primary factors for the selection of dust collection devices [8]
.5 1:1 -., os
c::
....0
c::
0
....
's .§
OJ
c::
0
....
~
0
~
0)
~
8
8.u
~
0)0
0
"1:1 V')
O)N
'0
r:>.
~
0)
"1:1
1:)
::l
"1:1
0
....
-'"0
OJ
'"0
b()
c::
.~
--E3
1i'~
~.£
~
Q).~ r:>.
e
i5 0
'I
J:,
>
0
~
0
I > 0
0-
....
to;! >.
.... ~] ~ .... .5 S
.r:>.
.Do
-« .... .... ::l
fZl
.D
-« V')
N
.Dr:>.
-« ::l Z
0)
CI
0'-
.....:1.5
08-
.....:I 0 ~8
Cyclones 0 ++ • 0 0 0 ++ 0 0 0 0
•
Wet washers-
low energy 0 ++ • ++ 0 0 0 0 0 0
•
Wet washers-
high energy 0 0 ++ ++ 0 0 0 ++ + ++
Dry electrostatic
precipitator 0 0 0 ++ 0 0 ++ 0 + 0 ++
• •
Wet electrostatic
precipitator 0 0 0 ++ ++ 0 + 0 ++
++ 0 0 0 ++ 0 ++ ++ ++
••
Aggregate filters 0 0
++ 0 ++ 0 ++ ++ ++
•
Fabric filters 0 0 0
Fibrous filters 0 0 ++ ++ 0 ++ 0 0 0
this depends upon the density of the particles). For particles larger than about
300 p.m a collecting efficiency in excess of 95% should be possible.
To improve the collecting efficiency of the basic gravity settling chamber,
when working with products oflow density or of a fibrous nature, for example,
one or more mesh separating screens may be fitted at an angle across the gas
flow (Figure 5.3b). This represents perhaps the simplest form of impingement
separator in which particles are separated from the gas stream by impingement
on collecting bodies arranged in some manner across the flow. The collecting
body may be a mesh or grid, a baffle plate, a set oflouvres, or a combination of
these. In general the more complex the device (i.e. the larger the number of
changes in flow direction) the greater will be the pressure-drop across it.
In both the gravity settling chamber and impingement separator, care
should be taken to ensure that its design allows, as far as possible, a uniform
distribution of velocity in the gas entering and leaving. Within the device itself,
particularly in the region of the gas exit, the velocity should be generally less
than about 3 mls if excessive re-entrainment of collected particles is to be
avoided.
Various forms of inertial separator are available which rely on centrifugal
effects, the best known being the cyclone, dealt with in section 5.5. A
DUST CONTROL 213
~~~~~~:'r~'ru,
,
solids out solids out
wear plate
somewhat simpler device, that does not have the spiralling vortex character-
istic of the cyclone, is the skimmer (Figure 5.3c) in which dust particles are
concentrated by centrifugal action on the outer wall of the scroll and then
skimmed off. Mechanically-assisted centrifugal separators are also available
commercially. These devices have the advantage of being compact and
collecting efficiencies are likely to be comparable with those of a high-
efficiency cyclone.
H
214 BULK SOLIDS HANDLING
;J4/.,
. ,..
-. -
gas/solids in
cleaned
0.60 (0.50)
-0_
0.60 (0.50)
Figure 5.6 Proportions of a typical cyclone separator. (Dimensions in brackets indicate possible
modifications for high collecting efficiency.)
the material being handled: (ii) the pressure drop across it at the normal
operating gas/solids flow rate, and (iii) its cost (including repair/replacement
cost when handling abrasive materials). This information should normally be
supplied by the cyclone manufacturer.
Many attempts have been made to develop theoretical expressions for the
prediction of collecting efficiency based on the dimensions of the cyclone and
on the properties of the gas and solid material to be separated. None has
proved to be really satisfactory and reliance must be placed on experimental
data for cyclone performance. The data is normally presented in the form of
a plot of collecting efficiency against particle size for cyclones tested
with some 'standard' material (Figure 5.7). Over limited ranges, reasonably
reliable corrections can be made to a cyclone efficiency curve to
predict the performance of the device at different gas flow rates, for
different gas viscosities, and for particles of different densities. Table 5.3
DUST CONTROL 217
60
g
>- low efficiency
u
c: Cngh 1h'0lJIt1put)
.1I1
.IO! 60
::
4> hg) efficiency
.~
U
.'R
0
u 40
20
20 40 60 80 100
particle size u.mJ
Figure 5.7 Performance curves for typical cyclone separators showing the variation that can
occur between designs for high efficiency and for high volumetric flow rate.
summarizes these correction factors by which the particle sizes at the rated
conditions should be multiplied.
As an example ofthe way that these correction factors may be used, consider
a cyclone tested with a particulate solid of density 3000 kg/m 3 and a conveying
gas of viscosity 1.8 x 10- 5 Ns/m2 at a rate of 0.03 m 3/min. An estimate of the
collecting efficiency curve for the cyclone operating with a material of density
ppkg/m3 and gas of viscosity fl g Ns/m 2 and flow rate Vgm3/min could be
obtained by multiplying values of particle size on the tested collecting
efficiency curve by a factor K, where
0.03
5 - .-
Vg
218 BULK SOLIDS HANDLING
A similar correction may be made for scale on cyclones that are geometri~
cally similar by using the correction factor.
K' = ,j(diameter of actual cyclone/diameter of test cyclone)
provided that the difference in size is not great.
d~ VII IIV/ V
IIV II
./ ~~ III II V/
~~- - ..... ~ I-
...... E$ y. ~- f-. - _. I
f7~rt t.1' 1/ 1/
]II g
....
t:::: ... I
I ~
(3 V --::::: :::::V .... ~ r.l~V 11 (")
;'
o I
". I j~ ~
10
~ V VV ........... I I
lU 100 V II II
.... 1-- ... I ~
I I
l250 IT
8. ! ~D I!
I
I I VI. It
I .7
cC
I I
,.3 1°.5 1 I tl
50 100 200 500 1000 2000 5000 5 10 15 20 50
cyclone body diameter (rrm) coefflCientC
Figure 5.S Cyclone pressure-drop chart; /!ip = C x area of gas inlet/area of gas outlet x inlet velocity head.
N
.......
\0
220 BULK SOLIDS HANDLING
of water spray. Although there are many different types of wet washer, the
principle of operation is essentially the same. Solid particles entering the
device are 'wetted' by coming into contact with either an irrigated surface or
water droplets of a size much larger than that of the particles themselves. The
water is then drawn off into a suitable sump where it is left to stand for
sufficient time to allow the solid particles to settle out.
The main mechanisms by which dust particles are wetted and collected are
[11]:
(i) Impingement, in which the dust particles are made to impinge and adhere
to water droplets or a water film.
(ii) Diffusion, the mechanism by which the smaller particles are collected by
liquid droplets.
(iii) Condensation: if a liquid spray causes the gas to pass through its dew
point, condensation will take place, with the dust particles acting as
condensation nuclei. The increase in effective size of particles simplifies
their subsequent collection by mechanical means.
In addition to capturing the solid particles the water in the wet washer also
serves to keep the internal surfaces of the device clean and to carry the
collected dust to the disposal point.
The principal types of wet washers in use are [llJ, [12J:
(i) Low pressure-drop types
(a) Spray chambers
(b) Packed irrigated towers
(c) Irrigated porous beds
(d) Mechanically induced spray scrubbers
(e) Irrigated cyclones
(ii) High pressure-drop types
(a) Self-induced spray scrubbers
(b) Venturi scrubbers.
Probably the most important single advantage of wet washers is the
reduction in hazard level when handling potentially explosive materials.
However, their application is, in general, somewhat limited, and therefore
these devices will be described here only briefly. For further information the
reader is directed to [8J, [l1J, [13J and [14].
clean at outlet
core
breaker
---t--R.-.t
spray
manifold
• water inlet
clean air
outlet ~
t
®s~ . . . . ~----r- ____~____________,-__________---i--L-~~
air inlet .., 7 /
water Inlectlon /'eceleration
section parallel throat section
spray
acceleration and cyclone
mixing section collector
water and I
sludge outlet ,
particles is the venturi scrubber (Figure 5.12). Water is injected into the dust-
laden air which has been accelerated in a throat section to a velocity of around
60~ 100 m/s. The resulting high relative velocity between water droplets and
solid particles ensures a high collecting efficiency. The dust-carrying droplets
are separated from the air in a cyclone separator. Energy requirements of
venturi scrubbers are high, pressure-drops being normally in excess of 500 mm
H 2 0.
Various developments have been proposed recently [8J with the aim of
reducing the high power usage of wet dust collectors. These include:
(i) Electrically augmented scrubbers providing an electrostatic charge to the
dust particles or to the water droplets, or both
(ii) Two- or three-stage venturi scrubbers
(iii) Bubble foam scrubbers
(iv) Flux force and condensation scrubbers in which a hot humid gas is
brought into contact with a cold liquid.
---
decrease in
efficiency due
to 'bounce off'
particle size ~
velocity ~
Figure 5.13 Variation of collecting efficiency as a net effect of particle size and gas velocity [14].
226 BULK SOLIDS HANDLING
Table 5.4 Summary of the characteristics of some typical fibres used in the manufacture of filter
fabrics
oS oS
.;:l
'"'
;:l
0
..<:
on
o:~
u
0:
~
u
0:
~
0..0:
S ' ;::: 0:
~ "'>,
t;:E '"
'00 '"
'00
0:
"'.-0
<I) 0: o g
<I)
o:Eoj
<I)
'"'
<I)
'"' t:t;
a '" o ;:l
~ 0 '00 ~
.u :;:::
a~
'"0:<1)"0;:l'"'
oj~ 0..'<:>
~u .E .~ <1)"0
..<: .-
<I) oj
..<:..>0 o..S
::E~ <t: ~
'""'<.- ug u"@ ;:l 0
'" u
Fibre
cleaned ......
gas outlet _ _---,
fabric bags
. . ~
" '& ~
"
' . ' ••
'\' ,',
:: l '·:·:·
solid material out
Figure 5,14 Typical bag filter unit (mechanically cleaned).
solenoid valves
compressed
r;=::;C:;iF=;;:==;;===...... air inlet
cleaned
air OUtl~_ _ _L..-
fabric bags
. " ~ .:
g""~·,+,:?;:J;{~:··V. ~··:.)
',., '.:"'..:< "'<,::~
( ,.
::,~
,, '
, ', ... .
' , . , ' ,',
":'.) ~::,.:.>
.;i~:((\
solid material outlet
Figure 5.15 Fabric bag filter unit showing cleaning by use of high-pressure pulsed reverse air-
jets.
Table 5.5 Guide values of filtration velocity for fabric filters [8J
cleaning
pressure-drop at which intervals
/ ' cleaning is triggered
1~
t
a.
o
~
Q)
~ residual pressure-drop
virtually steady
5
(J)
(J)
Q)
~\
0. /' gradual increase of
/' residual pressure-drop
/
/' during conditioning
initial pressure-drop
across clean fabric
time •
Figure 5.16 Typical variation of pressure-drop across a fabric filter.
filter may have a serious effect on the performance of the system. Typically
the pressure-drop across a fabric filter should be around 100-150mm H 2 0
(or 4-6 in water gauge), and with a properly maintained cleaning routine this
value should not change appreciably during use. In normal use there will be, of
course, a small regular fluctuation in the resistance of the filter as a result of the
build-up of collected dust and its removal during cleaning. This is illustrated in
Figure 5.16, which also shows the gradual increase in the residual resistance of
the fabric that occurs during the initial conditioning period.
sfA..rlib"/ ~Q
o 1' 0'
discharge
, I ,\
b
..l.
0 *1 I _J......\~
I¢«rtf'o
I J_ I , l .c:1
rapping
mechanism ~
tc
cleaned
gas
outlet
."
dusty
gas
inlet
."
collecting
electrodes
discharge electrodes
Figure 5.18 Electrostatic precipitator (plate-type).
and on the types of fabric and cleaning techniques available, may be obtained
from literature published by the manufacturers of such equipment or from
textbooks and guides such as [8], [11], [13] and [15].
5.9 Notation
C Cyclone pressure-drop coefficient (Figure 5.8)
D Diameter of cylindrical body of cyclone
K,K' Correction factors for cyclone collecting efficiency
Vg Gas volume flow rate
~.pc Pressure-drop across a cyclone
Pp Particle density
Jig Gas viscosity
References
1. Croner's Health and Safety at Work. Croner Publications, UK. [Amendment July 1984.]
2. Health: Dust in Industry. Dept. of Employment and Productivity, HM Factory Inspectorate
Technical Data Note 14. HMSO, London (1970).
3. Schofield, C Dust: the problems and approaches to solutions, in Proc. Solidex 82 Con!,
Harrogate, UK, March/April 1982, Paper B1.
4. Threshold Limit Values 1980. Guidance Note EH 15/80, Health and Safety Executive. HMSO,
London (1980)
5. Threshold Limit Values. Ann. pubL, American Conf. of Governmental Industrial Hygienists,
USA.
6. Occupational Exposure Limits 1985. Guidance Note EH40/85, Health and Safety Executive.
HMSO, London (1985) (AnnuaL)
7. Schofield, C, Sutton, H.M and Waters, K.A.N. (1979) The generation of dust by materials
handling operations; J. Powder and Bulk Solids Technol., 3 (1), 40-44.
8. Muir, D.M. (ed.) (1985) A User Guide to Dust and Fume Control. (2nd edn.), Instn. Chern.
Engrs., London.
9. Principles of Local Exhaust Ventilation and Factory Dust Control. Health and Safety
Executive, HMSO, London (1975).
to. Caplan, KJ. (1977) Source control by centrifugal force and gravity. In Air Pol/ution, Vol. IV,
97-148.
11. Separation of Dust from Gases. EEUA Handbook No. 19, Constable London (1967).
12. Swift, P. (1976) Industrial dust collectors up-to-date. Filtration and Separation, May/June,
257-270.
13. Perry, R.H. and Green, D.W. (eds.) (1984) Perry's Chemical Engineers' Handbook, 6th edn.,
McGraw-Hili, New York, 20.89-20.97.
234 BULK SOLIDS HANDLING
14. Stenhouse, J.I.T. (1969) Mechanisms of gas filtration, in Process Engineering Technique
Evaluation-Filtration, Morgan-Grampian, London, 70-76.
15. Code of Practice for the Purchase and Operation of Fabric Filters for Dust Control, British
Materials Handling Board (1985).
Recommended further reading
Muir, D.M. (ed.) (1985) A User Guide to Dust and Fume Control, (2nd edn.), Instn. Chern. Engrs.,
London.
Code of Practice for the Purchase and Operation of Fabric Filters for Dust Control, British
Materials Handling Board (1985).
Perry, R.H. and Green, D.W. (eds.) (1984) Perry's Chemical Engineers' Handbook, 6th edn.,
McGraw-Hill, New York, 20.75-20.121.
6 Explosion hazards
6.1 Introduction
Many bulk solids, when dispersed in air to form a cloud or suspension and
ignited, rapidly propagate a flame through the suspension, with a subsequent
sudden increase of pressure as a result of the release of heat and gaseous
products from the burning dust. This is commonly called a 'dust explosion', in
contrast to a 'fire' which would be said to occur if the burning dust were in a
pile or layer. In fact, dust will generally smoulder or burn with a flame: some,
especially plastics, tend to melt or flame or give off noxious vapours which are
readily detected, but others may glow and smoulder, remaining an undetected
hazard which could persist for days. Although only a minority of dust fires
actually result in an explosion, the potential danger is a very real one. Typical
examples would be the explosions of airborne dust following the sudden
disturbance of a smouldering layer during cleaning or the collapse of a burning
pile of material.
When an explosible product is dispersed in the open air, the result of ignition
is likely to be a flash of flame developing little hazardous pressure. However, if
the suspension is confined, for example in an enclosed hopper or in a
pneumatic conveying system, large pressure effects would be expected,
depending upon the volume of the suspension, the nature of the product and
the ease of escape to atmosphere.
A wide range of particulate solids may be regarded as posing an explosion
hazard, including common foodstuffs such as sugar, flour and cocoa; synthetic
materials such as plastics, chemicals and pharmaceuticals; metals such as
aluminium and magnesium, in addition to traditional fuels such as coal and
wood. However, research has shown that, although a material may be known
to burn in air when it is in solid form, it is in fact only when existing as particles
having diameters less than about 200 f1m that the material may become
dangerously explosive. Oxidation of such fine particles occurs rapidly, in
association with a rapid rise of temperature, since the surface area of the
particles in contact with the air is large and their volume relatively small.
It is important to appreciate that the main danger to equipment and
personnel is not necessarily from an explosion occurring within the bulk
handling plant itself. Such an explosion may rupture a weak component (for
example, a cyclone receiver) and the resulting sudden release of burning dust
and gases may then throw up external settled dust into a very large cloud. A
secondary explosion of this airborne material can be devastating and the
importance of good 'house-keeping' cannot be over-emphasized.
236 BULK SOLIDS HANDLING
Figure 6.1 Example of results of a violent industrial dust explosion, in this case, aluminium dust.
Reproduced by permission of the Health and Safety Executive. ©Crown Copyright.
EXPLOSION HAZARDS 237
Figure 6.2 Explosion damage to a bag filter and cyclones. Reproduced by permission of the
Health and Safety Executive. © Crown Copyright.
6.2.1 Ignition
Two sources of ignition frequently met in industrial plant are a hot surface and
a spark. Consequently, the minimum ignition temperature and minimum
ignition energy are the ignition characteristics commonly measured in routine
testing for explosibility. Ignition temperature is not a fundamental character-
istic of a dust cloud: it depends upon the size and shape of the apparatus used
to measure it, as well as on the rate of temperature rise of the cloud. Therefore,
minimum ignition temperatures are determined in a standardized form of
apparatus. This enables meaningful comparisons between products to be
made. Typical values have been determined to be 370, 500 and 575°C for
sugar, cocoa and coal respectively. It is worth noting that a hot surface can be a
hazard even at a somewhat lower temperature if a layer of dust is allowed to
build up on it, since the insulating properties of the dust can result in localized
'hot spots' which could ignite the layer.
The minimum ignition energy is particularly relevant to ignition by sparks.
There are a number of ways a spark can be produced; for example, by
electricity, friction and hot cutting. However, a characteristic of all these forms
of spark is that a small particle or small volume of gas at high temperature is
produced for a small period of time. Since it is much easier for experimental
purposes to measure the energy delivered by an electric spark than by friction
or other thermal processes, the routine tests for determining this characteristic
use an electric spark ignition source. Typical values of minimum ignition
energy have been shown to be 30, 120, 50 m] for sugar, cocoa and coal
respectively, using the standard spark source circuit of the US Bureau of Mines
and the UK Fire Research Station. Lower values of minimum ignition energy
may be determined in tests involving different methods of spark generation. It
may be debated, for example, whether it is more appropriate to have a spark of
short or long duration, and whether the test would be more relevant to an
industrial situation if the spark circuit is designed to ignite a dust with greatest
efficiency [5].
It is quite possible with some products for an ignition source to occur
spontaneously as a result of self-heating. This phenomenon is the result of
exothermic oxidation or decomposition of the product, and in the case of
organic materials can be initiated by bacteriological action. The nature of self-
heating reactions is quite complex, but the critical factor is the rate at which
heat is generated, since a runaway situation occurs once the rate of self-heating
EXPLOSION HAZARDS 239
flame quenched
"t"
UPPER typically
LIMIT 2-10 (kg productlm 3 air)
'EXPLOSION -
- RISK '
, , ,
exceeds the rate of heat dissipation and, in general, bulk solids have a very low
thermal conductivity.
I
classification tests
[-
I
1
Group A Group B CLASSIFICATION tx:I
non-explosible C
eXPIOLSible t'"'
~
~
t'"'
8
r/l
minimum maximum minimum minimum maximum EXPLOSION ::c
ignition permissible explosible ignition explosion CHARACTERISTICS >
tempera ture oxygen concentration energy pressure z
concentration I I and rate of
to prevent I I
I I pressure rise
ignition I I
I
"2
C'l
I I I
I I I I
I I I I
I I I I
I I I I
hot surfaces use of type of system static containment RELEVANT HAZARD
inert gas electricity and explosion OR METHOD
relief venting OF PREVENTION
Figure 6.4 Basic scheme of explosion tests in the UK.
EXPLOSION HAZARDS 243
Table 6.1. Classification test apparatus [10].
Direction of dispersion
Apparatus of product Igniting source Application
V64
combustion tube 305 mm long.
mm inside diameter
mushroom-shaped
deflector
air reservoir
brass. tube 10 mm
inside diameter dispersion cup~ pressure
gauge
full-port /
solenoid valve
Ir-
Figure 6.5 The Hartmann bomb.
244 BULK SOLIDS HANDLING
solenoid valve
/
;.
temperature
controller
/ platinum
ignition co il
combustion tube
tube 6.4 mm
/
inside diameter
/
76 mm inside
diameter
I power supply
.... - 460 mm - ...... - - -- 920 mm -----I~
combustion tube
/1020 mm total length
/ 76 mm inside diameter
pressure gauge 2
0-280 kN/m
air reservoir
460 ml capacity
deflector
plate
ignition coil
fired, and the resulting pressure rise is monitored using the pressure transducer
fitted to one side of the vessel.
Gradually, test data from the 20-litre sphere apparatus is replacing that
previously obtained from the Hartmann bomb which generally tends to give
somewhat high values of maximum explosion pressure [11]. Also, the
Hartmann bomb is of questionable value for the measurement of maximum
rates of pressure rise. Nevertheless, it is relatively inexpensive and convenient,
EXPLOSION HAZARDS 245
stainless steel
sphere ~
"~--~ :~~r--~
exhaust port
igniter (detonator)
and a detailed discussion and comparison of results from these two pieces of
equipment can be found in [11].
Depending upon the outcome of the explosibility tests, a bulk solid is simply
classified as follows:
Group A Products which ignited and propagated flame in the test
apparatus.
Group B Products which did not propagate a flame in the test apparatus.
Obviously, Group A products represent a direct explosion risk and
therefore it would be a wise precaution, or even a legal requirement, to
incorporate protection measures ofthe type indicated in the following section.
The range of products which falls into this group is widespread and, as
indicated in the Introduction, includes common foodstuffs like sugar, flour
and cocoa; synthetic materials such as plastics, chemicals and pharmaceut-
icals; metals such as aluminium and magnesium as well as traditional fuels
such as coal and wood. Group B products, although not explosible, may
present a fire risk and the presence of a flammable gas or vapour may render a
Group B product explosive. Sand, alumina and certain paint pigments are
examples of Group B products. Further details of products which have been
categorized according to this A and B classification may be obtained from [9].
If a product is shown to be of Group A type, further information on the
extent of the explosion hazard may be required when considering suitable
precautions for its safe handling. The following parameters can be determined
by use of the test methods described in for example, [2], [8] and [10].
246 BULK SOLIDS HANDLING
tv
.j::>.
-....l
248 BULK SOLIDS HANDLING
6.4.2 Containment
The philosophy behind this approach is that, once an explosion has begun, it
should be allowed to take its full course whilst suitable precautions are
employed to ensure that it does so in a safe manner. Two separate protection
methods fall within the category: containment and explosion relief venting. If
either of these approaches is adopted it follows that the plant should be
divided into small separate volumes, as far as possible, between which the
explosion is unable to propagate, and that part of the plant within which the
explosion occurs must be either strong enough (i.e. containment) or sufficiently
well protected to withstand the explosion (relief venting).
In practice, containment is only likely to be attractive on plant of small
dimensions, because the cost of building large hoppers, cyclones and the like to
withstand explosion pressures is usually not competitive with alternative
methods of protection. The maximum explosion pressure which can occur
within the system can be determined by tests (see Figure 6.4 and Table 6.2).
For the general case a safety factor is normally added to the measured
maximum explosion pressure, and a value of 50% is often taken. If the
250 BULK SOLIDS HANDLING
Table 6.4 The West German system of dust classification, on which is based the NFPA method of
determining explosion vent area [5,14].
StO 0 0 No explosion
St 1 < 100 <200 Weak explosion
St2 100-200 200-300 Moderate/strong explosion
St3 >200 >300 Very strong explosion
St 1
Pred
St 2 bar g)
"
"""",
St 3 0.4
~ 0.6
I"I'..
"", "" '"
~
;..-'"/
:..-
,
I-"'i.-' :;.-'"
..",,,.,,
V/."=
""
1'\ ~ ::;.-
r-.... V
"
10 1
vent area Cm 2 )
" 0.1 1
vessel~olume Cm 3 )
100
,
St 1
Pred
St 2 bar g)
0.6
"
St 3
'.'\
""
0.8
'\ I" /' / . ; 1.0
I" ......-:
V "
1.5
2.0
, /'./
./ V/
'"I""-",
'\
/
h'"
'/
;'/
/' /
......-: /'
1'\ V..-:
"""-" I'.'
V/
10
venl area C:r,2)
0.1 1
" 100
[b) Strong ignition source: vent release pressure =0.5 bar gauge
KST=(dP ) V I /3
dt max
where (dp/dt)max is the maximum rate of pressure rise and Vis the volume of the
vessel.
This constant (called the 'explosion rate constant') provides the basis of the
West German method of classification of powders. It can be regarded as the
rate of pressure rise that would occur in a vessel of one cubic metre, but it
should be noted that its value will be affected by the shape of the vessel, the
strength of the ignition source and the degree of turbulence. Values of KST can
be determined experimentally (a vessel of at least 20-litre volume being
recommended) and products placed in a 'Dust Class' as indicated in Table 6.4.
Based on the original work of Bartknecht, a series ofnomographs has recently
been prepared by the USA National Fire Protection Association [6] which
allows vent areas to be calculated for products according to their Dust Class
(or KST value), the vent release pressure (Pstat) and the maximum allowable
overpressure during venting (Pred). Typical nomographs, for a strong ignition
source and vent release pressure of 0.2 bar (2.9lbf/in 2 ) and 0.5 bar (7.2lbf/in 2 ),
are shown in Figure 6.9.
For more complete details of the vent ratio method, nomograph method
and other design techniques for the sizing of explosion relief vents, the reader is
directed particularly to [13] and [14].
Protection of ducts and pipelines tends to be more difficult since vents, for
example, would need to be positioned every few metres. It is likely to be more
practicable to design the pipe system for containment of an explosion, in spite
ofthe fact that the pressure on the pipe walls can almost instantaneously reach
values of 25-30 bars if detonation occurs; that is, when the velocity of the
advancing flame front exceeds the velocity of sound [5].
A wide variety of types of explosion relief vent is available to the industry,
and includes bursting diaphragms, hinged flaps or doors, blow-out panels and
automatic triggered vents. Once the required vent area has been determined,
the type of vent must be selected on the basis of cost, operating conditions and
the type of vessel or component to be protected. For a detailed discussion of
vent closure design, see [14].
...,
t
I~,---------
;'
Pm" / / '
I
I
II
/
time ---.
Figure 6.10 Pressure record for a suppressed explosion.
vent to
atmosphere
deteclor
suppressant
Figure 6.11 A basic scheme for the detection and suppression of an explosion in a receiving silo.
pressurized
suppressant
container
control
va lve
Figure 6.12 A 'barrier' of suppressant used to prevent the propagation of a flame front along a
duct.
dangerous if the process involves drying off flammable solvents. Recent work
[19J draws attention to the hazards resulting from increasing use of plastic
containers, especially in the chemical industry. Almost anyone who has
poured granular material from a plastic sack will have heard the crackle of
electrostatic charges, and it is generally considered that if a spark is audible it
could be incendive and therefore dangerous. Various solutions to the problem
include the use of plastic sacks and bags with woven-in conducting wires which
must be earthed, the reduction of charge on the incoming powder, for instance
by neutralization of the charge using ionized air [19J, and the provision of
antistatic clothing and conducting footwear for personnel.
This has been a necessarily brief discussion on the subject of electrostatic
charging in bulk solids handling. There is now a fairly extensive literature on
258 BULK SOLIDS HANDLING
the subject, but for practical advice the reader is referred to Refs. [5J and [6J,
and to the recently published British Standard Code of Practice [20].
6.6 Conclusion
Careful study of the literature will soon make it clear that there is still much to
be learned about the fundamental mechanism of dust explosions, especially
with regard to ignition characteristics and ignition sources. The motivation for
such learning is too often the need to find out what went wrong rather than to
ensure that no dangerous situation occurs. Nevertheless, a systematic
assessment of the situation following, for example, the flow chart (Figure 6.13)
suggested by Field [21J, with rigorous attention to a few essential details, such
as elimination of ignition sources (especially electrostatic sparks), provision of
adequate explosion vents or detection/suppression systems and general 'good
housekeeping' should go a long way towards the reduction of the explosion
hazard.
References
1. Corn starch dust explosion at General Foods Ltd., Banbury, 18 November 1981. Health and
Safety Executive Report, HMSO, London (1983).
2. Field, P. (1982) Dust explosions, in Handbook of Powder Technology, Vol.4, Elsevier,
(Amsterdam).
3. Cross, J. and Farrer, D. (1982) Dust Explosions. Plenum Press, New York.
4. Palmer, K.N. (1973) Dust Explosions and Fires. Chapman and Hall, London.
5. Cross, Jean (1981) Fire and explosion hazards. In Plastic Pneumatic Conveying and Bulk
Storage, ed. G. Butters, Applied Science, Barking.
6. Committee on Explosion Protection Systems (1978) Guidefor Explosion Venting. NFPA No.
68, National Fire Protection Association, Boston.
7. Dust Explosions in Factories. HM Factory Inspectorate Health and Safety at Work Booklet
No. 22, HMSO, London (1976).
8. Raftery, M.N. Explosibility Tests for Industrial Dusts. Fire Research Technical Paper No. 21,
Ministry of Technology and Fire Offices' Committee, HMSO, London (1962).
9. Dust Explosions in Factories. Classified list of dusts that have been tested for explosibility in
the form of a dust cloud. Department of Employment, HM Factory Inspectorate SHW 830,
HMSO, London (1974).
10. Field, P. (ed.) (1979) The hazards of industrial explosion from dusts. Oyez Intelligence
Reports, Oyez Publishing Ltd.
11. Watkins, G.K.P. and Moore, P.E. Dust explosion protection, in Proc. Solidex 86 Con!,
Harrogate, UK, June 1986, Paper B5.
12. Abrahamsen, A.R. and Field, P. Application of dust explosion pressure data to the sizing of
explosion relief vents, in Proc. Solidex 84 Con!, Harrogate, UK, April 1984, Paper C6.
13. Lunn, G.A. (1984) Venting Gas and Dust Explosions- A Review. Instn. Chern. Engrs., London.
14. Schofield, C. Guide to Dust Explosion Prevention and Protection: Part 1- Venting. Inst. Chern.
Engrs., London.
15. Gillis, J.P. and Fishlock, F.H. (1982) Explosion venting and suppression of bucket elevators.
(Report ESV-81-066 of the Nat. Grain and Feed Assoc.). J. Powder and Bulk Solids Techno/., 6
(2), 5-16.
16. Moore, P.E. (1984) Explosion suppression trials. The Chemical Engineer, December, 23-26.
EXPLOSION HAZARDS 259
17. Forsyth, V.G. Dust explosion protection in pneumatic conveying processes. Fire Prevention
135,25-30.
18. Pay, F.J. (1978) Electrostatic: potential hazard when handling powders in bulk. Bulk: Storage
Movement Control, January/February, 51-55.
19. Gibson, N. and Lloyd, F.e. Dust explosion risk in intermediate bulk containers. Proc. Solidex
82 Conf, Harrogate, UK, March/April 1982, Paper B4.
20. British Standard 5958: 1980 Control of undesirable static electricity (Code of practice). British
Standards Institution, London.
21. Field, P. Industrial dust explosion hazards: assessment, prevention and protection. Proc.
Solidex 82 Conf, Harrogate, UK, March/April 1982, Paper B2.
7.1 Introduction
The belt conveyor is one of the commonest means of transportation for bulk
solids and is capable of carrying a greater diversity of products at higher rates
and over longer distances than any other kind of continuously-operating
mechanical conveyor.
In essence, a belt conveyor is simply an endless strap of flexible material
stretched between two drums and supported at intervals on idler rollers
(Figure 7.1). Developments of the basic configuration include troughing the
belt or fitting sidewalls to increase the carrying capacity, and fitting transverse
slats or texturing the surface of the belt so that operation on a steep incline is
possible (Figure 7.2). These and other aspects of practical belt conveyor design
will be discussed in this chapter.
The earliest reported use of belt conveying, almost two hundred years ago,
was for handling grain, and this was virtually the only application of the
technique during the next hundred years. Attempts to carry heavier materials
seem to have caused problems as a result of wearing of the idler bearings and
splitting of the conveyor belt itself. More recently, especially during the last
thirty years or so, development of the belt conveyor has been rapid. The
greatest use of belt conveyors at present is in the mining and quarrying
industry. However, there is now effectively no restriction on the type of bulk
materials that can be carried, and efforts are being concentrated on increasing
the carrying capacity without sacrificing reliability.
Many examples exist of actual belt conveyors that are remarkable in respect
of the distances over which they operate or the quantity of bulk material that
they have transported. One of the earliest of the really large-scale installations,
constructed in Pennsylvania, USA, in 1924, carried a daily average of lO 000
tonnes of coal [1]. A much more recent example of a very long conveying
system is the phosphate conveyor in Spanish Sahara [2] which consists of ten
individual sections making up an overall length of lOOkm (62 miles).
Another recent example is the 15-km installation in the Selby coalfield, UK,
which is capable of conveying 3200 tonnes of coal per hour at speeds of up to
8.4 mls [3]. Claimed to be the highest-capacity belt conveyor in the world,
however, is the remarkable 3 m wide Japanese example, installed in a test
plant, which, running at 5.3 mis, has successfully conveyed sand and rock at a
rate of 30000 tonneslhour [4].
This chapter will be a necessarily brief study of belt conveying. It is written
with the aim of giving an awareness of the capabilities of various types of belt
BELT CONVEYORS 261
(+~
~SOlidS leed
head end
- .~~~
carrying idlers return Idlers
lollds
discharge
Figure 7.2 A belt conveyor carried on three-roll idler sets up a steep incline. The cleated
pattern on the surface of the belt can just be seen. (Photo courtesy of Fyson Conveyors).
installations, where high strength and low stretch are important requirements,
steel-reinforced belting is available.
When selecting the belt construction, the choice of carcass is dictated by the
following principal considerations:
(i) . Maximum tension in belt when in operation
(ii) Impact forces occurring during loading
(iii) Flexibility required in transverse direction (for troughing) and longitudi-
nally (to wrap around drums and pulleys).
Natural or synthetic rubber, or a blend of the two, would normally be
BELT CONVEYORS 263
o Filler yarn
Nylon binder yarn
chosen for the cover of the belt. The quality or grade of the cover, and its
thickness, are selected after careful consideration of the intended service
conditions. The main features influencing the choice of cover are:
(i) Nature of conveyed material (i.e. size, abrasiveness, temperature, oil or
water content, corrosiveness, etc.) and quantity to be conveyed
(ii) Method by which material is fed to belt (i.e. sympathetically, or from a
height, etc.)
(iii) Speed of belt
(iv) Environment (i.e. exposure to rain, sunlight, freezing conditions, fire
hazard, etc.).
Since the primary purpose of the belt cover is to protect the carcass against
damage it is normal for the top cover (i.e. the carrying side) to be of greater
thickness than the back cover. Typically the back cover is 1-1.5 mm thick,
whilst the top cover may be from the same thickness for conveying light
materials and up to around lOmm thick for heavy and sharp materials.
In order to increase the adhesion between the belt cover and the carcass, one
or two additional layers of open-weave fabric (called tie- cloths or 'breakers')
may be fitted next to the carcass. A further benefit ofthese breakers is that they
increase the impact and puncture resistance of the belt and cushion the carcass
as heavy lumps of conveyed material pass over the idlers.
Frequently it is required to operate a belt conveyor on an upward incline.
The normally accepted maximum angle of inclination for smooth-surfaced
troughed belts is around 16°-20°.The actual value depends mainly upon the
characteristics of the conveyed material (especially its angle of repose) and to a
lesser extent on the speed, length and tension of the belt and on the disposition
of the supporting idlers. In order to work on a somewhat steeper incline (up to
around 30°) a belt may be selected having a pattern of cleats or flights moulded
into its surface to reduce the tendency for the conveyed material to slip. The
height of these cleats is likely to be between 15 and 25 mm and, in addition to
allowing operation at steeper angles, may result in a significant increase in
carrying capacity in comparison to a smooth troughed belt. Typical patterns
of modern cleated belt are illustrated in Figure 7.3b [12].
A relatively recent development in conveyor belts has been the introduction
of 'vertical' sidewalls, which may be supported by transverse slats as illustrated
in Figure 7.3c. The principal advantage of this type of belt is that it will
operate successfully on a much steeper incline than the normally accepted
maximum for troughed belts. Indeed, conveyors are now available having
pockets moulded into the surface of the belt, so that they can operate
vertically, and these will be discussed under the heading of Bucket Elevators in
Chapter 8.
Since by its nature a conveyor belt has to be endless, jointing of the ends is
obviously an important consideration. The two methods in common use are
BELT CONVEYORS 265
the vulcanized splice and mechanical fasteners. The vulcanized splice gives a
much stronger and longer-lasting joint but is difficult and costly to make on
site. Mechanical fasteners are much cheaper but do tend to restrict the working
conditions of the belt. Also, leakage of fine particles of conveyed material can
occur through the 'fingers' of a mechanical joint.
7.2.2 Idlers
For conveying bulk solids it is usual practice to increase the carrying capacity
of the flat belt by modifying its cross-sectional profile so that it forms a trough.
This is achieved by using 'troughing idlers' which consist of sets of two to five
rollers (usually three), generally from 100 mm to 175 mm diameter, arranged to
support the belt and at the same time to bend it into a trough shape. The
standard three-roller troughing set (Figure 7.4c), which has largely replaced
the idler with concentrator rolls (Figure 7.4b), is generally used with an outer
roll angle of 30° to 35°. However, the optimum troughing angle will depend to
a large extent upon the angle of repose of the product being conveyed. With
very free-flowing products, for example, the deepest acceptable trough is likely
to be preferred. The greater flexibility of man-made fibres has, in recent years,
allowed belts to be run with the outer (or 'wing') rollers inclined at as much as
70° to the horizontal, resulting in very deep troughing. The two-roll set
(Figure 7.4d) is becoming increasingly common for handling bulky lightweight
materials on narrow belts, while on very wide conveyors there may be some
advantage in using five rollers to give a smoother transverse curve of the belt
and consequently longer belt life. A method that has been used to ensure a
smooth curving belt cross-section is to suspend the idlers, in a set of three or
five, or even more, on a catenary (Figure 7.4e).
In order to assist the alignment of the belt, idler sets may be made with a
slight forward tilt in the direction of belt travel. Modern practice is to have an
angle of 1°(as seen in the plane of the belt) between the axis of the wing rollers
and the axis of the centre roller. The current British Standard [6] and ISO
Standard measure the angle of forward tilt of the wing idlers in elevation, and
stipulate that this must not exceed 3°.
Other types of idler are available for special applications, for example,
rubber-covered 'impact rollers' to reduce wear on the belt at the loading point,
and 'self-adjusting troughing idlers' which are suspended on springs in such a
way that the troughing angle automatically increases with the load on the belt,
thus increasing its capacity. Although the rollers are usually of steel, for use in
severe working conditions (e.g. when handling corrosive materials), solid
plastic or plastic-coated rollers are available.
Return idlers are usually flat and of the same diameter as the carrying idlers.
However, since they are in contact with the top cover of the belt, care must be
taken to guard against build-up of fine materials on these idlers. For this
reason various forms of rubber disc or spiral wire rollers have been developed
(Figure 7.5) and these may also be designed to assist belt alignment. For wide
belts, and particularly for high-speed belts which may tend to develop a
vertical vibration on the return side, V-idlers set at a 10° angle are
recommended.
It has been pointed out previously that the belt itself represents a large
proportion of the capital cost of the conveyor and therefore careful attention
must be given to all factors that have an influence on its useful life. In order to
avoid spillage of conveyed material and to minimize wear of the belt, it is
essential that it is not allowed to sag unduly, and therefore the spacing of the
idlers is of prime importance. The required spacing is a function of belt width
and of belt tension, and therefore the bulk density of the conveyed material
must be taken into account when determining the idler pitch on the carrying
side of the belt.
On long belts there is a significant variation in tension along the length, and
thus there may be some advantage in graduating the idler spacing to equalize
the belt sag [2].
Two other important features of idler rollers are that the frictional resistance
to rotation is minimal and that the inclination ofthe wing rollers is matched to
BELT CONVEYORS 267
q
f
(a) Impact resistant roller
~ .'
~ l I?'
r~ ~;.....-.r
(a) Belt too stiff and/or wing (b) Belt too fle~ible
rollers too steeply inclined
Figure 7.7 Transition from troughed belt at the discharge point showing raised position of
terminal pulley to reduce edge stresses in the belt.
BELT CONVEYORS 269
C) o::;:;---c;B
-B.....c..)_ _ _~------'
. .+)
...
(e) Dual drive arrangement having both drums
in contact with clean side of belt
of the belt close to the head end. Where the conveyor is operating downhill and
involving regenerative effects, the tail end drum should be driven, or a
separate driven pulley on the return strand fitted as close as possible to the tail
end.
The effectiveness of the conveyor drive is dependent upon a number of
factors, principally the difference in tension between the 'tight side' and the
'slack side' of the belt, the friction between the belt and the drive drum and the
angle of wrap, or arc of contact, of the belt to the drum. The power that can be
transmitted from the driving drum to the belt is limited by the point at which
the belt begins to slip. In order to increase the power it is necessary either to
increase the coefficient offriction, for example by applying a rubber lagging to
the surface of the drum, or to increase the angle of wrap by 'snubbing' the drum
or providing a multiple drive. Figure 7.8 shows some common types of drive
arrangement and the corresponding angles of wrap are listed in Table 7.1. For
a much fuller discussion of drive arrangements see [11].
With the plain drive (Figure 7.8a) the angle of wrap is limited to 180°. The
snubbed drive (Figure 7.8b) is more popular, since in addition to the larger
270 BULK SOLIDS HANDLING
angle of wrap it has the advantage that it brings the carrying and return
strands of the belt closer together and thus reduces the depth of supporting
structure required.
With a tandem drive, two drums are geared together and driven by a single
motor (Figure 7.8c) and this arrangement gives an angle of wrap almost
double that of a single drum. The same advantage is obtained with a dual drive
(Figure 7.8d) but in this case the two drums are separately motorized. Note,
however, that a drawback to both of these arrangements is that one of the
driving drums will be in contact with the carrying (i.e. 'dirty') side of the belt.
Using bend and snubbing pulleys as shown in Figure 7.8e, it is generally not
difficult to reverse the belt so that only the clean side is in contact with the two
driving drums. A further disadvantage of the geared tandem drive is that,
because of slight differences in the tension of the belt as it passes over the
drums, there will inevitably be some slip between the belt and the second drum.
It is perhaps appropriate at this point to remark that even on a single drum
there will inevitably be a certain amount of belt 'creep' resulting from the
varying tension in the belt as it passes around the drum. The term 'creep'
actually refers to the relative movement between the belt and the surface of the
drum that happens as the stretch in the belt decreases with the reduction in
tension. The arc of the drum surface over which creep occurs will tend to
increase as the tight-side tension increases, for example as a result of increasing
the load on the belt, and if the 'angle of creep' approaches the 'angle of wrap'
the belt will clearly be on the point of slipping. It is for this reason that a certain
inherent tension should be maintained, even in the slack side of the belt.
The inherent tension in the conveyor belt, needed to ensure that the drive is
maintained, can be provided in a number of ways. The simplest method, used
for small or light-duty conveyors of the type shown in Figure 7.1, is to adjust
the distance between the head and tail drums, for example by pulling back the
tail drum on a screw tensioner (Figure 7.9a). A similar type of tensioner
operating on an idler pulley is illustrated in Figure 7.8d. A common alternative
method is to use a 'drop-weight' or 'gravity take-up' device (Figure 7.9b) which
can be easily adjusted to give the tension required. The gravity take-up has the
great advantage that it can readily accommodate small changes in the length
of the belt, such as the stretching that occurs on starting from rest.
Hydraulically or electrically powered automatic take-ups are also available,
BELT CONVEYORS 271
variable-speed types and so-called 'dry-fluid' types charged with steel shot
instead of the more usual oil. Any fluid coupling is, in essence, a form of slip
clutch which allows a controlled difference in the speeds of rotation of the
input and output shaft. In its basic form the fluid coupling can be regarded as a
pump and a turbine, fitted in the same casing, with the output fluid from the
pump being used to drive the turbine. Thus, the 'impeller' is fitted to the input
shaft and the 'runner' is fitted to the output shaft. Flow control devices, such as
guide vanes, located within the casing between the impeller and the runner,
will then enable the operating characteristics of the coupling to be varied. In
this way the fluid coupling can produce a smooth acceleration of a fully-loaded
belt conveyor from start-up to normal operating speed. For variable-speed
operation, special types of fluid coupling are available, such as the scoop-
controlled hydraulic coupling which is normally capable of operating steadily
at speeds down to 25% of maximum.
the head-end drum there are basically two methods that can be employed. The
simplest of these is to use a plough at each desired discharge point. A timber or
steel platform is positioned beneath the belt to flatten it so that the plough
blade, which may also be constructed of timber or steel, can be lowered on to
the belt to direct the conveyed product into a chute at one side of the belt. Use
of a V-shaped plough allows the product to be discharged simultaneously to
chutes on each side of the belt.
A more satisfactory method in most cases, especially where a single variable-
discharge point is specified, involves the use of a 'tripper' comprising a pair of
bend pulleys which raise the belt towards a discharge chute directing the
product to one side of the conveyor or the other. In the travelling tripper
(Figure 7.10), the pulleys are mounted on a wheeled carriage which may be
propelled either by hand (over short distances), by power obtained from the
conveyor belt and transmitted to the carriage wheels through a suitable
gearbox, by a winch-hauled endless rope system, or by a separate driving
motor mounted on the carriage itself.
that the cleaner is effective without causing damage to the belt and also that
excessive build-up of cleared particles does not occur on the brush or scraper
and so reduce its efficiency. An effective cleaning method is by a water spray to
soften and loosen the material sticking to the belt, followed by one or more
rubber wiper blades to plough the material off. However, this technique
presents the considerable problem of subsequently disposing of the waste
water and it is therefore rarely used except on high-speed conveyors. For a
comprehensive coverage of belt cleaning methods the reader is directed to
[13].
carrying
side 01 belt
return side
01 belt
Figure 7.12 Cross-section of a typical troughed belt conveyor showing angle of surcharge of
material on the belt.
Recommended
Bulk density Angle of max. angle of Surcharge
Material (tonnes/m 3 ) repose inclination angle
(*Surcharge can be 0° if cement is aerated and max. inclination could then be 5-10°).
J / Granular: abrasive or
IUIT¥ly, mildly abrasive
....'"
~
3 V. / /'
~
Granular: very abrasive
or lumpy, moderately
.§
Vj / / ' abrasive
~
~
'0
<II Lumpy and very abrasive
'/ ~ ./
<II
0. ,/' ~
'"
a; 2
'L Belts used with
~
~
belt-p(opelled trippers
~~~~~W ~~
I For picking and
I~belts
Figure 7.13 Guide to maximum recommended belt speeds in normal applications. Note:
(i) Considerably higher speeds may be possible in some situations. (ii) When operating on upward
inclines close to the maximum for the product the speed may need to be significantly lower.
of the significant cost advantages that can be gained; 6 mls is fairly common,
and up to 10m/s is possible in some situations. It has been suggested recently
[14] that if care is taken over the dynamic design of the system, belt speeds
above 15 mls are technically feasible.
K
278 BULK SOLIDS HANDLING
SU'"charge angle {)
Figure 7.14
I~I
Cross-section of load stream on a flat belt.
(7.2)
and
.12
ms = (,Pbvb tan (j (7.3)
where b is the width ofthe load stream on the belt and (j is the surcharge angle.
Tabulated values of A for flat belts of various widths are given in [7J, and for
various configurations of troughed belt in [7] and [11].
:::>
c5 0.16
-0
~
g<II 0.12
.s::.
en
0.08
0.04
troughing angle, {3
0.22 I ~
/.
..........
-
~\
r- ~....... r-",
vr
__ f-
020 a~ol
r- rcfe
.......---
rOE!
Hi /
degrees) /' r--. ~
~
\
-
0.18
~§
~ 0. 16 1-- 4t /V v~v ""'v-:." ,
~
0>
c:o
'0; 0. 14 _ 35/
/
LV
V /
Yv v~ !--
f--
'~
h. ,
~
r--:
~~ // ' /r"
c:
0>
E
:§ 0. 12 - 3,( / /
5
~ 0. 10 I-- 2 ( / / //
j 0.08 ~
20// VV I 1- - -
'" t5~~ /
~
0.06 -
- 10 I' • ff-.. . ~
' ,fJ
0.04 1-- 5 /
-
0.02
o 10 20 30 40
I soI I 60 70
angle of wing idlers to horizontal fJ
(troughoflg angle) - degrees
Figure 7.16 Shape factors for standard three-roll idler set having all rollers of the same size.
A useful alternative approach for the somewhat more difficult cases of two-
roll and three-roll idler configurations is to express the cross-section of the
load-stream in terms of the 'contact perimeter' b of the material on the belt
using a shape factor U which is a function of the transverse profile of the belt
and the surcharge angle of the conveyed materials:
(7.4)
so that
(7.5)
For the flat belt U clearly has the value (tan b)/6, but for other belt profiles it
is more convenient to present charts from which the relevant shape factor can
be determined.
Typical charts are given here for two-roll idler systems (Figure 7.15) and
standard three-roll systems having rollers of identical length (Figure 7.16). A
full analysis and discussion of optimum idler configurations can be found in
[2].
280 BULK SOLIDS HANDLING
-r-.....r-.... ........
~
0.9
.... ~
0.8
1\
0.7 0
4 8 12 16 20
angle of inclination (degees)
Figure 7.17 Slope factor k, for smooth (un patterned) belts operating on a gradient.
Values of the slope factor k., which allows for the reduction in the cross-
sectional area of the load stream when conveying on a gradient, can be
determined from Figure 7.17 (from [7J).
Naturally some allowance must be made for 'edge clearance'; that is, the
distance between the conveyed material piled on the belt and the edge of the
belt. One formula relating the minimum width B min of the belt to the contact
perimeter b (recommended in BS 5934/ISO 5048) is:
B min = 1.11b + 0.056 (7.6)
where B min and b are in metres.
Thus, for a given idler configuration (and hence, shape factor U) and given
belt speed v, the minimum belt width required to transport material of bulk
density Pb at a rate ms can be estimated from
m )0.5
Bmin = 1.11 ( -k- S
- + 0.056 (7.7)
Pb sUv
400
500
600
650
800
1000
1200
1400
1600
1800
2000
BELT CONVEYORS 281
The belt selected would then normally be the nearest standard size above
B min available from the manufacturer. Preferred widths of conveyor belt, as
specified by the UK Mechanical Handling Engineers Association [11], are
listed in Table 7.3. Note, however, that the minimum belt width may be
dictated by the lump size of the conveyed material as explained in section 7.3.1.
(In this case equation (7.7) can be used to give an indication of the belt speed
required.)
angle of contact
----...;,,;;;;;....,...-
Tl
(tight side)
-....
Te=Tl- T2
T2
(slack side)
where J1 is the coefficient of friction between the belt and the drum and 8 is the
angle of wrap. It should be noted that the value of J1 is very much dependent
upon operating conditions and may range from 0.35 or more for a clean lagged
drum to as little as 0.05 for an unlagged drum in a wet and dirty situation
(Table 7.4).
Rearranging and combining equations (7.8) and (7.9) we have
(7.10)
where
1
K d =----- (7.11 )
exp(J18) - 1
Clearly the value of the drive factor Kd will depend principally upon the
coefficient of friction between the belt and the driving drum and the angle of
contact. Figure 7.19 is a chart based on equation (7.11) from which Kd can be
estimated for various operating situatiQns. Note that when ascrew tensioner is
in use instead of an automatic take-up device, it will be necessary to put an
initial stress on the belt and therefore a higher value of wrap factor should be
used. Generally for a single drum Kd should be 20% greater if the drum is bare
and 30% greater if it is lagged, and for a tandem or dual drive Kd should be
about 25% greater for both bare and lagged drums.
The tensile forces in a working conveyor belt will vary along the whole
length of the belt, and will change when the belt is stopped or started and when
the product feed rate is altered.
When selecting a conveyor belt it is necessary to know the maximum
tension to which it will be subjected, and for simple belt configurations this is
equal to the 'tight-side' tension T j • The corresponding minimum tension
(equal to the 'slack-side' tension T2 ) is also an important design parameter, as
it must not be so low that slipping occurs between the driving drum and the
belt. Furthermore, a certain minimum tension in the belt is necessary to ensure
that the sag between the idlers does not exceed the usually recommended
figure of around 3% of the idler pitch. This is particularly important on the
carrying side where excessive spillage of material from the belt can occur if the
sag is too great.
Various methods are available for determining the maximum and minimum
belt tensions and where they occur, the complexity of the analysis depending
BELT CONVEYORS 283
r--1-r--- - -- --r--1,,--.--.--r"'"T'".
lJ
3.0
- ~ I_ plain dri ve (1 800 ) J I
- t- snubbed ---r----r----t--t--+ tandem or - -
- drive <1Ja1 drive c---- -
- '~ -+--+--+-...,..-----"'---.,,
. -
2.5 I \
I
~
II)
r-r ~~~
\ -+-+-+-+~~-+--+--+-+-+-+-+-4
I \
m.ms ---+--t---t-+-H
CD
:-18 2.0 I---iI--rJI-+-+~-+---+- bin
\ wet and (jrty
f -t--'-t--f-I--'..-""'-'r /, clean wet
\..'iL,.dr y
lIt,TJ H -fli\r l--+-+-+-->V:z. -;---+--+- lagged~
15 1.5 J wet and (j(ty -
o I\, / / clean wet -
! '/ / c ay -
~ '{./ ..I
1.0 t--t~1\->t---t--+t"
'--!'-<~+-¥/-'//'7l---+-""""~-I-+--1H---l
~, I \ / / .......
I ... ........1,.(, _ 0. 15
I
I
I - - -
. .." , ,,__
0.25
0.30
_ ._1---_ --= _-_-;:
'- - - _ 02:0
O~~~~~~~~~~-L~~~~~~~ O.~
200 300 400 500
angle of oontact (degees)
Figure 7.19 Approximate values of the drive factor (Kd) for conveyor belts fitted with gravity or
automatic tensioning devices. (For belts tensioned manually, values from this chart should be
increased by 25% if drum is ba re or 15% if lagged.)
upon the configuration of the conveyor. Full details may be found in the
literature, for example [lJ, [2J, [8- 11].
For a simple belt system, the procedure involves estimating the
driving force needed to move the loaded belt (as explained in the next section)
and equating this to the effective tension Te. The maximum and minimum
tensions in the belt can then be estimated from equations (7.10).
An important requirement at this stage is to check that the value of the
minimum tension is sufficient to prevent the belt sagging excessively between
the idlers. The tension throughout the length of the belt must always exceed
the so-called 'sag tension', which can be estimated as follows:
For the carrying side,
(7.12)
and for the return side
(7.13)
284 BULK SOLIDS HANDLING
where mb and m L are respectively the mass per unit length ofthe belt and ofthe
conveyed material on the belt, Lie is the idler pitch on the carrying side, L ir is
the idler pitch on the return side and Ks is a 'sag factor' which has values 4.2 for
3% sag, 6.25 for 2% sag and 8.4 for 1.5% sag [2].
{
(1) MAIN Occur continuously
Occur on all RESISTANCES - over the length of
belt conveyors the belt
(2) SECONDARY
RESISTANCES
(4) SPECIAL
SECCN:>ARY Occur locally
RESISTANCES
(5) SLOPE May have positive,
zero or
RESISTANCE negative values
Figure 7.20 Classification of resistance to motion of belt conveyors (British/ISO standard).
A detailed list of these various resistances may be found in [2J and [7J, but
in order that the explanation of the design process may be continued a
summary of the most important resistances is given below:
80
miss of belt T
I
/'
V
f.-- (including both carryilg ,/'
strand and retum strand) ./
60 ,
I
--
/
heavy duty / " ......--
/~I-av~ --
-
/ V
V--
......--v---
I--
~
Ight duty - I---
......-- _....-- 'I
f.--
I I
mass of trough!]! idlers
I I
l.-- -- [...----
--
I-- (1 metre pitch) I
____ VJ27mm ---- l--- L.--- f-
- -
152/1~mm
/ / /
mass of retl.mIdlers
r 1
1521168~
201-----/ (3 jtre ,itch) 127 rrrn~{
102m"(
o I
200 400 600 800
I
1000 1200 1400 1600 1800 2000
belt width (mm)
Figure 7.21 Charts for estimating the total mass of moving parts per unit length of conveyor.
Example: for 1000 mm wide belt, 127 mm idlers, on average duty, total mass = 6.5 + 24.5 + 25.5
= 56.5kg/m.
The value of the 'load-friction coefficient' is likely to be slightly higher than the
belt friction coefficient J.1rl' but for design purposes is generally taken to be the
same. Thus,
(7.16)
where mL is the mass of conveyed material per unit length of the belt and Lis
the conveying distance.
Note that mL can conveniently be written in terms ofthe carrying capacity of
the belt and the belt speed as
(7.17)
so that
rhsgL
(7.18)
FfL v-
=J.1r2-
BELT CONVEYORS 287
The belt friction resistance and the load friction resistance together make up
the so-called 'main resistance' F H to the movement of the belt. Thus
FH = Ilrl (m ie + mir + 2mb cos r:x)gL + Ilrz mLgL (7.19)
(iii) Load slope resistance, F st• Where a belt conveyor operates on an upward
incline, the largest contribution to the total driving force required is likely to
result from the gravity force on the load. However, it should be noted that F st
may be positive or negative, depending upon whether the movement of the
conveyed material is upwards or downwards,
Thus the load slope resistance can be expressed relatively simply as
(7.21)
or
rhsgH
F st = - - (7.22)
v
where H is the net change in vertical elevation and can be positive or negative.
(iv) Load acceleration resistance, F aL' If the load being fed on to the belt has
an initial component of velocity Vo in the direction of the belt, the resistive force
on the belt can be expressed as
(7.23)
or
(7.24)
The load acceleration resistance is probably the most significant of the
'secondary resistances'. Others are the resistance due to friction between the
conveyed product and the side walls or skirt plates in the loading region,
bearing resistance of snub pulleys and bend pulleys (but not driving drums),
and resistance due to wrapping of the belt on the various pulleys and drums.
References [2J and [7J give guidance on the calculation of these resistances,
but BS 5934/ISO 5048 [7J also recommends, for belt conveyors longer than
80 m, an abbreviated approach in which the secondary resistances are given
by
(7.25)
where the coefficient KSR varies from 0.025 for conveyors longer than 3000 m
up to more than 1 for conveyors less than 80 m in length (Figure 7.22).
Although the so-called 'special resistances' occur only on certain install-
ations, they may be significant in comparison with the other resistances to
288 BULK SOLIDS HANDLING
c1.1
Q)
:2
:;
8
Q)
\
.j
~
0.5 I\.
» i
~~ 0.1
r--.
o
10 20 50 100 200 50010002000 5000
centre-ta-centre length L of conveyor (m)
Figure 7.22 Variation of secondary resistance coefficient KSR with length of belt conveyor from
[7].
movement of the conveyor belt. The special resistances include such effects as
drag resulting from the forward tilt of the idler wing rollers and drag due to
belt cleaners, ploughs, trippers and skirt plates (other than in the loading
region). As with the secondary resistances, [2J and [7J give methods of
estimating the special resistances.
The load acceleration resistance is probably the most significant of the
above constituents. Thus
(7.26)
or
(7.27)
The required driving force at the motor drum will be effectively equal to this
total resistance, and consequently the 'effective tension' Te can be substituted
for F R, so that
(7.28)
Maximum and minimum tensions in the belt can now be estimated as
explained in the previous section
The operating power required at the driving drum can be expressed as the
product of the effective tension and the belt speed:
p= Tev (7.29)
so that the motor power can be determined from
Te v
P=~ (7.30)
m '1
where '1 is the efficiency of the motor/drum transmission (usually around 85-
95%).
BELT CONVEYORS 289
7.4 Belt conveyor variants
'1-·
vulcanized in suitable outer covers (Figure 7.23b). The belt sits on, but is not
attached to, the drive cables and thus does not transmit tension. When empty
the belt is flat and is positively located on the drive cables by longitudinal V-
grooves. Its lateral rigidity is sufficient to allow it naturally to form a trough
when carrying a load (Figure 7.23c), but longitudinally the flexibility of the belt
permits it to wrap around the head and tail drums of the conveyor. A very
recent development [16] has the belt pre-formed into a trough profile
(Figure 7.23d). Built-in reinforcement gives the belt sufficient lateral stiffness to
maintain its profile between idlers whilst allowing the inclined sides to flatten
naturally as the belt passes around the head and tail drums.
There are many examples of cable belt conveyors having a proven record of
successful operation, including a number working over long distances, in the
range 5- 15 km, and conveying at rates of up to 1000 tonnes/ hour. More
recently a cable belt system has been designed to transport bauxite at a rate of
2040 tonneslhour over a distance of 50 km on a 950 mm-wide belt travelling at
more than 6 mls [17], the longest single flight being over 30 km.
top cover
return Idle
centre belt - reun
support strand
roller
Figure 7.24 Non-spill design oftroughed belt conveyor in which wing idlers are replaced by low-
friction strips.
BELT CONVEYORS 291
air carrYi~l'~~~~~~~
strand
belt - holes
plenum
- charrber
retlSO idler
make the conveyor weatherproof and dust-tight, a top cover may be fitted to
the vertical sidewalls, so that the carrying side of the belt is effectively running
inside an enclosed duct.
An extension of the concept of a low-friction surface replacing rollers has the
carrying side of the belt supported on a thin cushion of air trapped between the
underside of the curved belt and the continuous steel or plastic trough in which
it runs (Figure 7.25). Conveyors of this type are marketed under various
names, such as 'Aero belt', 'Hovertube', 'Simveyor' and 'Jetbelt', available in
trough widths up to 0.6 m, and lengths of 2 to 100 m. Air is supplied to the
plenum chamber beneath the curved trough by a suitable blower at a rate of
some 20- 40 m 3 /h per linear metre, and passes through small holes in the
trough to form a thin, lubricating film on which the belt effectively 'floats'. This
film is maintained at pressure by the weight of the conveyed product on the
belt and the flow rate of air to the plenum chamber needs to be sufficient only
to replace the air that bleeds continuously from the gap between the edges of
the belt and the surface of the trough. Thus the air supply rate should be
adjusted to suit the belt speed, which is normally up to about 7 m is, and
loading so that a suitable edge clearance is maintained. Thus are ensured the
advantages of the system in terms of reduced frictional resistance, minimal
wear of the belt and the trough, and minimal spillage over the sides of the belt.
spring clip
drive belt
conveyed material
and vertical planes are possible within a short space, so that twists and turns
can be accommodated to suit almost any requirement of the plant layout.
Probably the earliest form of pipe conveyor was the 'zipper' conveyor in
which the edges ofthe belt have moulded teeth that are meshed and unmeshed
by rollers in much the same manner as the familiar clothing fastener
(Figure 7.26a). A more recent design, registered under the name·'Solitube', has
the belt assembled with spring clips which, in the natural state, hold it closed in
the form of a tube having a 'tear-drop' cross-section (Figure 7.26b). This tube is
BELT CONVEYORS 293
supported by a system of outriggers connected to twin independent driving
belts. This independent drive arrangement enables the tube to be moulded in
rubber compounds suitable for negotiating filling and emptying stations and
bends rather than for power transmission. Also, the drive belts guide and
support the conveying tube and, by geometric displacement of the idler rollers
and movement of actuating arms, provide a means to open the tube against the
resistance of the spring clips. The tube is filled with product via an inlet spout
which is inserted into the aperture at the feed station and emptied under
gravity by rotating the whole assembly through 180 0 before opening it. With
the standard 80 mm diameter tube running at 2 mis, the Soli tube has a
potential volumetric capacity of about 30m 3/hour.
The Japan pipe conveyor has more in common with a conventional belt
conveyor since it has a head and tail pulley over which the belt passes flat.
Beyond the loading point the belt is rolled into tubular form by a series of
idlers (Figure 7.26c). Curves in any direction can be negotiated under the
control of further circumferential idler sets, and as the belt approaches
the discharge point at the heat pulley, it undergoes the transition from
tubular back to flat belt. Conveyors built to date include belt diameters
ranging from 100 mm to 500 mm, and capacities ranging from 36 to
1800m 3 /hour. Operating speeds are from 1 m/s to 4m/s and conveying
distances of several hundred metres are being achieved [19].
Operating in a very similar way to the Japan pipe conveyor is a recently
proposed system based on a pre-formed rubber belt having a rectangular
trough section [16]. The sides ofthe trough, which may be notched along their
upper edges in the same manner as the previously mentioned zipper conveyor,
can be turned in by rollers to form a closed tube.
Figure 7.27 A sandwich belt conveyor installation used on a self-unloading vessel ('loop-belt'
system).
"' - -
7.5 Notation
A Cross-sectional area of bulk solids stream on conveyor belt
Bmin Minimum overall belt width
b Width ofload stream on belt (i.e. cross-sectional contact length)
FaL Load acceleration resistance
F fb Belt friction resistance
FfL Load friction resistance
FH Total main resistance
FN Total secondary resistance
FR Total resistance (main and secondary)
F st Load slope resistance
g Gravitational acceleration (specific gravitational force)
H Net change in vertical elevation
Kd 'Drive factor' or 'wrap factor' defined by equation (7.11)
Ks Sag factor in equations (7.12) and (7.13)
KSR Secondary resistance coefficient
ks Slope factor
L Length of conveyor (centre to centre)
Lie Idler pitch on carrying side of belt
LiT Idler pitch on return side of belt
mb Mass of belt per unit length
Me Total effective mass of moving parts of belt conveyor
mie Mass of carrying idlers per unit length
miT Mass of return idlers per unit length
mL Mass of conveyed material per unit length of belt
ms Carrying capacity (mass of solids per unit time) of a belt
conveyor
P Operating power required at driving drum
Pm Motor power, in equation (7.30)
T" Effective belt tension
Tsag Conveyor belt 'sag tension'
Tl Tension in the tight side of the belt
T2 Tension in the slack side of the belt
U Shape factor for load cross-section
v Linear velocity of belt
296 BULK SOLIDS HANDLING
8.1 Introduction
In the preceding chapter on belt conveyors, brief mention was made of
adaptations to the basic flat- or troughed-belt to enable it to operate on steep
inclines. For example, whereas a conventional belt conveyor would generally
be limited to a slope of about 20°, texturing the surface of the rubber belt to
incorporate moulded ribs or nubs will allow conveying up an incline of some
60-70°, or even more, depending upon the nature of the bulk solid being
carried. Taking this idea further, the rubber belt could be fitted with sidewalls
and curved or sloping transverse slats so that it is capable of lifting the
particulate or granular material vertically. The conveyor then approaches the
design concept of the well-known bucket elevator.
In many situations where the lifting of bulk solids is involved, the bucket
elevator is the most simple, efficient and reliable machine that could be used
(Figure 8.1). It can be obtained in a wide range of capacities and the current
trend is towards standardized units, although for 'difficult' materials and high
conveying rates it is advisable to use specially engineered equipment. The
detailed construction of the bucket elevator obviously varies from one
manufacturer to another and certain design features such as the pitch of the
buckets, the operating speed and the feed and discharge arrangements may be
chosen to suit the product being handled. However, the essential components
of the device are:
(i) An endless belt or chain(s) as a traction element to which are attached a
series of carrying vessels or buckets
(ii) A single or double casing which serves to enclose or partially enclose the
moving buckets
(iii) A 'head' at the upper end of the elevator which includes a belt pulley or
chain wheel to turn the traction element and a suitable discharge chute
(iv) A 'boot' at the lower end which again includes a belt pulley or chain wheel,
a tensioning device (usually), and a means of feeding the material to be
conveyed so as to ensure optimum filling.
It is convenient to classify bucket elevators according to their bucket
spacing and mode of discharge, and the two principal types-
centrifugal discharge (spaced bucket) and continuous discharge-will be
described in the next section.
Another important group of bucket conveyor/elevators discussed in this
BUCKET ELEVA TORS 299
chapter includes all those having various types of pivoted or hinged buckets.
These allow combinations of horizontal and vertical conveying without the
need for transfer points and, as a further advantage, allow unloading at any
desired point in horizontal section.
The final type of elevator to be described here is the profiled rubber belt, but
it should be noted that this by no means exhausts the list of potential methods
for raising bulk solids through a vertical distance. Some methods, such as
screw conveyors, spiral vibratory elevators, en-masse conveyor/elevators,
sandwich belts and tubular drag conveyor/elevators are discussed elsewhere in
this book; others are omitted, principally because oftheir limited or specialized
application. Neither is it possible here to discuss the enormous variety of
applications that are found for bucket elevators, ranging from small light-duty
300 BULK SOLIDS HANDLING
units in the food and pharmaceutical industries, to the very large dockside
installations capable of unloading ships at rates greater than 5000 tonnes/hour
(Figure 8.2).
The second half of the chapter is concerned with the design and selection of
bucket elevators, and guidance is given on the calculation of capacity and
power requirements for the more conventional types.
elevator is considerably slower, typically around 0.7 mis, and the buckets must
be larger or more closely spaced to give a comparable capacity to the
centrifugal discharge pattern.
-
Ca) Buckets horizontal for filling/carrying
o
-
Cd) Buckets tipped for discharging
The properties of the bulk solid being handled will also have a strong
influence on the choice between centrifugal-discharge and gravity-discharge
elevators. As explained previously, the principal factors to be considered are
the lump size, the abrasiveness and the cohesiveness of the product. Table 8.1
[lJ serves as a guide to the choice of discharge pattern and bucket type for a
few different bulk solids covering a range of particle sizes.
Various materials are used for the construction of elevator buckets. For
example they may be stamped and welded from sheet steel, typically 2 mm to
Table S.l Guide to the selection of bucket elevators [1] w
0
0\
Average
loading
*Type efficiency
Bulk load of of buckets
characteristics Typical loads Elevator type bucket I1b Speed mls
8.3.2 Loading
With a conventional bucket elevator the bulk solid is either scooped up from
the boot by the buckets as they round the lower pulley, or it is fed directly into
the buckets as they begin their upward travel from the boot. In practice, bucket
filling is likely to be by a combination of these two methods.
The centrifugal discharge elevator, because of its spaced-bucket configur-
ation, relies on the scooping action for loading the buckets and is therefore
restricted to the handling of relatively fine free-flowing bulk solids, or to
materials having such a high water content as to render them free-flowing. In
either case the resistance to the movement of the buckets through the product
in the boot of the elevator is not excessive, and operation at the somewhat
higher speeds necessary to ensure satisfactory emptying of the buckets under
centrifugal action is possible without tearing the buckets from the belt.
Extremes of size of the product being handled should generally be avoided.
Loading problems can occur with materials so fine that they become readily
aerated and, at the other end of the size spectrum, severe damage can be caused
to the elevator if large lumps (greater than about 50 mm) are encountered in
the boot.
Bulk solids that are highly abrasive or that include large lumps must be fed
directly into the buckets. This method of loading requires the buckets to be
closely spaced so that there is little opportunity for the bulk material to fall
between them. Transport of these more difficult types of product is the main
application of the continuous bucket elevator since, although it is well able to
handle the finer free-flowing materials, it tends to be somewhat less
economical to operate than the spaced-bucket machine. Loading directly into
the buckets, especially where lumpy materials are concerned, necessitates a
lower working speed to minimize the tendency for the product to bounce or
splash from the buckets.
Loading of pivoted-bucket conveyors is, in some senses, rather easier than
for fixed-bucket types since it can be carried out on a horizontal section. The
main requirement is to ensure that the bulk solid does not fall between the
buckets. This means either that the feed must be intermittent, and controlled to
shut offfor a short period after each bucket becomes full, or (the method used
almost exclusively at the present time) the buckets must be very closely spaced,
preferably with an overlap to close any gap into which particles might fall.
Solids leed
~ ~
't9kb~
Figure 8.9 Concertina-effect to close up the buckets during loading of a pivoted-bucket
conveyor.
BUCKET ELEVA TORS 309
Current practice is generally to have the buckets closely spaced on the carrier
chains, as illustrated in Figure 8.5, but an alternative scheme is to have a
special arrangement of track which causes a concertina effect of the chain links
as the buckets pass through the loading station (Figure 8.9).
8.3.3 Discharge
The manner in which the transported bulk solid is ejected from the buckets as
they pass over the head-wheel (i.e. centrifugal, gravity or a combination of the
two) depends upon the speed of the buckets and their spacing. A simple model
of the situation existing at the head ofthe elevator is illustrated in Figure 8.10.
As the loaded buckets travel vertically towards the head-wheel the only
force acting upon the load is the gravity force F G. However, as the belt or
chain turns and begins to carry the bucket round the head-wheel, an
additional accelerative force FA also acts on the load. These two forces
combine to give a resultant F R, which changes in both magnitude and
direction as the bucket moves along its curved path. However, the line of
action of F R always passes through a fixed point P, called the pole point, which
lies vertically above the centre of the head-wheel. Noting the similarity of the
force triangle and triangle OCP (Figure 8.10), the distance of the pole point P
above the head-wheel centre 0 can be written
FG
L=r- (8.1)
FA
where r is the radial distance of the centre of mass C of the load in the bucket
from the head-wheel centre.
Now, ifm is the mass of bulk solid in the bucket and v is the linear velocity of
L
310 BULK SOLIDS HANDLING
L-g
- -;
(r)2 -- g
. 1
4n 2 N 2 (8.5)
It is thus evident that the distance of the pole point above the head wheel
centre depends upon the rotational speed of the head-wheel (or the linear
velocity of the buckets and the radius of the head-wheel). As the rotational
speed N increases, the pole point P moves downwards and the ratio of the
accelerative (or centrifugal) force FA to the gravity force F G increases.
It has been suggested [lJ that the discharge characteristic of a bucket
elevator can be conveniently classified according to the position of the pole
point (Figure 8.11). Thus, if the pole point lies outside the circle passing
through the outer edge of the bucket (i.e. L> r.) the centrifugal force will be
relatively small and the elevator can be classified as a gravity-discharge type.
However, if the pole point lies within the circumference of the head wheel (i.e.
L < r b ) the centrifugal force predominates and the elevator is classed as
centrifugal-discharge. Where ra > L> rb the discharge will involve a combin-
ation of gravity and centrifugal effects.
In the case of centrifugal discharge, after the bulk material leaves the bucket
it tends to follow a parabolic path until deflected by impact with the casing (or
p.
Figure 8.11 Classification of bucket elevators according to the location of the pole point.
BUCKET ELEVATORS 311
discharge chute) or a preceding bucket. It is important that the casing of the
elevator is correctly designed so that the material leaving the buckets is thrown
cleanly into the discharge chute, and therefore there is a need to predict the
trajectory of the discharged particles. For a detailed analysis the reader is
directed to references [2-4], but the following, greatly simplified, approach
should provide an understanding of the problem.
Using a model in which the bulk solid leaves the bucket as one 'lump',
without first sliding and without being affected by air resistance, the point of
discharge can be identified as when the radial component of the gravity force
becomes equal to the centrifugal force, i.e. when
mv 2
mgcos8=- (8.6)
r
where angle8is measured from the vertical (Figure 8.12a). Thus the position of
the bucket at the point of discharge is given by
8=8L=COS- 1 ( ; ; ) (8.7)
Now, provided that the 'lump' of material leaves the bucket smoothly
without, for example, hitting the top edge of the bucket, it will follow a free
y= _ x J(gr)2
v 2
_1 _ x2r (gr)3
v
2
2
(8.1 0)
Using this equation to plot the trajectory of the particles allows the position
of the mouth of the discharge chute to be determined to ensure that material
enters cleanly without spilling down the inside of the elevator casing.
Gravity discharge tends to occur in low-speed bucket elevators, typically
running at 0.4 to 0.8 m/s and handling wet, flaky or cohesive materials. If the
elevator is inclined, the contents of each bucket can fall directly, under gravity
alone, into a suitable discharge chute, but with vertical elevators care must be
taken to ensure that the falling material is suitably directed. Continuous
discharge elevators are designed with the back of each bucket shaped to form a
short discharge chute for the contents of the following bucket. This arrange-
ment does not work for spaced-bucket elevators and, if these are to operate at
low speed so that centrifugal effects in the discharging buckets are small, the
only satisfactory approach is to mount the buckets on twin parallel chains
which are snubbed back under the head-wheel (Figure 8.3b).
8.3.4 Capacity
Although the bucket elevator is essentially simple in concept, in order to
obtain optimum performance in terms of running costs and reliability,
attention must be paid to its design in relation to the nature of the product
being handled.
In addition to the nature of the material itself, the main parameters that
would be fixed in the design specification are the required solids throughput
and the height of the vertical lift. Additional constraints may be placed on the
design by the space actually available below the feed point and above the
delivery point.
The principal variables in the elevator design are:
(i) The bucket size and pitch
(ii) The belt (or chain) speed
(iii) The diameter of the head and tail pulleys (or sprockets).
The selection of a centrifugal discharge or continuous discharge type of
BUCKET ELEVATORS 313
Table 8.2 Preliminary selection data for centrifugal-discharge bucket elevators (belt type). From
data in [5]
Table 8.3 Preliminary selection data for continuous bucket elevators (chain type). From data in
[5]
Sprocket
Size of bucket diameter Head Capacity
Bucket sprocket Chain (for Pb = 1600 kg/m3)
Width Projection Depth spacing Head Tail speed speed
(mm) (mm) (mm) (mm) (mm) (mm) (rev/min) (m/s) (kg/s) (tonne/h)
elevator is obviously related to (i) above, and is largely governed by the nature
of the product to be handled. Guidance on the selection of elevator type has
been given previously (see Table 8.1) and preliminary design details for a given
application can then be developed from tabulated performance data such as
that given in Tables 8.2 and 8.3, derived from data in [5]. It should be noted
that the figures in these tables are for a granular material of bulk density
1600mg/m 3 (such as sand or crushed stone). For other products the capacity
at the stated belt speeds will vary in direct proportion to the bulk density, but
the optimum belt speed is a function of the product being handled. The
recommendations given here for the calculation of capacity and driving power
strictly apply only to bucket elevators operating vertically and not to inclined
elevators or pivoted-bucket types having both vertical and horizontal
sections. However, in the words of a recent European document [6], 'the
design of these can be calculated in implementing artfully the aforesaid
recommendation by extension or deduction'!
314 BULK SOLIDS HANDLING
where Vb is the volume of each bucket, 'lb is the bucket filling efficiency, v is the
belt velocity and A is the bucket pitch.
Mass throughput is then given by
. v
ms = PbVs = PbYJbVbI (8.12)
where Pb is the bulk density ofthe material in the buckets. Note that the actual
quantity of material in each bucket is expressed as YJb Vb' where Vb is the
nominal capacity of the bucket when filled with a horizontal surface (water
capacity), and the filling efficiency YJb normally has a value of 0.65 to 0.75.
However, the quantity of material that gets into a bucket depends principally
upon the feeding arrangement, the shape and speed of the buckets and their
pitch on the belt or chain, and so the value of YJb could in fact vary over a wide
range (from around 0.4 to slightly greater than unity). Typical values of bucket
filling efficiency are to be found in Table 8.1, and volumes of buckets of various
types may be estimated from Figure 8.13. Note that the size of bucket selected
should be consistent with the maximum lump-size of the material being
handled, the bucket projection required being some four or five times the size
of the largest lump.
200
100
I I;
Ii) 50
I
M I
.~
u /.:.. V-buckets -
a; 20
""o
.5 10 V i
'0
<I> 5 /ShaIiOW
E buckets
g" 2 VII I
IJ iL-crdeep
0.5
/1 Ucj ets
Figure 8.13 Chart for the estimation of the volume of elevator buckets.
BUCKET ELEVATORS 315
8.3.5 Driving power
The conventional approach to an assessment of the power requirement of a
bucket elevator is similar to that used for belt conveyors and involves an
estimation of the various resistances to the movement of the elevator.
The main resistance is of course that resulting from the vertical lifting of the
load in the buckets.
N ow the total mass of material on the upward side of the elevator can easily
be determined as the product of the mass in one bucket and the number of
buckets. Thus the gravity force opposing motion of the elevator is given by
H
FH = Pbg1]b VbT (8.13)
where H is the difference in height between the feed and discharge points.
The next most significant resistance is likely to be that caused by the feeding
of product to the buckets. This comprises a drag force on the buckets and on
the belt or chain(s) as they pass through the material in the boot. The scooping
action occurs principally in the centrifugal-discharge type of elevator, but in all
bucket elevators there will be significant work done as the product is
accelerated from the feed point.
Rigorous mathematical analysis ofthe resistances associated with the filling
of the buckets is very difficult, and the approach usually adopted is to express
the losses in this region as an 'equivalent height' H r which is then included in
equation (8.13) for the determination of the main resistance. This equivalent
height, or loading factor, is likely to be in the range 3-12 m. The actual value to
be used depends upon the nature of the product and the method of filling;
Table 8.4 gives recommended loading factors taken from [7].
The combined resistive force, F U' is thus given by
H+Hr
Fu = PbgYfbVb A (8.14)
or
Fu=FH(l+~) (8.15)
8.4 Notation
FA Accelerative (centrifugal) force on contents of bucket
FG Gravity force on contents of bucket
FH Net gravity force on upward side of elevator, equation (8.13)
Fu Combined resistive force on elevator
g Gravitational acceleration (specific gravitational) force
H Height of discharge point above feed point
Hf Equivalent height or loading factor, accounting for resistances
associated with bucket filling
L Distance of pole point above centre of head wheel (Figure 8.10)
m Mass of contents of bucket
lizs Capacity (mass flow rate)
N Rotational speed of head-wheel (revolutions per second)
P mot Motor power
r Radial distance of centre of mass of load in bucket from centre
of head-wheel (Figure 8.10)
ra Radius of circle passing through outer edge of bucket
(Figure 8.11)
rb Radius of head-wheel
t Time
Vb Volume of bucket
V. Volumetric capacity (flow rate)
v Linear velocity of centre of mass of load in bucket
x Horizontal coordinate of centre of mass of bucket contents after
ejection
y Vertical coordinate (measured downwards) of centre of mass of
bucket contents
I1b Bucket filling efficiency
110 Overall drive efficiency
A Linear pitch of buckets
e Angular position of bucket, measured from vertical
eL Angular position of bucket at instant of discharge of its contents
Pb Bulk density
BUCKET ELEVATORS 317
References and bibliography
References
1. Spivakovsky, A. and Dyachkov, V. Conveyors and Related Equipment. Peace Publishers,
Moscow.
2. Beverly, GJ., Roberts, A.W. and Hayes, J.W. (1983) Mechanics of high speed elevator
discharge. Bulk Solids Handling 3 (4) 853-859.
3. Fort, J.c. (1973) Berechnung und Auslegung von Becherwerken (Calculations and design of
bucket conveyors). Fordern und Heben 23 (8) 432-436.
4. Koster, K.H. (1985) Centrifugal discharge of bucket elevators. Bulk Solids Handling 5 (2) 449-
464.
5. Perry, R.H. and Green, D. (1984) Perry's Chemical Engineers' Handbook. 6th edn., McGraw-
Hill, New York, 7.11 to 7.13.
6. Anon. Recommendation for the calculation of throughput, power requirement and tensile
forces in belts and chains of vertical bucket elevators. FEM (Federation Europeenne de la
Manutention), Section II, Continuous Handling, Paper 2.122, January 1981.
7. Anon. Handbook Jor Conveyor and Elevator Belting. Apex Belting Pty. Ltd., Australia.
9.1 Introduction
In addition to the very familiar belt conveyor and the scarcely less familiar
bucket elevator, there are a number of alternative mechanical techni-
ques that are commonly used to carry, drag or scrape bulk solids from
one location to another. It is not particularly easy to place these various
techniques into distinct categories, and the division of this part of the book
into separate chapters and sections, while not being entirely arbitrary, should
be regarded as a matter of convenience rather than as a serious attempt at
classification of bulk handling systems. In some cases there is an almost
continuous gradation of design from one type of conveyor to another, so that
the placing of an artificial 'boundary' between the two types becomes
somewhat subjective. For example, if an apron conveyor is fitted with deep
pans and operated on a steep incline it becomes a bucket elevator, and if a
bucket elevator is fitted with shallow bottomless buckets and enclosed in
a casing it becomes an en-masse conveyor.
In Chapters 7 and 8 the conventional belt conveyors and bucket elevators
were discussed in some detail along with a number of important variants of
these systems. In this chapter other types of mechanical conveyor that rely on
continuous ropes or chains for their operation will be described. The number
of such conveyors that are, or have been (sometimes briefly!) available to
industry is quite large, and the decision has been taken to limit the scope ofthis
chapter to the following groups: drag conveyors, en-masse conveyors, tubular
drag conveyors, apron conveyors and aerial ropeways. It is believed that the
reader will thus be able to acquire an awareness of all the major types of
continuous mechanical conveying system although, as explained, the coverage
is not intended to be exhaustive.
The first groups that will be considered are those which drag or scrape the
bulk solid along some kind of trough or duct with the aid of a continuous rope
or chain which mayor may not be fitted with 'flights'. Attention will then be
turned to the class of conveyor which has slats or pans fitted to the chains in
order to carry the bulk material, and finally a system is briefly described where
the endless rope is used to support large widely-spaced buckets carrying the
conveyed product-that is, the aerial ropeway.
(Figure 9.2). However, it is quite possible to have two separate troughs, or one
trough divided longitudinally into upper and lower sections, so that both
strands of the chain are actively conveying material in opposite directions.
Drag conveyors tend to have fairly limited application, although they are
the generally accepted means of handling certain materials such as hot cement
clinker and ash. They are also widely used in the mining and chemical
industries for conveying a variety of bulk solids. Operating speeds are quite
low, typically around 0.1 to 0.6 mis, and conveying capacities tend to be rather
small.
The estimation of conveying capacities of drag- and scraper-conveyors is
essentially a matter of determining the average velocity of the bulk solid along
the trough and the effective depth of the bulk solid stream, and for further
guidance the reader is directed to [1].
3oo,----,;---,----.--r--,---,--,---7r--,----, 440
~ 390
~ 200~~---+--_+--_+--___I7'~_t_----7'T---"....~t-::7"""I 340
5.
.s::
Cl
5
£
5100~~--_+~~~~~~--~~+--+_--~~240
>-
~ 100
c
o
o
o~~~~~~~-J~-J.
0.1 0.2 0.3 0.4 0.5
conveyor chain velocity (m/s)
Thus
(9.1)
and the mass throughput is given by
(9.2)
For horizontal conveyors rv can generally be taken as unity, but on vertical
and inclined sections its value is likely to be around 0.6 to 0.85, depending
upon the nature of the material and the way that the section is fed.
The optimum velocity of the chain and flights is very much dependent upon
the nature of the conveyed product. For free-flowing particulate and granular
materials, velocities in excess of 0.5 mls are usually possible, whereas abrasive
materials and products which tend to become aerated (such as cement) should
not be conveyed at more than about 0.25 m/s. For fibrous and flaky products
the optimum velocity is likely to be around 0.4 m/s. Attempting to operate at
too great a speed results in excessive abrasion, degradation of the product and
reduced efficiency as the flights pull through the product, leaving the top layer
stationary or moving at reduced speed.
The capacity chart (Figure 9.6, from [2]) gives an indication of the
volumetric throughputs that could be obtained in a typical range of widths of
en-masse conveyors operating horizontally. For vertical operation the
capacity values are likely to be reduced by anything from 10% for coarse
granular materials, to 35% for fine granular materials, to 50% for free-flowing
powders.
Estimation of the power requirement is not easy, as so much depends upon
the nature of the product being conveyed and the configuration of the
CHAIN AND FLIGHT CONVEYORS 325
Figure 9.7 Basic en-masse conveyor. Controlled or flood feed, with multiple inlets and outlets.
Figure 9.10 Tubular drag conveyor installation showing a typical arrangement of feed and
discharge points.
Combinations of horizontal and vertical runs are also common and the en-
masse principle works well in integrated conveyor/elevator installations of'L'
or 'Z' arrangement (Figure 9.8a, b).
The versatility of the en-masse conveyor makes it suitable also for combined
processing/transport applications such as cooling, heating or drying of the
conveyed product. Movement of a blended mixture of products without
segregation can be readily achieved in an en-masse conveyor. Sources such as
CHAIN AND FLIGHT CONVEYORS 327
[2] and manufacturers' literature give more details on many examples of
successful and unusual application of this method of conveying.
2000 ~
250 ...
1000
..................... 200 ~
'""'
c:
500 I- '-r- - . 150 E
~
v.- ~'"
(/) ........ ....... ........
I-~ 100
v ,/"
V
~ 100
~ .......- vV
........
............... V
75
=
D
~ 50
'0
'ua"
(II
........- ....... ........-
. . . .V . . . . . ........ /
I -::f ~
10 L
.......- . . . . V ,.....- ...........-
f-- ........
2
0.3 0 .5 2 5 10 20 30
chain speed (metres/min)
/
/
/'
/
Figure 9.13 An apron conveyor (,leakproof type).
CHAIN AND FLIGHT CONVEYORS 329
overlap and thus form a continuous moving surface on which bulk solids can
be carried (Figure 9.13). In this respect alone apron conveyors are similar to
belt conveyors, but they have the advantage of being able to handle heavy,
large-lumped, abrasive and hot materials. Very high capacities-greater than
2000 tonnes/h -are possible, and running costs relatively low. However,
because of the nature of their construction, apron conveyors are very heavy
and very expensive in terms of investment cost.
Various types of pan are available to suit different applications, but all are
designed to fit together, either interlocking or overlapping, to minimize the
risk of solid particles falling through the conveyor or becoming lodged in the
gaps.
For conveyors operating horizontally or on a slight incline (up to about 20°)
there are advantages in using pans that are almost flat (Figure 9. 14a), but for
operation on steeper slopes apron conveyors should be fitted with deeper pans
(Figure 9.14b, c). These deeper pans are also better when handling bulk solids
containing large lumps.
Apron conveyors are normally available in widths from 200 mm to 2 m,
and fitted with side flanges of up to 300 mm in height. Operating speeds are
quite low, being generally less than 0.2 m/s and rarely exceeding 0.5 m/s.
Calculation of the carrying capacity of an apron conveyor is very similar to
that for belt conveyors and is thus largely a matter of estimating the cross-
sectional area of the load stream, which can be represented by one of the
shapes shown in Figure 9.15.
Thus, for a flat pan,
(9.3)
and for a flanged pan
(9.4)
-::::::a
(0 @ ~) 53 <i c~
\0 <iii i?
(a) "Flat" pan (b) Flanged pan
-
(c, d) Deep pans
0.8
o 10 20
angle of Inclination
Figure 9.16 Slope factor k, for apron conveyors.
Figure 9.17 Longitudinal profile of a typical aerial ropeway designed to transport ore at a rate of
145 tonnes/hour over a distance of 15 km [3].
332 BULK SOLIDS HANDLING
Figure 9.18 Bicable and monocable ropeway systems. (Top) Bicable ropeway carrying iron ore at
a rate of 250 tonnes/h over a distance of 10 km. (Bottom) A monocable system. (Courtesy of
BRECO)
CHAIN AND FLIGHT CONVEYORS 333
by a secondary cable linking the wheeled carriages from which the buckets are
hung. The monocable system, however, has a single cable which serves as both
the carrying and the hauling element (Figure 9.lSb).
On modern aerial ropeways, in order to achieve the required high capacities,
bucket speeds of up to about 5 m/s are becoming common and, as a
consequence, special handling techniques are needed at the filling and
emptying stations. This usually involves disconnecting the buckets from the
rope driving system, for example by automatically lifting the buckets from the
main carrying cable on to rails where they are retarded and passed at a
controlled rate past the loading or unloading point. One method of re-
attaching the buckets to the transport cable is to release them on to a
downward sloping rail which causes them to accelerate to the speed of the
cable so that coupling can take place without damage.
The dimensions and carrying capacity of aerial ropeways are dependent
upon many factors, not least the nature of the territory that the system has to
cross. Typical conveying distances would be up to about 20 km with spans
between towers of around 500 m or more. Transport rates of up to 500
tonnes/h are usual, although a rate of 2500 tonnes/h has been reported [3].
Bucket capacities are typically around 2 tonnes, with buckets spaced at
intervals of 50-100 m and travelling at up to 5 m/s.
9.7 Notation
References
1. Spivakovsky, A. and Dyachkov, V. Conveyors and Related Equipment. Peace Publishers,
Moscow.
2. King, B.c. The application and design of en-masse conveyors. Proc. Solidex 80 Cotif.,
Harrogate, UK, March/April 1980, Paper A3.
334 BULK SOLIDS HANDLING
3. Spyer, V. (1984) Aerial cableways as a transport mode in Brazil with special reference to
Minera<;iio Morro Velho. Bulk Solids Handling 4 (2) 413-415.
4. Bullivant, D. (1983) Modern aerial ropeways and the environment. Bulk Solids Handling 3 (1)
185-187.
10.1 Introduction
The modern screw conveyor is essentially a development of the well-known
Archimedean screw which was conceived some 2000 years ago as a means of
raising water for irrigation. Applications of this device were naturally very
limited until relatively recent times, and its evolution has consequently been
slow. A fundamental feature of the original pattern of Archimedean screw
which distinguishes it from other types of screw conveyor is that the helical
screw (or 'flight') is attached to the inner surface of the cylindrical casing and
rotates with it (Figure 10.1). It will be noted from the diagram that the
Archimedean screw operates effectively as a positive displacement elevator,
the angle at which it will work successfully depending upon the diameter of the
casing and the pitch of the screw.
In the late 18th century the need for efficient mechanical handling of grain to
feed the expanding world population provided the impetus for the improve-
ment of screw conveyors for the transport of grain and other dry bulk
materials. For such materials it was found that there was no need for a perfect
seal between the helical flight and the casing. Consequently an easier
construction was adopted, comprising essentially a central shaft to which was
fitted the flight, the whole assembly rotating within a fixed casing (Figure 10.2).
In the earliest recorded examples of screw conveyors the flights consisted
simply of a series of wooden ploughs set in a helical arrangement around a
wooden shaft. Later versions used steel flights cut from flat sheet as circular
rings, split on one side and with the two edges then pulled apart to form one
helical section of the screw. Any number of these sections could be riveted
together to make a continuous helix of the required length which would then
be fitted to a steel or iron core. Around 1900 the smooth 'helicoid' flight was
introduced, formed by rolling a continuous strip of steel into a helix.
The design of the screw conveyor was thus basically simple and could be
produced, at least in a crude form, at relatively low cost. As a result its use
became widespread, at first in agriculture and then throughout the developing
industrial world, for handling a great variety of bulk solids.
The advantages and disadvantages of screw conveyors can be conveniently
summarized as follows [1]:
Advantages
(i) Low investment cost compared to other conveying devices of comparable
capacity
336 BULK SOLIDS HANDLING
Figure 10.2 Standard pattern of industrial screw conveyor with helical screw rotating inside a
fixed casing.
(ii) Compact design, comparatively easy to seal against water or dust passing
in or out; the solids being handled can be blanketed with a dry or inert gas
where necessary
(iii) Fairly simple fabricating with unsophisticated equipment; a high degree
of part standardization exists within the industry
(iv) Generally lower maintenance than with most types of mechanical
conveyor; there are less moving parts to wear or get out of order
(v) Ability to handle a wide range of solids.
Disadvantages
(i) Lumpy, fibrous or sticky materials may cause problems
(ii) Lengths are limited by the allowable torque capability of the drive and
coupling shafts
(iii) Power requirements can be high with solids that tend to pack
(iv) Conveying efficiency is considerably reduced when screws are inclined or
mounted vertically.
SCREW CONVEYING 337
It is fairly evident that the screw conveyor has evolved into two basic types:
(i) The high-speed enclosed screw or 'auger' conveyor, originally developed
for grain handling and now extensively used for elevating products that are
light and free-flowing
(ii) The low-speed industrial-type screw conveyor ('V-trough' conveyor),
generally larger and of heavier construction and ideally suited to the
movement of more dense or cohesive products over short distances
horizontally or on a slight incline.
A very common application of the helical screw device for moving bulk
solids is as a feeder to assist and/or control the flow of material from storage
hoppers. The screw feeder has already been introduced in this context, and
some of its special features described, in Chapter 4.
A brief explanation will be given here of the principles of operation of screw
conveyors and then the general construction ofthe two types will be described
and their application discussed. Procedures will also be outlined for the design
or selection of screw conveyors for particular duties.
particles lifted
vertically by
radial
clearance
Dimensions for portable and mobile screw conveyors (augers) of the tubular
type constructed of mild steel for agricultural and light industrial use are
specified in BS 4409 [3].
In recent years a number of variants of the auger conveyor have become
available. Generally these have involved differences in the form of the screw
itself; for example, several manufacturers offer this type of conveyor with an
'open pitch' screw. However, perhaps the most interesting development has
been the flexible screw conveyor in which an open pitch spiral spring, rotating
within a flexible nylon tube of around 40-80 mm diameter, forms the basis of
an economical and versatile unit capable of competing with pneumatic
conveyors on a wide variety of light-duty, short-distance applications
(Figure 10.5).
340 BULK SOLIDS HANDLING
(10.1)
where Dc and Dsh are respectively the internal diameter of the casing and the
diameter ofthe shaft on which the flights are fitted, Ais the pitch ofthe screw, ts
is the thickness of the screw flight and N is the speed of rotation.
In practice the capacity of the conveyor is likely to be well below this
theoretical maximum. The shortfall is greatest for augers operating at high
speeds and steep angles with short choke lengths [4]. In absolute terms,
however, the volumetric throughput of the auger tends to increase with
increasing speed up to around 2000 rev jmin for small-diameter machines
(approximately 40 mm): at higher speeds there is little change in the
throughput. For augers of larger diameter the maximum capacity is likely to
be reached at lower speeds.
Variation in throughput with angle of elevation is mainly attributable to the
increased tendency for the conveyed product to rotate with the screw as the
inclination of the conveyor becomes steeper. For a given auger speed the
SCREW CONVEYING 341
500
f-
200
/!;
WI
VI
150
~
~~
100
,l> V
'II
:2 .,Q ~
1:;
50
fi'1!J ' /
;lC! /
Q
8 20
~ W! V
~
0>
15 1/ /
:::J
'"
~
10 14ger speed _
~( rev/mi n)
~ 5 f-- ~ ~8
""'\ ~ 1~88
is. (I BOO
i--
V /
140
2
tillII
ill 1//
1.5 -
jj '/1/ <:
1 In;- :-:-J lO.
.
90 ~ ......
A(
\. .'\.
'\. .'\. \. ..\. \.. \.
75 > II>
\. \. . \. .\. \ . \. 45 '*~0>
60
~\'
50 70
\
100
.\
150 200
" ~
3
30 '0 '0
~5
~ ~
CD
..
CD~
Figure 10.6 Predicted capacity of different size augers at various rotational speeds and angles of
elevation [2]. This chart relates to augers having the following proportions:- pitch =
screw diameter; choke length = twice pitch; shaft diameter = one third screw diameter; screw
clearance = 0.0833 x screw diameter; average particle size = 0.05 x screw diameter.
volumetric flow rate of product may fall by 50% as the conveying slope
increases from horizontal to vertical.
The 'choke length' (Figure lOA) also has a significant influence on the
performance of an auger conveyor. A minimum choke length equal to one
screw pitch is essential even at low speeds, but a choke length of up to three
screw pitches may be required at high speeds.
Roberts and Hayes [2] have published charts for the prediction of
volumetric capacity and power absorbed for auger conveyors having screw
diameters in the range 40-300mm. These charts, reproduced in SI units as
Figures 10.6 and 10.7, are based on a set of empirical equations relating to the
transport of a free-flowing granular material similar to grain, and illustrate the
influence of the speed of the auger and its inclination to the horizontal.
M
342 BULK SOLIDS HANDLING
1000 I-t-H-++---t--+--+-+-#J'itfi
~~ auger speed
QQ) I-t-HHi~W~A (r€lv/min
~~ 200
Q) ~
20 ~88 1--1----+-!
g~
co>
'Oc
Q)O
'00
'62
1~~~+-+-+-l
~~
Q
Figure 10.8 A ribbon-type screw conveyor, showing a typical arrangement of the screw in the
trough.
~
I
Figure 10.9 Diagram to show a typical arrangement of bearings for a screw/shaft assembly. Left-
and right-hand screws are used in this example to provide two feeds to a single discharge point.
that screws of opposite 'handedness' can be used to feed material from two
directions to a single discharge point. Needless to say, when designing a screw
conveyor installation' it is essential to ensure that the correct direction of
rotation is specified.
The 'regular' pattern of flighting has a pitch approximately equal to the
diameter of the screw and is generally made by one of two methods:
(i) A set of identical rings is made from sheet metal and each is cut radially and
formed into a single helix. These are then assembled on the shaft and
welded to form a continuous helix, the thickness of which will be constant
from the inner edge to the outer.
(ii) A continuous metal strip is rolled into a helix by reducing the thickness of
one edge of the strip to approximately half that of the other edge. The
resulting helicoid flight is then welded on to the shaft to give a screw in
which the flight thickness tapers from its inner to its outer edge.
A wide range of ' special' types of screw is available from manufacturers to be
used in applications for which the regular pattern of screw is, for some reason,
not the most appropriate. Some examples of these are illustrated in
Figure 10.1 O.
344 BULK SOLIDS HANDLING
~J\f'\j V 'Vf \Y \J
(d) Ribbon flighting. Used for conveying
(a) Regular helicoid flighting
substances that are sticky, gummy'
or viscous
(b) Cut screw flighting. Used for (e) Regular screw flighting with mixing paddles.
conveying, cooling and moderately Used to mix materials where the conveyor
mixing materials, simultaneously length provides time for proper mixing
(c) Cut and folded screw flight. Continual (f) Double flight conveyor screw. Used to
lifting and tumbling of the material promote a smooth and gentle flow of
by the folded flights improves material
aeration and promotes mixing
Figure 10.10 Some examples of different patterns of screw conveyor flighting for special
applications.
shaft or pipe
diameter
radial
clearance
screwl
clearance
Figure 10.11 Screw conveyor terminology.
Materials that are very sticky, and especially those consisting of 'particles'
that are long and stringy, are mostly unsuitable for screw conveying since they
tend to clog the screw, either rotating with it as one mass or becoming jammed
between the screw and the casing. At best, such products may require screws of
special heavy construction.
For more detailed guidance on the influence of product characteristics on
the design or selection of screw conveyors see, for example, [4].
~
~~
~:5 400 1-- - -
~~
0,-
uu
~
~~
..
.....
u ..
A - k x nominal area
b of trough
As the screw rotates within the trough the conveyed material is 'picked up'
against the side of the trough and then tumbles back, only to be picked up
again, and so on. This action, although in fact intermittent, results in an
effectively continuous movement of the material along the trough at
approximately the same speed as the advancing screw. Thus the distance that
the conveyed material moves forward during one revolution of the screw is
approximately equal to the pitch of the screw, and the average velocity U of
this material can be written
U=AN (10.2)
where A is the pitch of the screw and N is the rotational speed in rev/so
The volumetric throughput of the screw conveyor is then given by
(10.3)
SCREW CONVEYING 347
0.50
:~ k - 0.45
','
rrinerals)
o~----~--~~----~--~
5 10 15 20
trough Inclination
(degrees to horizontal - upward)
Figure 10.14 Typical loading factors for screw conveyors having pitch A, where O.6D" <
A< l.OD", Note: these loading factors should be reduced for conveyors having screws of large
pitch or having small-diameter screws supported on cumbersome intermediate bearings [7, 8].
C'
'~
~ 150 I -- - t - - -
I~ 100
30% loading
iii
Q;
I (non-abrasive -:----+--~
terials)
8 30% loading
(abrasive materials)
l
E 50
~ 15% loading
/'
'~
~ cuI and
folded
~ flight
<; 3
~
~
'0 I
iI
<J
2
E
~
0.4 0 .5
conveyor loading faclor. k
Figure 10.16 Capacity factors for screw conveyors with special types of flight. (For standard
flight CF, = 1).
E1.4
t5
ot5 1.3
.l!!
~
·0
/
/
<IS 1.2
~
V
t
(J
1.1
V
/
.S'
)(
.~ / 2 3 4
number of mixing paddles per pitch
Figure 10.17 Capacity factors for screw conveyors with 45° reverse pitch mixing paddles fitted
within the flights.
~
"""
u.0
0 ........
"
'0
~ 2
U
«I
0 ...........
"5i>
0
""" """
0.2 0.0 1
power (Pmat + Pfrict) kW
2
"""
Figure 10.18 Values of the 'overload factor' F o'
The 'material factor' F m' also called 'progress resistance coefficient', depends
upon the characteristics of the bulk material, but apparently not in any
kind of consistent manner that would allow it to be determined from a simple
bench test. Values of F m for a large number of bulk solids can be determined
from data in [4]. Table 10.1 lists a few of the more common bulk solids with
corresponding values of F m which, in general, range from 0.8 to 4.0.
Once an assessment has been made of the total power required to transport
the material and to overcome the inherent conveyor friction, it is necessary to
take into account the drive efficiency and so determine the normal input
power. The value of the drive efficiency would naturally depend upon the
arrangement in use, but typically should be around 85-95%.
In addition, it is usual practice to make allowance for possible overload
conditions which may occur, for example, when starting up a fully-loaded
conveyor. The problem is likely to be particularly acute for small conveyors
using low power driving motors, as in this situation the torque range required
may be more than a small motor can provide. In [4J the use of an 'overload
factor' F 0 is recommended; this is a function of the total power required, up to
about 4kW (see Figure 10.18).
Thus the size of driving motor required is indicated by
P = (P mat + Pfrict)F 0
mot 11 (10.12)
Table 10.1 Bulk densities and material factors for a selection of common bulk
solids [4]
Bulk density
Material Pb(kg/m 3 ) Fm
tumbling and turbulence within the rotating screw. Although attempts have
been made to develop analytical models of the 'flow' in inclined screw
conveyors, for example, [9], most of the published information is of a
qualitative nature.
Special designs of screw conveyor are available for vertical operation, as
described in section 10.5, and modifications can be made to the standard
form of conveyor which will improve, to a limited extent, its performance when
operating on an incline. Nevertheless, there tends to be a slope, typically
around 45°, for which its throughput falls to a minimum (Figure 10.19).
SCREW CONVEYING 353
100~--------------------~
~
z:
.~ 50
Co
'o"
design for
65 90
inclination of conveyor (degrees)
Figure 10.19 Variation in performance of screw conveyors when operating on an incline [4).
Provided that the incline is not too steep (generally, less than 20°) the
efficiency of a standard design of screw conveyor may still be acceptable,
especially if the rotational speed is increased somewhat to compensate for the
loss in the average forward velocity. Figure 10.14 gives an indication of the
extent to which loading factors should be reduced when operating on shallow
upward inclines, the general recommendation being a 2% reduction in k per
degree of inclination.
Alternatively, modifications may be made to the conveyor itself, for
example:
(i) Reduce the clearance between the trough and the screw to a minimum.
(ii) Use a tubular trough, again with minimum radial clearance. The loss in
efficiency of conventional U -trough conveyors when working on an incline
is partly caused by the tendency of the bulk solid to fall backwards over
the top of the rotating screw. A close-fitting tubular trough helps to
contain the material and prevent this fall-back, especially if the screw is
rotating at a somewhat higher speed than usual.
(iii) Reduce the number of intermediate hangers supporting the screw, and if
possible eliminate their use altogether. Obviously this will mean that the
screw sections are longer, and it may be necessary to make these of heavier
construction to reduce the risk of the screw shaft flexing to an unaccept-
able extent when under load.
(iv) Use screw of shorter pitch, for example, two-thirds or even one-half of the
standard pitch. This will result in an improvement in the angle of the screw
flight relative to the bulk solid through which it passes. An increase in
rotational speed may be necessary, however, to compensate for the fact
that the forward movement of the bulk solid per revolution of the screw
will be less as a result of the reduction in pitch.
Once the capacity of an inclined screw conveyor is determined, estimation of
the additional power consumption, over that for horizontal operation, is
relatively straightforward.
354 BULK SOLIDS HANDLING
Thus
(10.13)
where H is the vertical elevation of the top end of the screw above the feed
point, and the power of the driving motor will then be given by
,(
400 ~
'0
Q)
'0
c:
~
200 E
0
u
~
o 100 200 300 500
diametElf of screw (mm)
Figure 10.20 Approximate capacity of vertical screw conveyors [6].
Figure 10.21 The contra-rotating screw feeder device used on the Siwertell bulk discharger.
flights fixed
to shaft
flights fixed
to casing
works by lifting a batch of material from each stationary flight to the next until
the discharge point is reached and, in doing so, achieves volumetric efficiencies
much greater than more conventional vertical screw elevators.
10.6 Conclusion
Although various important aspects of the design and construction of screw
conveyors have been covered in this chapter, there is clearly a great deal more
to be studied in order to acquire a thorough working knowledge of these
devices. In particular, the materials of construction, torsional ratings and
drive configurations, considered to be outside the scope of this brief
introduction, need to be appreciated before taking major decisions concerning
the design or selection of screw conveyors. Probably the most useful source of
guidance is the CEMA handbook on Screw Conveyors [4], but a number of
other publications should also prove useful, for example, [1], [2], [6] and [10],
the last-named having over sixty further references.
10.7 Notation
Ab Cross-sectional area of moving bed of bulk solid in a screw
conveyor
CF r Flight capacity factor (Figure 10.16)
CFm Mixing paddle capacity factor (Figure 10.17)
Dc Internal diameter of conveyor casing
Dsc Diameter of screw
Dsh Diameter of conveyor shaft
Fm Material factor, equation (10.11) (Table 10.1)
Fs Screw factor, equation (10.11)
g Gravitational acceleration (specific gravitational force)
H Vertical elevation of conveyor discharge above feed point
k Trough loading factor (Figure 10.14)
L Length of screw conveyor
rhs Mass flow rate (capacity or throughput)
N Speed of rotation of screw (revolutions/second)
SCREW CONVEYING 357
P fric ! Power required by screw conveyor to overcome friction
between moving parts
P ma ! Power required by screw conveyor to move bulk solid at a
specified rate
Power required by screw conveyor to raise bulk solid through
height H
Total power absorbed by screw conveyor
Thickness of screw flight
Average velocity of bulk solid in the axial direction within a
screw conveyor
Volumetric flow rate (capacity or throughput)
Pitch of screw
Bulk density of conveyed material
References
1. Thomson, F.M. (1973) Applications of screw conveyors. In Bulk Materials Handling, Vol. II,
ed. M.e. Hawk, School of Engineering, Univ. of Pittsburgh, 84-98.
2. Roberts, A.W. and Hayes, l.W. (1979) Economic Analysis in the Optimal Design of Conveyors,
Chapter 3, Performance of enclosed screw or auger conveyors, Tunra Ltd., Univ. of
Newcastle, Australia.
3. British Standard BS 4409: Part 2: 1970. Screw conveyors-Portable and mobile tubular type
(augers) for agricultural and light industrial use. British Standards Institution, London.
4. Screw Conveyors. CEMA Book No. 350, Conveyor Equipment Manufacturers Association
(USA), 1971.
5. British Standard BS 4409: Part 1: 1969. Screw conveyors-Trough type for industrial use.
British Standards Institution, London.
6. Colijn, H. (1985) Mechanical Conveyorsfor Bulk Solids. Chapter 3, Screw conveyors, Elsevier,
Amsterdam.
7. British Standard BS 4409: Part 3: 1982. (Also ISO 7119-1981). Screw conveyors-Method
for calculating drive power. British Standards Institution, London.
8. Screw conveyors for bulk materials-recommendations for the design. Federation Eu-
ropeenne de la Manutention, Section II, Continuous Handling, FEM 2.121, September 1985.
9. Kuznetsov, V.l. (1983) Calculation of the capacity of screw conveyors with an arbitrary angle
of inclination. Soviet Engg. Research 3 (8) 15-18.
10. Bates, 1. Application and design of helical screw equipment. Proc. Solidex 80, Solids Handling
Conference, Harrogate, UK, March-April 1980, Paper B2.
11. Robinson, G. (1981) The Siwertell bulk discharger. Bulk Solids Handling 1 (3) 405-408.
12. Korach, D. A new look at vertical screw conveyors. Proc. 11 th Powder and Bulk Solids Conj,
Chicago, USA, May 1986, 101-107.
11.1 Introduction
Vibratory conveyors are commonly used in industry to carry a wide variety of
particulate and granular materials. Although the majority of engineers
involved in bulk materials handling will be aware of vibratory conveying as a
useful technique, few have the necessary understanding of this method to be
able to design or select a system with confidence. However, there is little doubt
that vibratory conveyors have some useful advantages, and an insight into
their mode of operation and into the parameters governing their performance
should enable the system designer to ensure that his choice of conveyor is the
most efficient and the most reliable.
The basic vibratory (or oscillatory) conveyor consists of a trough (generally,
but not necessarily, horizontal) which is supported on or suspended by springs
or hinged links and caused to oscillate at high frequency and with small
amplitude by an appropriate drive mechanism (Figure 11.1). The actual
configuration of the mountings and the type of drive unit used depends upon
the application and will be discussed in more detail in sections 11.3 and 11.4.
The fundamental action of the vibrating trough on the bulk material carried in
it is to throw the particles upward and forward so that they advance along the
trough in a series of short hops.
There is a need to differentiate here between 'feeders' and 'conveyors',
although the distinction is in fact mainly one of application. An important
aspect of vibratory handling is the ease with which the flow rate of the
conveyed product along the trough can be adjusted by altering the amplitude
and/or the frequency of the vibration. This has led to the widespread use of
vibrating troughs as feeders, for example, mounted directly beneath a hopper
to control the rate of discharge.
Thus a feeder must be capable of operating under varying head-loads,
whereas a conveyor requires a regulated feed rate and should not be subjected
to changes in head-load. A further difference between vibratory feeders and
conveyors is that the former are normally operated at higher frequencies and
smaller amplitudes. Table 11.1 gives an indication of the approximate ranges
of operation of vibratory equipment.
The size of vibratory feeders can vary over a very wide range from tiny units
delivering just a few grams per second (for example, in pharmaceutical
tabletting machinery) to heavy duty vibrating troughs handling hundreds of
tonnes per hour. Possibly the largest of these machines currently in use is a
VIBRATORY CONVEYORS 359
Frequency Amplitude
Type of machine (Hz) (mm)
combination feeder and screening unit, having a trough 4 m wide and over
11 m long, designed to handle discarded motor vehicle batteries [1].
In general, the trough in a vibratory feeder is quite short (less than about 2 or
3 m), but flow rate control by amplitude or frequency variation works well
also on longer troughs, and the distinction between feeder and conveyor
becomes blurred.
At this point it would perhaps be appropriate also to distinguish between
360 BULK SOLIDS HANDLING
(11.3)
and it follows that on the forward movement of the trough the acceleration
should always be less that J1rg, while on the return stroke the acceleration
should be, for the major part of the travel, greater than J1rg.
Operating frequencies of 1 or 2 Hz are typical, with strokes of up to about
250 mm (compared with 3 to 20 Hz frequency and stroke usually less than
25 mm for vibratory conveyors). Smooth granular or lumpy products of
relatively high density are generally the most appropriate products for this
method of conveying. However, reciprocating conveyors have a somewhat
limited application because ofthe severe abrasive effect ofthe continual sliding
of the conveyed material on the surface of the trough, and therefore they will
not be considered further in this book.
When selecting or designing a vibratory conveyor for a given application
the most important requirement is to be able to predict with a reasonable
degree of confidence the mass flow rate of the bulk material being conveyed
along the trough. This is equal to the product of the bulk density of the
conveyed material, the cross-sectional area of the bulk flow and the average
conveying velocity. The problem thus becomes effectively to predict the
average conveying velocity, and this depends principally upon the amplitude
and frequency of the trough displacements, its slope (if not horizontal), the
VIBRATORY CONVEYORS 361
angle of oscillation and the nature of the bulk solid itself. These aspects will be
considered in some detail in this chapter, following which the main features of
practical vibratory conveying equipment will be briefly discussed. On a first
reading, it may be preferred to turn directly to section 11.3 for a description of
the principal design features.
highest
- - - - position
-r~~ __~______________~~~~TROXH
lowest
- - - position
Figure 11.3 Simple harmoninc motion of the trough, along line inclined at angle f3 to the
horizontal.
Now the horizontal and vertical displacements of the trough at time t can be
written
X T = ).,( 1 - cos 2nft) cos (J (11.6)
and
YT = ),,(1 - cos 2nft) sin {J (11.7)
Also the horizontal and vertical components of the acceleration of the
trough can be written
XT = )"(2nf)Z cos 2nft cos {J (11.8)
and
(11.9)
Now the bulk material being conveyed will lift off the surface ofthe trough at
the moment when the acceleration of the trough, in the downward vertical
direction, becomes equal to the gravitational acceleration g; that is, when
YT = - g (11.10)
The time at which this occurs is then given by
While in flight, the particles will tend to follow a parabolic trajectory to the
next impact point, after which they will be carried forward and upward for a
VIBRATORY CONVEYORS 363
short interval before being thrown again as the trough decelerates. Thus, as the
conveyed bulk solid is transported forward along the trough, the total time of
contact will be very small and the amount of abrasive wear occurring should
be minimal. For the most efficient operation of the conveyor there should be
no backward movement of the particles at any part of the cycle and therefore
the impact point should coincide with the start of the flight phase.
An important parameter in the modelling of vibratory conveyors is
therefore the ratio of the vertical acceleration of the trough to the gravitational
acceleration g, as this will determine the point at which the flight phase begins.
The maximum value of this parameter, which would normally be determined
at the design stage by chosen values of frequency, amplitude and angle of
oscillation, is sometimes called the 'dynamic material coefficient' or 'throw
factor' and given the symbol r.
Thus
r = .h = A(2nf)2 sin f3
m• x
(11.12)
g g
At the start of the flight phase YT/g = - 1, and it follows that, if the positive
value of r is less than unity, the bulk solid will not leave the surface of the
trough and forward movement will be little, if any.
Combining equations (11.11) and (11.12) it is seen that the flight phase
begins at a time t 1 given by
(11.13)
The determination of the time at which the particles re-impact on the surface
of the trough is a little more difficult. Clearly this is where the 'tuning' of the
conveyor becomes important, since for efficient transport the particle
trajectories should be matched to the vibrations of the trough.
Figure 11.4 shows the vertical displacement of the conveying trough with
time and also the variation of the vertical component of the trough
acceleration. Typical flight phases and contact phases are shown, with impact
occurring within the same cycle as the lift-off.
Another essential consideration when selecting the operating condition for
a vibratory conveyor is the relationship between the frequency and the
amplitude of oscillation. In general the higher the frequency, the smaller must
be the amplitude. It is convenient to express this relationship in terms of a ratio
of the maximum trough acceleration to the gravitational acceleration g.
Thus
(11.14)
364 BULK SOLIDS HANDLING
YTmax 2>'sin /3
ft - 2 I I number of
I I cycles
I I
I-
tI - -.. i~act of material
on trough
material lift-off
L~'rl---r-+-----+---+---i----
-<
Figure 11.5 The relationship between amplitude, frequency and dynamic machine coefficient K.
where
K=
sT = __
r
max
(11.15)
9 sin f3
and is termed the 'dynamic machine coefficient' or 'machine number'.
The relationship between amplitude and frequency expressed by
equation (11.14) can be represented graphically by curves of the type shown in
Figure 11.5. Each of these curves corresponds to a different value of the
VIBRATORY CONVEYORS 365
parameter K: in practice vibratory conveyors are usually designed to have K
between 1 and 4, but for vibratory feeders K may be as high as 12, since inertial
effects are less of a problem in the smaller units.
Yp
4
number of cycles
Figure 11.7 Horizontal motion of material in a vibrating trough.
~ 12
r--
I----- 1--
)
II
/
~~
J
o 1
fliglt ratio n
Figure 11.8 Relationship between dynamic material coefficient r and flight ratio n, equation
(11.17).
1.0 3. 0
as
0~~n~1--~
02~-Q3~~n~4~~05
~~Q6
~~n·7
1-'1 tan (J
Figure 11.9 Values of transport efficiency I'/u as a function of dynamic material coefficient r,
drive angle fJ and coefficient of friction ilr [6].
eo 10
f-- r- ~ \ J.
r\ / -
~ /
-
-
"- .t-
i'- ../ L-
V I'- ....... 1-
-=
- ,
K
.........
. . . .V
-
o lD 2.0 3.0
dynarric material coeffOent r
Figure 11.10 Optimum values of drive angle fJ to give greatest transport velocity [2].
order to keep the inertia forces within acceptable limits, vibratory conveyors
are generally operated with r in the range 1.5-2.0. Optimum values of the
drive angle {J, for greatest transport rate, are plotted against the dynamic
material coefficient r in Figure 11.10, from data in [2J, and from this chart it is
seen that {J is likely to be in the range 30° to 50°. The dynamic machine
coefficient K is also plotted on Figure 11.10.
Three empirical multiplying factors which are recommended to modify the
value of transport velocity predicted by equation (11.20) are:
Fm A factor to allow for different material characteristics. Its value needs to be
determined experimentally, but would normally be less than unity for low
load densities and small grain size; 0.8 to 0.9 for heavy, granular, dry
material; 0.1 to 0.8 for material with more than 20% minus 300/lm; 0 for
particle size less than about 60/lm (no transport).
F h Factor to allow for depth of bulk material on trough. Value varies from
unity for small depths to about 0.75 for depths of 300mm.
VIBRATORY CONVEYORS 369
Fj Factor to allow for slope of trough. Value is around unity for horizontal
conveying and upward conveying to about 15°, but decreases rapidly for
steeper slopes. For downward slopes F j is greater than unity, up to about
1.8 for a 15° downward slope. Note, however, that this factor may be much
affected by the friction between the bulk solid and the surface of the
trough.
The transport velocity of the bulk solid along the trough is thus predicted
using the expression
(11.21)
Finally, the solids mass flow rate, or capacity, of a vibrating conveyor can
then be predicted by introducing the cross-sectional area of the bulk material
in the trough and its bulk density.
Thus
(11.22)
material to the trough floor that results from an increase in either of these
effects allows the use of a smaller oscillation angle whilst still achieving
satisfactory forward motion. Naturally, fitting the trough with a high-friction
lining (e.g. rubber) will give an improvement in performance for the same
reason. Furthermore, it may be noted that increasing the depth of the
conveyed material should also result in an increase in friction at the trough
floor and therefore improve the conveying velocity. However, this effect has
not been observed consistently in practice.
(i) Positive mechanical drive. The usual application for this type of drive is on
the longer heavy-duty conveyors where low-frequency high-amplitude oscill-
ation is appropriate. Figure 11.11a illustrates the general arrangement of a
positive-drive vibratory conveyor supported on guide springs. In this case the
VIBRATORY CONVEYORS 371
\
(b) Free-oscillatilg conveyor
Figure 11.12 Vibratory conveyors with rotating eccentric mass mechanical drive.
VIBRATORY CONVEYORS 373
for conveyors and 15-30 Hz for feeders. Unlike the positive-drive types,
eccentric-mass vibrating conveyors do not have a fixed amplitude. Generally
the amplitude would be in the range 1-10 mm but this is very much dependent
upon the load on the trough. Conveying velocities are likely to be somewhat
less than would occur in positive-drive conveyors, while conveying distances
would be much the same for each type.
The growing importance and use of variable-frequency controls which have
proliferated on the commercial market in recent years has had a significant
effect on the application of eccentric mass vibrators. Conveyors and feeders
driven by three-phase ac vibrator motors can now be offered with a variable
speed control which provides an element of adjustment on feed rate whilst the
equipment is operating. Eccentric-mass vibrators are now able to compete on
cost effectiveness with electro-magnetic units for driving large feeders, although
for handling low volumes of bulk materials the electro-magnetic drives are
probably still superior.
(iii) Electro-magnetic drive. This drive mechanism relies on the cyclic energiz-
ation of one or more electromagnets to generate the vibratory motion of the
trough. In most designs there is no contact between the parts of the
electromagnet, one part being mounted on the supporting framework and the
other on the oscillating trough (Figure 11.13).
Electromagnetic drives are generally designed to work from the 50 Hz (or
60 Hz in the USA) alternating current mains supply. Since each cycle has two
impulses the effective operating frequency is 100 Hz (or 120 Hz). Reduction of
the frequency to a minimum of 50% of these values is possible if a half-wave
rectifier or thyristor control is used. Amplitudes tend to be very small (typically
0.1-3 mm) and consequently the conveying velocity is quite slow, rarely being
more than about 0.3 m/s. Whilst electromagnetic excitation oflong conveyors
is possible, particularly when tuned to operate close to the resonant frequency,
the most common application of this type of drive is on short vibratory feeders
(Figure 11.14).
N
374 BULK SOLIDS HANDLING
use of cone pulleys between the motor and the pump unit, allows variation of
the frequency of oscillation of the trough. Also, capacity control of the
conveyor can be readily achieved using manual or automatic pressure control
valves on the pneumatic or hydraulic supply. The applications of this type of
drive are similar to those of electromagnetic drives but it is capable in general
of heavier-duty work.
Average
Approximate Average transport
size bed depth velocity
Material (mm) (mm) (m/s)
from [6], lists typical operating bed depths and transport velocities for some
familiar materials.
Although the 'fundamental' application of vibratory conveying is for the
horizontal (or near-horizontal) movement of particulate or granular bulk
solids, there are many opportunities for variation. Conveying on a downward
slope presents no real problems and conveying on upward slopes of up to
about 15° should also be possible in most cases. Systems with multiple inlets or
outlets can be constructed, in the latter case perhaps having the exit points
controlled by suitable shut-off gates. The outlets may be arranged 'in series'
along the length of the conveyor or alternatively the conveyor may be designed
to split the flow from one inlet point into two or more streams.
Vibratory conveyors are especially amenable to adaptations which allow
some kind of processing operation (such as screening, de-watering, cooling or
drying) to be undertaken while the product is being transported. Where the
product is such that its escape or contamination must be avoided, the trough can
be fitted with a sealed cover. Plastic or stainless-steel troughs are useful where
cleanliness or hygiene is a prime requirement.
Segregation or mixing of the conveyed material can occur in the vibrating
trough, and it is not always immediately predictable which of the effects will
prevail in a given case. Sometimes 'de-mixing' of a previously blended product
in a vibrating conveyor can be a great nuisance, but in other situations this
phenomenon can provide the means of a simple and effective way of removing
contaminants: for example, by skimming off a segregated top layer of
unwanted material. On the other hand, it has been found [8] that instant coffee
and chicory can be blended in a vibrating trough after feeding them separately
to the conveyor. With larger-sized materials manual 'picking' of contaminants
may be convenient because of the continual tumbling movement and relatively
slow forward progress of the product. For the removal of ferrous contami-
nants, some kind of magnetic separation system could easily be devised.
It is a relatively simple matter to combine various screening operations with
vibratory conveying in order, for example, to remove large lumps or to remove
very fine particles. Quite sophisticated classifying devices have been developed
using vibration as the mechanism of forward transport.
Contacting the conveyed product with gas or liquid is also rendered much
simpler by vibrating it in a suitably-designed trough which may have, for
instance, perforated sides or floor. Heating and cooling operations are easily
carried out using hot or cold air, and washing of products is also very straight-
forward in principle.
11.6 Notation
Cross-sectional area
Acceleration
Horizontal component of force
Vertical component of force
Material depth factor, equation (11.21)
Slope factor, equation (11.21)
MaterialOow factor, equation (11.21)
Frequency of vibration
Gravitational acceleration (specific gravitational force)
Dynamic machine coefficient, defined by equation (11.15)
Mass
Mass Oow rate of bulk solid
Flight ratio, defined by equation (11.16)
Linear displacement of trough
Acceleration of trough (= d 2 sT /dt 2 )
Duration of contact phase
Duration of Oight phase
Period of vibration of trough
Time
Start time of particle flight (,lift-off')
End time of particle flight ('impact')
Average conveying velocity
Horizontal displacement of trough
Horizontal component of trough velocity
Vertical displacement of trough
Vertical component of trough acceleration (= d 2 YT/dt 2 )
Angle of oscillation of trough to horizontal
Dynamic material coefficient, defined by equation (11.12)
17u Efficiency of transport, equation (11.20)
VIBRA TORY CONVEYORS 379
Amplitude of vibration
Coefficient of friction between surface of trough and conveyed
bulk solid
Bulk density
Angular acceleration
References
1. Dumbaugh, G.D. An analysis of drive methods for vibrating equipment used in bulk solids
systems. Proc. 10th Powder and Bulk Solids Conf, Chicago, May 1985, 452-470.
2. Oehmen, H.H. (1981) Theory of vibrating conveyors. Bulk Solids Handling 1 (2) 245-254.
3. Ganapathy, S. and Parameswaran, M.A. On the design of the unbalanced mass excited
vibratory conveyor: power requirements and motor selection. Bulk Solids Handling 6 (1) 59-63.
4. Ng, K.L., Ang, L.A. and Chng, S.c. (1982) A computer model for vibrating conveyors. Proc.
Instn Mech. Engrs 200 (B2) 123-130.
5. Gaberson, H.A. (1972) Particle motion on oscillating conveyors. Trans. ASME, J. Engg.for
Industry, February, 50-63.
6. Colijn, H. (1985) Mechanical Conveyors for Bulk Solids. Elsevier, Amsterdam, 265-271.
7. Schofield, R.E. Vibratory conveying of bulk materials. Int. Conf on Bulk Solids Storage,
Handling and Flow, November 1976, Stratford-upon-Avon, UK.
8. Hill, T.J.E. The application and design of vibratory conveyors. Solidex 80 Conf., Harrogate,
March/April 1980, Paper B1.
9. Haneman, S. and Mocha, H.K. (1978) Vibration has wide range of practical uses. Bulk Storage
Movement Control, May/June 1978, 101-103.
gas n
(usuaRy at) In
solids gas/soids
disengagO-lg device
bl=====IOI==~I!::::==::::l
blower Of l~devJ::e
COfIl)r8SSOf
soidS out
Figure 12.1 The elements of a pneumatic conveying system.
BASIC PNEUMA TIC CONVEYING SYSTEMS 381
fan-driven vacuum systems, mostly used for handling sawdust and grain, and
it was the beginning of the 20th century before positive pressure systems were
much used. Conveying velocities were relatively high, with the particles carried
in suspension at low concentration-the so-called 'dilute phase' mode of
transport. Gradually the technology of pneumatic conveying was developed,
starting perhaps from the need to separate the conveyed product from the air
stream, in cyclones and filters, and then extending to the problem of
introducing the bulk solid into the conveying line against an adverse pressure
gradient (hence, the rotary feeder and, later, the screw pump). In the 1920s it
began to be recognized that by introducing a small amount of air into fine
particulate materials they could be made to exhibit some of the characteristics
ofliquids, including the ability to 'flow' freely. Interest in this phenomenon of
'fluidization' no doubt helped the designers of pneumatic conveying systems to
realize that they were not restricted to the mode of transport in which the
individual particles are carried in suspension at high velocity, and so 'dense-
phase' conveying became established as an alternative, with a high proportion
of the particles effectively sliding on the lower surface of the pipe.
Although the movement of solid particles by air through pipelines has thus
been established practice for over half a century, this method of transportation
is being 'rediscovered' because of its suitability for modern industrial processes
and the economics of handling in bulk. Pneumatic conveying of particulate
and granular materials is now commonplace in many industries, such as the
pharmaceutical, food, chemical, glass, cement, plastics, mining and metal, and
normally provides for storage, transport, recovery and metering of the
products. Indeed it would be difficult to envisage how the everyday handling of
products such as plastics, flour and sugar during in-plant distribution could be
cost-effective without pneumatic conveyors.
The difficulties encountered when designing or selecting a pneumatic
conveyor to meet a particular need are normally due to:
(i) The wide range of pneumatic conveying systems which are available
(ii) Variation in the product, caused by conveying or by a change in the
process or original source of the product
(iii) The inability of manufacturers to specify a system based upon product
characteristics, frequently resulting in a dependence on dubious empirical
correlations
(iv) The need to know whether or not the product is explosive, toxic, abrasive,
friable, hygroscopic, fine or granular, since a small change in a product's
characteristics can affect considerably the convey ability of the product
(v) The gas-solid flow in a pipeline being extremely complex and each
product having its own unique flow characteristics.
Nevertheless, across the world, the number of manufacturers of pneumatic
conveying systems has, in recent years, risen substantially, and installations
are becoming increasingly complex (Fig. 12.2).
382 BULK SOLIDS HANDLING
Figure 12.2 A pneumatic conveying system for handling PVC resins, showing the complexity
and flexibility of modern installations. (Photo Courtesy Neu Engineering Ltd.)
Table 12.1 Comparative analysis of pneumatic conveying and other forms of bulk solids
transport.
fan or
blower
receiving hopper
_
:. ~ .
~
~-~
~.. ~ • . • ~\C ~
air
picking up, at a feed point, the bulk solid to be conveyed and discharging it
finally into a receiving hopper (Figure 12.3). These systems generally use fans
or blowers which normally have a maximum pressure of under one bar
(14.5Ibf/in 2 ). Basically, the air is delivered from the fan or blower into the
pipeline; the material is fed into this pipeline from the bottom of a storage
hopper or silo and is then conveyed in suspension with the air along the
pipeline to the discharge point; this is usually another hopper or silo, and from
here the material can be gravity-discharged for use. This introduces two
fundamental problems: how to get the material into the conveying air stream,
and how to separate the material from the air at the end. The necessary two
plant items will be introduced here briefly to help provide a basic understand-
ing of the complete conveying system.
The first of these problems, that is, introducing the material into the
pipeline, arises because the conveying gas is under pressure, and so the feeding
device has to cater for this. A number of pipeline feeding systems which will
satisfactorily transfer material from a hopper into a pipeline under these
conditions are shown in Figure 12.4. All three devices shown are capable of
feeding at a controlled rate, and they are all capable of continuous operation,
since the top of the supply hopper can be open to the atmosphere in each case.
For feeding against pressures in excess of one bar the rotary feeder is generally
unsuitable, and alternatives are the screw pump which is capable of working at
pressures up to about 2.5 bar (36Ibf/ in 2 ) and, for higher pressures, the various
types of blow tank. Blow tank systems are discussed in section 12.4 and all of
the feeders mentioned above are described in more detail in Chapter 13.
Separation of the conveyed bulk solid from the conveying air stream at the
388 BULK SOLIDS HANDLING
<W/~~
. tar
.-'•.1
-,
solids
Overter valves
conveying ina
storage
silo or
hopper
Figure 12.6 A typical positive-pressure system showing delivery of bulk solid from one point to
several receiving hoppers.
discharge end of the pipeline is usually achieved with the aid of a cyclone
separator or bag filter unit (Figure 12.5) and these devices are also mentioned
in Chapter 13, but described fully in Chapter 5.
Low-pressure pneumatic conveying systems can handle a wide range of
pulverized, granular and fibrous materials. They can be readily adapted and
extended to provide an economical and flexible installation in which a bulk
solid, picked up at one point, can be directed to anyone of a number of
receiving hoppers using pipe switches or diverter valves. A typical plant layout
is illustrated in Figure 12.6. In general, a positive-pressure system is not
suitable for multiple pick-up points because the air leakage through several
rotary valves can be quite high in relation to the total air requirement for
conveying.
There are a number of precautions to be taken in the design and operation of
any pneumatic conveying system and it is convenient to classify these under
the following key areas:
BASIC PNEUMA TIC CONVEYING SYSTEMS 389
storage
hoppa"
liter lrit
1111111
solids
outlet
vacuum t:I:l
conveying ~ II In ~
n
"C
suction nozzle Z
~
s:::
>
\ ::l
(")
;:·(~~~~:::i,~.
"<\,,,', '''''''\" ~
;;;
feed ~
hopper Z
receivi"g o
hopperS
i1t~orage ~
~ ~
~
VJ
\0
392 BULK SOLIDS HANDLING
storage
I"(Q)6r
Figure 12.10 High-pressure pneumatic conveying system using a blow tank feeder.
tine -
Figure 12.11 Single blow tank cycling.
state, conveying rate and so the system designer will endeavour to ensure that
the ratio of the time-averaged mean flow rate to the steady-state value is as
high as possible.
The system illustrated in Figure 12.10 incorporates a valve at the start of the
conveying line, and this arrangement permits rapid pressurizing of the blow
tank with a consequent increase in the time-average flow rate relative to the
steady-state value. However, this valve inevitably is subjected to harsh service
and it is common practice to omit it, so allowing the blow tank to begin
discharging automatically, as soon as the necessary pressure has been reached.
Figure 12.12 shows a typical operating cycle from which it is seen that after the
product begins to enter the conveying line there will be a short time interval
before steady-state conveying is achieved. Then, towards the end of the
conveying cycle, when the batch of product has almost been discharged, the
blow tank has to be de-pressurized and the entire conveying line has to be
cleared of product and vented. This process also takes a significant interval of
time and, when the time required to fill the blow tank and set the valves is taken
BASIC PNEUMATIC CONVEYING SYSTEMS 395
,
bIowi"Jg cycle
20
---- --
G>
16
.;
iii
j~ 12 ~ .2'
.~
'"~ &l
.~ ~
~~
t
>
8 >
f~ 4
~ ~ 1ii
'" B
0
0 2 3 4 5
tine Crrrutesl
Figure 12.12 A typical operating cycle for a single blow tank without a discharge valve .
blow lank
ar &'poly
conveyng ina
.....,. ~ ..
into account, it is apparent that there is a considerable period during which the
system is not actively conveying.
Another approach to pneumatic conveying with a single blow tank is
illustrated in Figure 12.13. In this system the whole charge of material in the
blow tank is pushed into the conveying line as a single plug under the influence
of air introduced to the top of the vessel at high pressure. This pressure has to
overcome the frictional resistance of the plug of material in the pipeline, which
places a limit on the length of the plug and therefore on the quantity of material
in each batch fed into the blow tank. For example, a typical plug in a 150 mm-
diameter pipe would be about 15 m long. This gives a plug volume of about
396 BULK SOLIDS HANDLING
0.27 m 3 , and for a bulk solid having a density of 1600 kgim 3 would represent
about 430 kg of product.
It should be noted that conventional blow tank and conveying line
characteristics do not apply to the 'single plug' type of system, the operating
sequence of which is shown in Figure 12.13, and the bulk solids flow rate is
very much dependent upon the velocity of the plug and, particularly, the
length of the conveying line. The velocity of the plug is usually quite low,
typically around 3 mis, but problems can arise on discharge as the high-
pressure air released behind the plug can cause severe erosion on venting.
-
Typical operalilg ~
II cischarge
pressuize
charge (:
CNf!K vent
cischarge fll
preswize
c:t1arg3 ~ one cycle
~ vS'l\
II dscta"ge
pres&lize
cI"erge (:
CNf!K vent
dscharge II
Figure 12.14 Parallel arrangement of blow tanks and typical operating sequence.
BASIC PNEUMA TIC CONVEYING SYSTEMS 397
presSU'e balance
and vent hi
batch operation of single blow tanks. There are two basic configurations of
twin blow tank -arranged in parallel and in series.
With the parallel configuration (Figure 12.14) one blow tank can be de-
pressurized, filled and brought up to working pressure again while the other is
being discharged. By this means almost continuous conveying can be achieved
through a common pipeline, so that the ratio of the time-average flow rate to
the steady-state value approaches unity.
The alternative arrangement with the two blow tanks in series, vertically in
line beneath a supply hopper, is shown in Figure 12.15. It is possible with this
system to use a high-pressure air supply for the continuous conveying of a
product. The transfer pressure vessel, rather than the main blow tank, cycles
between the conveying pressure and atmosphere and thus allows the main
blow tank to be kept topped up in order to maintain a continuous flow of
product to the conveying line. Automatic sequencing of the valves is controlled
so that when the bulk solid in the main blow tank falls to a predetermined low
level the transfer pressure vessel is vented and then filled from the supply
hopper. The vent line is then closed and the transfer pressure vessel is
pressurized, either by means of a pressure balance line from the blow tank, or
with a direct line from the main air supply. Once the pressure in these two
vessels is balanced, the connecting valve is opened so that the product level in
the blow tank is restored.
It is an important feature of the system illustrated in Figure 12.15 that there
is virtually no pressure difference between the lower pressure vessel and the
conveying line. Thus, the feeding device can be a rotary valve or a screw feeder,
as shown in Figure 12.16.
A particular application of these systems is for the direct injection of
pulverized coal (DIPC) into boilers and furnaces since the product often has to
398 BULK SOLIDS HANDLING
1181\ lire
_ prodJct feed
vessel
conveyi1g r.e
Figure 12.16 A twin blow tank system with screw feeding.
50
'Ul
S
100
'mOl
.~ 125
~ 10
150
200
250
0 2 3 4 5
ai' preSSU'e (bar gauge)
Figure 12.17 The variation of air velocity with pressure in a stepped pipeline (for a flow rate of
60m 3 /min).
that, if the air expands from 4 bar gauge to atmospheric pressure, it will be
necessary to increase the pipe diameter in two steps from an initial size of
125 mm in order to keep the velocity within a range appropriate for dilute-
phase conveying (that is, 15-30m/s).
The decision on where to step the conveying line is an interesting one that
has exercised both manufacturers and research workers. Whilst the first
criterion is to keep the transport velocity within acceptable limits, there might
also be some latitude which allows the overall system pressure-drop to be kept
to a minimum. However, as yet there appears to be no recognized procedure
for optimally designing a stepped-pipeline conveying system.
described here may not all be still commercially available, but are included for
interest. Certainly some of these systems, although quite complicated and
consequently expensive, have proved to be remarkably successful in transport-
ing 'difficult' products that would be impossible to handle in more conven-
tional pneumatic conveying systems.
Before describing the various low-velocity conveying systems it is worth-
while to attempt to explain the manner in which plugs of particulate or granular
material move along a pipe. Figure 12.18 illustrates the relationship, con-
firmed by experiment, between the length of a plug of material and the force
required to push it 'mechanically' through a pipe. This shows the reason why
bulk solids cannot be 'pumped' through a pipeline in a single-phase mode in
the manner of a liquid: the pressures involved would be prohibitively high. In
order to transport bulk solids in a similar mode the wall friction effects must be
drastically reduced, and it is in this respect that using compressed air as the
motive force plays a vital role. The effect of the air expanding through the
interestices aerates the product so as to reduce the friction between the
particles and the pipe wall, so that the relationship between the length of a plug
of material and the force required to move it perhaps corresponds to the lower
curve on Figure 12.18. There will still be a practical limit on the length of plug
that can be 'pushed', as mentioned when discussing the so-called 'single-plug'
blow tank systems, and with some materials there may be a critical length of
plug, above which the plug becomes immovable as a result of the frictional
resistance at the pipe wall increasing at a greater rate than the propulsive force.
Figure 12.18 Pressure required to maintain movement of a plug of bulk solid in a pipe.
BASIC PNEUMA TIC CONVEYING SYSTEMS 401
Figure 12.19 Relationships between pressure and plug length for continuous and in,termittent
dense phase conveying.
. krife
proOJc1
r;:::x.se..!===;-.- air
air etSi:ns
Figure 12.21 The Buhler 'Takt-Schub' system.
on&Way vaJve
location 01 bbckage
/pres&re i1 byi)ass me v.tist
bIod<.age i1 ~ r.e
isfoori1g
shown in Figure 12.22. During normal conveying the pressure in the main
conveying line will be almost equal to that in the external by-pass line that runs
parallel to it from the blow tank. This results in a small steady flow of air
(some 5-10%) through the by-pass line, but if a plug forms in the conveying
line the situation changes, the pressure on the upstream side of the plug being
greater in the conveying line than in the by-pass line, whilst on the downstream
side ofthe plug the pressures are reversed. This makes it possible for air to flow
from the by-pass line into the conveying line through a series of one-way
valves, but additional valves, connected to special pressure sensors, ensure
that the air is injected only in the vicinity of the plug itself. After the plug has
dispersed, pressures return to their normal levels and steady flow is re-
established in the main conveying line and the by-pass line.
Although the Pneumosplit system is expensive, with between two and ten
one-way valves, typically five to ten pipe diameters apart, fitted between any
two pressure sensors, it has been shown to be capable of successfully conveying
BASIC PNEUMA TIC CONVEYING SYSTEMS 405
_ _ bIowtark
p
406 BULK SOLIDS HANDLING
futed oozzles
conveying 1i1e
into the forward end of the plug, thus causing it to be grAdually cleared. The
'Turbuflow' system (Figure 12.25) is very similar, but is claimed to work by
constantly restoring the turbulence of the conveyed bulk material as it moves
along the pipeline [7].
The Semco 'Trace-Air' and the Dynamic-Air systems both use a series of
'boosters' to inject additional air at intervals along the conveying line. These
BASIC PNEUMATIC CONVEYING SYSTEMS 407
boosters, which are generally set to admit air only when required, may be
located at equal intervals along the pipeline or may be placed at strategic
positions only, for example just after pipe bends. It should be noted that, unlike
the various forms of by-pass system, these boosters add air to the conveying line
and therefore increase the conveying velocity.
References
1. Dixon, G. Pneumatic conveying, in Plastics Pneumatic Conveying and Bulk Storage, ed. G.
Butters, Applied Science Publishers. 1981.
2. Marcus, R.D. and Rizk, F. The reliability of long distance pneumatic transport. Conf on
Reliable Flow of Particulate Solids, CMI, Bergen, August 1985.
3. Mainwaring, N.J. and Reed, A.R. Mechanisms for gas-solids flows at low velocity in pneumatic
conveying pipelines. Proc. 11th Powder and Bulk Solids Conf, Chicago, May 1986.
4. Hitt, R.J., Reed, A.R. and Mason, lS. The effect of spontaneous plug formation in dense-phase
pneumatic conveying. Proc. 7th Int. Powder and Bulk Solids Conf, Chicago, May 1982.
5. Krambrock, W. and Parekh, S. Pneumatic conveying of poor flowing abrasive or fragile bulk
materials. Proc. Pneumotransport 5, BHRA Conf., London, April 1980,419-442.
6. Maire, U. Low velocity pneumatic conveying of carbon black. Paper presented to Rubber
Division Meeting, Am. Chern. Soc., May 1984.
7. Moller, H., Pust, J. and Lubble, T. Turbuflow: a pneumatic conveying system with economical
power consumption. Bulk Solids Handling 5 (4) (August 1985) 789-794.
13.1 Introduction
In Chapter 12 the various types of pneumatic conveying system were
discussed, and attention is now turned to the components that go to make up
these different systems. In addition to the conveying line itself, which would
normally be of steel but may be alternatively of aluminium, plastic, glass or
rubber, the essential components of a pneumatic conveying system are the air
mover (for example, fan, blower, compressor or vacuum pump), the feeding
device, and the gas/solids disengaging device. In order to design and construct
a reliable and economic pneumatic conveyor it is essential to have a good
awareness of the different types of air-mover, feeder and disengaging unit that
are available, their advantages and disadvantages, and the criteria for their
selection. In this chapter the various designs of each of these components
commonly used in practical pneumatic conveying installations are described
and illustrated.
s'"
Q)
5-
1='
Q)
>
~
independent of the discharge pressure, are less likely to cause this type of
system failure.
Single-stage fans capable of delivering air at a reasonable pressure tend to be
rather large in diameter and pneumatic conveying applications therefore often
involve the use of smaller multistage machines. However, these machines are
still sensitive to fluctuations in back pressure and, except for very dilute, low-
Figure 13.2 A cutaway view of a typical regenerative blower (photo courtesy of Com pAir-
Reavell Ltd).
COMPONENTS OF PNEUMA TIC CONVEYING SYSTEMS 411
pressure conveying, the current trend is towards positive displacement Roots-
type blowers for all normal pneumatic conveying applications involving
pressures up to about one bar gauge.
Fans may be used on both positive and negative pressure systems and also
on combined 'suck-blow' systems where, with light or fluffy materials, it is
sometimes possible even to convey through the fan itself.
For relatively low-pressure duties there may well be advantages in small
regenerative compressors that have recently become commercially available
(Figure 13.2). Although the efficiency ofthese machines tends to be rather low,
they do possess a characteristic more akin to that of a positive displacement
machine in that they do not display the very sharp fall in flow rate in response
to a rise in back pressure. A beneficial feature claimed for these blowers is that
they are less sensitive than Roots-type or sliding vane machines to erosive
wear from dust-laden air.
The multistage axial flow type of machine is manufactured only in larger
sizes, producing extremely high flow rates that are rarely, if ever, appropriate
for pneumatic conveying applications.
~'"
operating principle
higher pressure than the Roots blower, and a single-stage machine is capable
of delivering more than 50m 3/min of air at a maximum pressure of around
4 bar. Significantly higher operating pressures may be obtained from two-
stage machines. Oil-injection also permits higher working pressures (upto 10
bar), but this type of machine is generally not available in capacities greater
than about 6m 3 /min.
Figure 13.5a illustrates the operating principle of a simple sliding-vane
compressor. It should be noted that some form of cooling is essential, since
quite high temperatures can be reached as a result of the combined effect of the
vanes rubbing against the casing and the compression of the air between the
rotor and the casing. The cooling may be by water circulated through an
external jacket or by injection of oil directly into the air-stream just after the
beginning of compression (Figure 13.5b). As mentioned previously, the latter
method does permit higher working pressures, but an efficient oil separation
system adds to the cost of the plant.
Figure 13.4 An example of an industrial Roots-type blower (cutaway view courtesy of Peabody
Holmes Ltd).
oi separator
discharge port
Figure 13.6 Helical lobe rotary compressor (Lysholm screw). Diagrammatic view showing male
and female meshing rotors.
now at minimum volume, is released into the discharge line. Note that like the
sliding-vane compressor, but unlike the Roots blower, compression of the air
takes place within the machine, the compression ratio being fixed by the design
of the rotors and the position of the inlet and discharge ports.
An interesting variant of the machine described above is the Zimmern
monoscrew type which is capable of operating at somewhat higher pressures.
The single rotor may be in the form of a cylinder or a disc cut with helical or
spiral grooves in which mesh the blades of two or more gate wheels. Air
entering the grooves as the rotor turns is trapped by the gate wheels and
compressed, eventually being released through an uncovered discharge port.
Although better known in refrigeration applications, the Zimmern monoscrew
has been produced as an air compressor.
Lysholm-type screw compressors are manufactured with capabilities
ranging from as little as 1 m3/min up to more than lOOm 3/min and, with oil-
injection, can develop maximum pressures of around 13 bar. As with oil-
injected sliding vane machines, it is essential to remove the oil from the
compressed air and with large compressors the injection, separation and
filtration equipment represents a substantial proportion of the plant cost.
Nevertheless, commercially available screw compressor packages are now
competing strongly with reciprocating machines at the high-pressure end of
the pneumatic conveying market. Figure 13.7 illustrates a typical air-
processing package consisting of screw compressor and motor, air and oil
filters, oil separator and after-coolers.
Figure 13.7 Typical screw compressor plant. Layout diagram to show oil injection/separation
system and ancillary components.
Figure 13.8 A reciprocating compressor suitable for pneumatic conveying applications (photo
courtesy of CompAir-Reavell Ltd).
416 BULK SOLIDS HANDLING
suction port
Figure 13.9 A liquid ring vacuum pump. Diagrammatic view of a typical pump showing the
principle of operation.
COMPONENTS OF PNEUMA TIC CONVEYING SYSTEMS 417
liquid ring also performs the useful functions of cooling the compressed air and
washing out small quantities of entrained dust.
prodJct leed
aIr + p.-oducl
discharged and entrained into the conveying line. The ability to feed against an
adverse pressure gradient is achieved by allowing a flow of air (leakage) to take
place through the rotor casing clearance on both the product feed and empty
return pocket sides of the rotor.
The most commonly used design of rotary valve is the 'drop-through'
pattern in which the bulk solid being handled (which should be reasonably
free-flowing) is metered through the rotating valve and falls into a separate
entrainment section beneath. This entrainment section may be nothing more
than a simple 'drop-out' box (Figure 13.11a), but an alternative configuration
that seems to be gaining in popularity is the venturi entrainment section
(Figure 13.11b). In the latter case, the reduced cross-section results in a higher
entrainment velocity and a lower pressure in this region, with a consequent
decrease in the air leakage back through the rotary valve. The net result is a
significant improvement when handling the finer, free-flowing types of bulk
solid.
A variation on the standard pattern of feeder, intended primarily for
handling granular and pelletized materials, where shearing of the product is to
be avoided, is the offset rotary valve (Figure 13.12). This is designed, usually
with a controlled supply of solids, so that the rotor pockets do not become full
and therefore the chance of material becoming nipped between the rotating
air---::Jc:::=t:==r;;air;-:.:-;p:;;;'rOduct
blades and the valve body is virtually eliminated. Another variation, intended
primarily for use with more cohesive materials that might tend to 'hang up' in a
standard pattern of rotary feeder, is the 'blow-through' valve (Figure 13.13). In
this device the conveying air passes through the rotor and purges the
discharging pockets, entrainment of product thus occurring actually within
the valve. Figure 13.14 illustrates some examples of modern, commercially
available rotary valves.
Before discussing the problems with and limitations of rotary valves it is
beneficial to have an understanding of how they work. The most simple
concept of the way in which these devices work is that the rotor pockets fill
completely with material fed to them by the supply hopper. Under such
circumstances the product mass flow rate rhs for any rotor speed N is given by
the simple equation
rhs = Pb VnN (13.1)
This equation represents the maximum possible throughput of a valve and is a
measurable quantity since the volume of one rotor pocket is denoted by V, n is
the number of rotor pockets and Pb is a characteristic bulk density of the
product being handled, which experience has shown may be approximated by
the 'poured' value obtained from static tests. This equation suggests that the
feed rate depends only on the rotor speed, as shown by the straight line in
Figure 13.15. However, when feeding a conveying line, the air leakage through
the valve can impede the product flow into the rotor pockets and thereby
reduce the feed rate. In extreme cases this can be a value much lower than that
predicted by equation (13.1). Since it is evident that both the rotor casing
clearances and system pressure affect the leakage, the feed rate depends in
some way on (i) the product being handled, (ii) the rotor speed, (iii) the rotor
casing clearances, and (iv) the system pressure. Consequently, valve perfor-
mance is more likely to take the form of one of the curves shown in
Figure 13.15. Unfortunately, there is little data available in manufacturers'
420 BULK SOLIDS HANDLING
Figure 13.14 Examples of modern commercially· available rotary valves. (Top) Drop-through
pattern; (Bottom) blow-through pattern. (Photos courtesy of Rota Val Ltd.)
COMPONENTS OF PNEUMA TIC CONVEYING SYSTEMS 421
dependent on product,
rotor clearances and
system pressure
rotor speed -
Figure 13,15 Typical feed rate characteristics.
literature on the effect of these operational variables on feed rate, and so the
sizing of valves for a particular application has been, until recently, a matter of
experience and good judgement.
A second problem with rotary valves concerns the extent of the air leakage
itself. As previously discussed, this will principally depend upon the system
pressure, rotor clearances and the product being handled. Figure 13.16 shows
a typical relationship between system pressure and leakage rate for various
rotor clearances. A lack of knowledge about this leakage at the design stage of
such systems can obviously lead to fans and blowers being incorrectly sized.
When a blower is oversized, the conveying velocity of the solids is increased
and, if the conveyed product is abrasive, this increased velocity may cause
rapid wear and premature failure of pipe bends and fittings. If the product is
friable, the increased velocity may cause excessive product degradation.
Conversely, with an undersized compressor the air velocity may not be
sufficient to hold the solids in suspension, resulting in the possibility of a
blocked pipeline.
For the reasons outlined here, rotary valves are not generally used to feed
from atmosphere into systems which have a pressure above about 0.8 bar
gauge, since the leakage, with its attendant problems, can become excessive at
pressures greater than this. If the undesirable effects described above are to be
minimized, reliable information on the valve performance is required when the
422 BULK SOLIDS HANDLING
pressure gradient _ _
Figure 13.16 Typical leakage rate characteristics.
/ /
/
open-ended
/
~
dosed-end (shrouded) angled blades (for
gartJar proc:1Jcts)
rotors are less expensive they have several disadvantages. With more abrasive
materials, wear of the rotor housing end plates is possible since the product is
in constant contact with them. Also, they are not as rigid as the closed-end type
since they have only one edge secured to the drive shaft. The closed-end type
are more rigid and can be used with abrasive materials. However, they cannot
be used in the blow-through types of feeders shown in Figure 13.13.
There are basically two rotor pocket configurations in widespread use, and
these are shown in Figure 13.17b. The most common is the type which has
deep pockets and therefore maximum volumetric displacement. It is more
suited to handling free-flowing products. The rotor with shallow, rounded
pockets has a somewhat smaller volumetric displacement, but this configur-
ation has been successfully used with the more cohesive types of product that
could tend to stick in deeper pockets. With abrasive products there may be
some advantage in fitting the blades with replaceable tips.
As air from the conveying line leaks through the valve, each rotor blade in
close proximity to the casing produces a drop in pressure in the direction ofthe
pressure gradient. Consequently, a method of reducing the leakage is to
increase the number of rotor blades. Obviously, there is a practical limit to the
number of blades that can be used in a rotor when handling a given product.
This constraint is largely dependent on the product itself, since increasing the
number of blades decreases the angle between them, and this is sufficient with
some products to prevent them from being discharged when presented to the
424 BULK SOLIDS HANDLING
outlet port. It is for this reason that the number of rotor blades is optimized
at between eight and ten on most commercially available valves.
The rotor clearances can have a significant effect on valve performance and,
in an attempt to minimize the effect of the leakage on the feed rate,
manufacturers make these clearances as small as possible. Clearances on new
valves are typically 0.075- 0.15 mm, since clearances smaller than this would
add considerably to the cost of manufacture and may even lead to the rotor
binding in the housing due to deflection ofthe rotor and movement within the
bearings when subject to the applied pressure gradient. Some manufacturers
fit flexible elastomer/polymer wipers to the rotor blades so that they are in
contact with the housing (Figure 13.17b). However, this approach is generally
limited to low-pressure applications (less than 0.25 bar gauge) since the
leakage at pressure gradients greater than this can deflect the wipers and so
lose the advantages.
A technique which has been developed by manufacturers and users of rotary
valves as a practical solution to the problem of air leakage is 'venting'. This
involves the provision of an alternative means of escape for the leaking air, so
that it does not impede pocket filling. This is normally achieved by the
provision of vent holes in the valve casing on the empty pocket return side of
the rotor cycle, as shown in Figure 13.18. However, opinion is divided on the
effectiveness of the technique. Some manufacturers strongly recommend its
use in all situations where valves feed against pressure gradients. Others argue
product teed
~I/'
fr
vented air
product
arx1ar
out
prodJct
and ar
out
__. /<:
pro<iJct feed
-~tl
air
'C~<J));:,~'~: prodJct
this way the air leakage from the conveying line to the supply hopper is almost
eliminated and the product can flow more readily under gravity into the line.
In order that a sufficiently low pressure is maintained at the feed point
without the cross-sectional area becoming too small, the total pressure-drop
through the conveying line must be kept quite low. For this reason the use of
venturi feeders is usually restricted to applications where a free-flowing
product is to be conveyed at low flow rates over short distances. A further
constraint on the use of this type of feeder results from the high velocities that
are reached in the throat section since serious erosion can occur in this region
when abrasive products are being handled. Finally, it should be noted that the
flow of product to the venturi feeder must be controlled by an appropriate
metering device, such as a screw-feeder or belt-feeder, if blockage of the throat
is to be avoided.
not interfere with the product about to flow through the upper gate. As with
rotary valves, the blower or compressor should be sized to allow for this
leakage. Like the venturi feeder, care must be taken to ensure that the product
is metered into the gate lock since it will cease to function correctly if it
operates under a head of material, as would be the case if it was situated
directly beneath the outlet of the supply hopper.
To a certain degree the gate lock might be termed an intermittent feeder
since it discharges material between five to ten times a minute. In contrast, the
rotary valve has up to approximately 250 discharges per minute from its
pocketed rotor. This reduction in the number of discharges obviously means a
higher volume per discharge when comparable rates are handled. This can, in
turn, lead to a blockage in the entrainment region if the pipeline is not correctly
sized. This type offeeder has been used successfully with system pressures up to
0.4 bar gauge, and with appropriate materials of construction it is suited to
handling both pulverized and granular abrasive products.
air. product
air· product
Figure 13.24 Various blow-tank configurations showing aeration of the product to aid
discharge.
430 BULK SOLIDS HANDLING
1.0
o.g/\
total air flow rate
0.8
Q) 0.7
'§
X
0.6
~
0
'"
~
S
.0
I
~
through the suction tube at all times, and to avoid filling the tube solidly with
the bulk material.
Many different types of suction nozzle have been developed over the years
but probably the most common pattern is that consisting of two tubes
arranged co-axially as shown in Figure 13.28. The annular passage between
the tubes permits the air induced into the nozzle by the exhauster to entrain
particles into the flow entering the inner tube. Recent research [3] has
demonstrated that the relative positions of the ends of the inner and outer
tubes can have a significant influence on the effectiveness of the suction nozzle,
COMPONENTS OF PNEUMA TIC CONVEYING SYSTEMS 433
Cal Inner tube retracted Cbl Air flow throttled on Ccl Inner tube extended
within outer tube inlet to annulus beyond outer tube
Figure 13.28 Co-axial tube suction nozzle showing typical modes of operation.
and therefore on the overall performance of the vacuum system, for a wide
range of different bulk solids. In order to achieve the highest practical solids
flow rates for any given air flow rate it is generally necessary that the inner tube
of the nozzle should project beyond the outer tube, as illustrated in
Figure 13.28c. The amount of the extension for optimum performance appears
to depend upon the nature of the bulk solid being handled: up to about 25 mm
gives good results with a 50 mm-diameter suction tube but more than this is
likely to result in the tube becoming blocked.
.j:>.
w
VI
436 BULK SOLIDS HANDLING
13.6 Notation
ms Solids mass flow rate
N Rotational speed (revolutions/second)
n Number of rotor pockets
V Volume of rotor pocket
Pb Bulk density
References
1. Reed, A.R. and Mason, J.S. Estimating air leakage through rotary valves. Bulk-Storage,
Movement, Control 3(3), (January/February 1977).
2. Reed, A.R. Estimating feed rates of rotary valves. Solids Handling 1(6) (November/December
1979).
COMPONENTS OF PNEUMATIC CONVEYING SYSTEMS 437
3. Reed, A.R. and Mason, I.S. The effect of suction nozzle design on the performance of vacuum
pneumatic conveying systems. J. Powder and Bulk Solids Technol. 7(4) (1983) 9-14.
4. Dixon, G. Pneumatic conveying. In Plastics Pneumatic Conveying and Bulk Storage, ed. G.
Butters, Applied Science Publishers, 1981.
Q
14 Pneumatic conveyor design
14.1 Introduction
In the two preceding chapters discussion has been restricted to general details
of the arrangements of pneumatic conveying systems and their components. It
is necessary now to give some more positive pointers to successful pneumatic
conveyor design.
It is probably still true to say that in industry pneumatic conveying of bulk
solids is widely regarded as something of an art. The specification of systems
and the selection of components tends to rely heavily upon the judgement
and practical experience of engineers who are familiar with the subject, and the
relatively small (but increasing) number of companies that specialize in the
manufacture and installation of pneumatic conveyors guard jealously the
knowledge that they accumulate.
Whatever the type of pneumatic conveying system to be installed, the design
decisions must centre upon the pipeline diameter and the size (and power) of
the air mover required. Amongst the many other design decisions to be made,
probably the most important concern the method offeeding the bulk solid into
the pipeline and the type and size of disengaging device to be used.
It is possible to find in the published literature many suggested approaches
towards the design of pneumatic conveyors, but none of these provides a single
reliable method for designing a complete system from a knowledge only of the
properties of the bulk solid to be conveyed. Certainly there has been, in recent
years, an improved understanding of the characteristics of gas/solids flow in
horizontal and vertical pipelines. There have even been papers reporting
specifically on the influence of bends and fittings. It is beyond the scope of this
book, however, to attempt a review of the different design methods available
and attention here is restricted to a discussion of some aspects of a design
approach that will enable a specification to be drawn up for a given
application with reasonable confidence.
In general, the designer would be presented with information on the
material to be transported, the mass flow rate required, the rough layout ofthe
conveying system and, possibly, the type of system (that is, positive-pressure or
vacuum, dilute- or dense-phase, and so on). The first design decisions then
concern the conveying velocity, the solids loading ratio (that is, the ratio of the
mass flow rate of conveyed solids to the mass flow rate of conveying air) the
diameter of the pipeline and the pressure-drop through the system, leading to
the specification of the air mover in terms of flow rate and delivery pressure.
The application and reliability of mathematical models is somewhat limited
PNEUMA TIC CONVEYOR DESIGN 439
in the field of pneumatic conveying. As explained in Chapter 3, many
proposals have appeared in the technical literature for the modelling of
gas/solids flows in dilute phase, and even some for dense phase. However, none
of these has become accepted as sufficiently reliable for the confident design of
pneumatic conveying systems. In the case of dilute-phase flow, since the solid
particles are uniformly distributed within the gas stream, it seems reasonable
to suppose that a simple analytical approach might allow the relationship
between solids flow rate, gas flow rate and pipe size to be predicted with
sufficient confidence to enable a preliminary design of the system to be
undertaken. For dense-phase flow, the mechanism by which the solid particles
progress along the pipeline is so complex that there seems to be little chance
that any 'first-principles' modelling approach will really be useful.
In order to design a pneumatic conveying system with confidence there is
generally no alternative but to rely upon available test data for the bulk solid
concerned. Frequently this data can be derived from previous experience with
the same product, but if the product is a 'new' one and no information is
available on its handling characteristics in a pneumatic conveying system,
appropriate trials will have to be carried out in a pilot plant. Naturally the
design engineer must make a decision on how closely the test data should
parallel the actual installation that is to be designed. The extreme case of a full-
scale 'mock-up' in which the actual bulk solid is tested might occasionally be
justified, but usually the trials would be undertaken in a test rig that is smaller
(either in terms of pipe size, or conveying distance, or both) and the results
scaled appropriately. It is always good policy to test the actual bulk solid
concerned, as even small differences in the physical properties of a material can
cause major differences in handling characteristics. An expensive mistake
could be made if, for example, a system successfully conveying cement is used
as the basis for designing one to handle, say, fertilizer.
In this chapter a general design procedure will first be outlined and then
more detailed consideration will be given to the determination of the
'conveying characteristics' of a bulk solid and the application of this data
within the design process. It should perhaps be emphasized at this point that it
is not the intention of the authors to set out here a definitive procedure for the
design of pneumatic conveying systems: for one reason, we do not have enough
pages available! However, it is hoped that there is sufficient detail in the
following discussion for it to be interesting, useful in giving an insight to the
design process and, in particular, to draw attention to some of the pitfalls that
may be encountered.
frictional resistance to the flow causes the air to expand. The average velocity
of the air across a section of the pipe must therefore increase in the direction of
flow so that in a pneumatic conveying system the lowest velocity normally
occurs at or near the point where the bulk solid is fed into the line. Clearly this
lowest velocity must be sufficient to transport the bulk solid without the risk of
blockages occurring in the system and, since the 'minimum transport velocity'
depends principally upon the nature of the bulk solid itself, it is usually the first
design parameter to be fixed.
Unfortunately the minimum transport velocities for different bulk solids are
not easily predicted since this parameter is influenced by many diverse
variables, including material properties such as particle size, density and
shape, cohesiveness and abrasiveness, and also (significantly) the solids
loading ratio. The only really satisfactory method of determining the
minimum transport velocity for a given particulate material is to carry out
tests on the material in a pilot plant having features that correspond as closely
as practicable to those of the plant being designed. Clearly this is where the
experience of the designer can be valuable, as he may have prior knowledge of
the conveying characteristics of the actual material or of a similar one.
As explained elsewhere in this book, there is a marked trend towards the use
of dense phase in preference to dilute phase for pneumatic conveying systems
because of the lower running costs and less severe effects on both the plant and
the conveyed bulk solid as a result of the lower velocities involved. However,
certain materials, especially those of a granular nature, cannot be conveyed in
a conventional dense-phase system, and the minimum transport velocity is
then determined by the point at which the particles begin to fall out of
suspension. For a wide range of materials this will occur at a velocity of around
16 mls and this is a good value at which to begin the preliminary design of a
dilute-phase system. It should be understood, however, that with bulk solids
containing large lumps, especially ifthe density is high, the minimum transport
velocities may be very much greater.
For bulk solids capable of being conveyed in dense phase the minimum
transport velocity is typically around 5-10 mis, but this is quite variable, and
there is really no alternative but to design from observed behaviour of the
materials concerned. In any case, for such materials, which generally tend to
have good air-retention properties, the minimum transport velocity depends
to a significant extent on the solids loading ratio. Conveying at higher values of
the solids loading ratio can often allow the gas velocity to be reduced, so
effecting a worthwhile saving in power consumption, but there is, of course, a
practical limit which can be determined only from conveying trials.
Once the minimum transport velocity has been determined, by whatever
means, it is recommended that a value twenty per cent higher should be used
for design purposes in order to provide a margin of safety against pipeline
blockage. Velocities greater than this are generally not advisable because of
the increased power and filtration requirements, the adverse effect (for most
PNEUMA TIC CONVEYOR DESIGN 441
products) on the solids flow rate and the possibility of excessive degradation of
the conveyed material and erosive wear of the system components.
It will be necessary, in due course, to calculate the volumetric flow rate of air
required ('free air' -that is, at normal ambient conditions) and this quantity is
related to the conveying air inlet velocity ug1 , discussed above, by the following
equation:
(14.1)
where D is the diameter ofthe conveying pipe, P1 and T1 are the pressure and
absolute temperature at the inlet, and Po and To are the standard ambient
pressure and absolute temperature. In Sf units, taking Po = 1 bar and
To = 288 K, the relationship becomes
(14.2)
rate of the conveying air, known as the 'solids loading ratio' or 'phase density',
is another design parameter that is difficult to predict with much confidence. In
so-called 'dense-phase' pneumatic conveying systems very large values of
solids loading ratio (cp) may be obtained~possibly up to several hundreds~
and in the extreme, cp approaches the value corresponding to the minimum
fluidizing condition. In fact, the conveying velocity and the solids loading ratio
are interrelated and it is perhaps a matter for debate which should be selected
first. To some extent the choice of solids loading ratio is dictated by economic
considerations and involves a comparison between the cost of the large-
diameter pipeline that would be necessary for a low value of cp, and the cost of
the compressor necessary to meet the greater pressure drop associated with
high values of cp.
Typical values of the solids loading ratio for dilute-phase systems would be
between 5 and 15. In the absence of more reliable information (for example,
from tests on a pilot plant) a reasonable procedure for the design of a dilute-
phase system is to begin by assuming a value of 10 for the solids loading ratio,
and then to adjust this figure upwards or downwards in order to match the
predicted pressure-drop through the system to the characteristics of the
blower or compressor used.
(14.3)
where mg is the mass flow rate of air, Pg is the density of the air, ug is the
conveying velocity and D is the pipeline diameter.
Setting ms = 10 mg the above expression becomes
D_ ( ms )1/2 (14.4)
7.9p g Ug
where ms is the mass flow rate of solids. When using equations (14.3) or (14.4) it
should be appreciated that the density Pg and velocity ug of the conveying air
should be taken at the same section of the pipeline. The 'pick-up velocity' is
PNEUMA TIC CONVEYOR DESIGN 443
usually the minimum value in the conveying line and, being at the upstream
end, would correspond to the maximum pressure and density. It is therefore
likely to be necessary to estimate the density using the anticipated delivery
pressure of the air mover.
The density of the conveying air can be calculated from the pressure p and
absolute temperature T using the perfect gas equation
p
Pg = RT
(14.5)
where R is the characteristic gas constant which, for air, has a value of
287 l/kgK. Thus, in SI units,
(14.6)
P g = 287(273 + t)
where p is in bar absolute, and t is the temperature in degrees Celsius, giving Pg
in kg/m3.
It must be stressed that, although for convenience the determination of pipe
diameter and pressure-drop are discussed separately here, in practice these
two variables should be considered together. Equation (14.4) gives a first
estimate of pipeline diameter which should be used to calculate a value for the
pressure-drop along the line at the required solids flow rate and conveying
velocity. If the pressure-drop is found to be excessive, a larger-diameter
pipeline should be selected and/or the solids loading ratio reduced. The full
calculation should then be repeated.
14.2.4 Pressure-drop
When calculating the pressure-drop through the conveying line it is advisable
to keep in mind the acceptable figures for the system in question. For example,
if the system is of the vacuum type the maximum practical value of the
pressure-drop is limited to around 0.6 bar (9Ibf/in 2 ). If the pressure-drop
exceeds this value, the resulting low pressure and low density at the suction to
the vacuum pump or exhauster means that this component has to be large, and
therefore expensive.
In positive-pressure systems the limiting factor is usually the solids feeder.
As explained in Chapter 13, continuous conveying systems using a rotary- or
screw-feeder are generally restricted to maximum pressure-drop of around
1 bar (14.5Ibf/in 2 ), although considerably higher values can be achieved if
special feeders, such as the Fuller-Kinyon pump, are employed. Still higher
pressures, up to around 7 bar (100Ibf/in 2 ), can be accommodated in batch
systems using blow tank feeders.
The reliable prediction of pressure-drop in a gas/solids mixture flowing
along a pipeline is one of the major difficulties facing the designers of
444 BULK SOLIDS HANDLING
'" ~r-.::
\~ ~
~~ 20
il-
"\
\~ t-:::: 18 .2
.'"
16
I
14 ~
12 CD
c:
10 'is
<II
8 g
I
"-
r- 6 '"
."2
'0
- - 1-' 4 '"
o 10 20 30 40 50
conveying velocity (metres/second)
necessary to select a larger pipeline diameter and repeat the calculation. It may
appear that reducing the solids loading ratio should also give a lower pressure-
drop, but this can only be achieved by increasing the air mass flow rate (since
the solids flow rate is fixed by the system specification), which leaves no
alternative to increasing the pipeline diameter.
20 reciprocating compressors
10
i
Q)
Ol
=>
~ 05
'~"-rnJIDJt-
straight lobe (Roots-type
gJ, • ~ rotary blowers
J01~
0.05 fans
5 10 50 100 300
pressure against free air delivered for various running speeds. Superimposed
on these operating characteristic curves are lines showing the power absorbed.
A typical performance chart for a Roots-type blower is reproduced as
Figure 14.3 and it is seen from this chart that locating the point corresponding
to the required delivery pressure and FAD allows the necessary running speed
and the resulting power consumption to be determined.
(i) Select suitable value of minimum transport velocity, say 15 mls (referring
to section 14.2.1)
(ii) Select suitable value of solids loading ratio, say 10 (section 14.2.2)
(iii) Calculate air mass flow rate and estimate suitable pipe diameter
(section 14.2.3)
(iv) Estimate overall system pressure-drop (section 14.2.4)
(v) Consider whether this estimated pressure-drop is acceptable (that is,
within a suitable range of values for the type of air-mover proposed); if it
is, go to Step (x)
(vi) Select next larger or smaller size of pipe, as appropriate
(vii) Calculate new air flow rate required to give selected minimum transport
velocity
(viii) Calculate new solids loading ratio to give specified solids flow rate
(ix) Go to Step (iv) (re-calculate overall system pressure-drop)
(x) Estimate additional air requirement (for example, to include air leakage
from rotary valve) and thus determine total air to be supplied by air
mover, as 'free air delivered' (section 14.2.1)
(xi) Using performance characteristics of selected air-mover, determine exact
operating condition and power requirement (section 14.2.6)
Figure 14.3 Typical performance chart for a Roots-type (straight-lobe) rotary blower.
and development laboratory, complete data can be recorded for almost any
particulate or granular bulk solid.
Several observations can be made from a first inspection of Figure 14.4.
Firstly, the range of solids loading ratios, up to a maximum of 10, suggests that
the system was working in a dilute-phase mode, and this is confirmed by the
fact that the lowest value of the conveying air velocity is 15 m/s. It should be
noted that the air flow rate on the horizontal axis is expressed on a volumetric
basis as 'free air', although an alternative is to use mass flow rate.
It is immediately apparent that a wide range of flow conditions could exist in
the pipeline to which Figure 14.4 relates. At an air flow rate of 15 m3/min
(FAD), for instance, the solids flow rate could be anything from zero up to 11.8
tonne/hour (for which the pressure-drop would be 0.8 bar) or more. Operating
with a greater air flow rate is generally not a good idea since a higher
proportion of the available pressure-drop will be needed to overcome wall-
friction losses for the air flow, leaving less for the conveyance of solids.
concerned. However, it is most unlikely that the pilot plant will be of exactly
the same configuration as the system being designed, and therefore it will be
necessary to modify the conveying characteristics so that they show the
relationships amongst the solids flow rate, air flow rate, and pressure-drops for
the required conveying distance and an appropriate pipe diameter. Much of
the skill in designing a pneumatic conveying system is in this modification of
existing data so that it becomes relevant to the system being designed, not only
in terms of conveying distance and pipe size, but also in terms of the number of
bends and their geometry, vertical sections of pipe (up and down), operating
sequences (in the case of batch wise conveying), and so on. It is possible here
only to give an outline of the technique of 'scaling' for pipe size and conveying
distance, but this should be sufficient for the reader to gain a general
understanding of the design method. Further information can be found in [4]
and [5].
Scaling the conveying characteristics for a specific bulk solid is best carried
out in two stages. The first stage involves scaling to the required distance, with
allowances for vertical sections and bends, and the second stage scales the
conveying characteristics in terms of the pipe diameter. Scaling with respect to
conveying distance is a fairly complex process and can result in marked
10
]..... 8
i'" 6
a
.0
ci
~ 0
~ solids -6
g loadi'lg
0:> ratio '"3
II>
4 II>
'8 10 '"C.
i5.
8 .i
2 6 .~
>-
4 '"0>c:
2 ()
1
0 5 10 15 20 25 30
vournetric air flow rate (free air) (m 3 /min)
Figure 14.4 Conveying characteristics for powdered limestone Pipeline: 125 mm diameter, 80 m
long, with seven long-radius 90° bends.
PNEUMA TIC CONVEYOR DESIGN 451
differences in conveying parameters. Significant changes can result in the
solids flow rate, solids loading ratio and the air requirements, all of which are
very much dependent upon the nature of the bulk solid concerned. In order to
illustrate the steps involved in scaling, reference will be made to Figure 14.5.
This is a set of conveying characteristics, presented in a similar way to
Figure 14.4, but relating to the dense-phase conveying of pulverized fuel ash
(PF A) in a 50 mm-diameter pipeline 100 m in length.
In the first instance the conveying characteristics for the PF A will be scaled
up to a distance of 150m. Now, provided that the extrapolation is not too
great, scale up of solids mass flow rate with respect to conveying distance can
be carried out with reasonable accuracy on the basis of a reciprocal law, that is
m oc-L1
S
(14.9)
The product mass flow rate scale on Figure 14.5 is thus changed according
to the relationship
(14.10)
16
'2
~
0
.c
.....
Q)
gc:
12 +---
I
Q)
'§
g
~
8
(/)
(/)
~ ,
()
~
"0
0 4
a
0
0.02 0.04 0.06 0.08 0.1
air mass flow rate (kg/s)
Figure 14.5 Conveying characteristics for pulverized fuel ash (PF A). Pipeline: 50 mm diameter,
100m long.
452 BULK SOLIDS HANDLING
so that when scaling from 100m to 150m, as in this example, all the product
mass flow rates are reduced by a factor of 2/3.
Now it is essential that conveying conditions, in terms of air velocities, are
the same for the two situations and therefore scaling must be carried out for
data points having the same conveying line pressure-drop and the same air
mass flow rate. Furthermore, the 'datum' conditions, corresponding to the
pressure-drop for air only flowing through the line, must be changed by an
appropriate amount to reflect the fact that, for the same inlet air velocity in a
longer pipeline, both the air flow rate and the pressure-drop will be different.
Figure 14.6 shows the result of scaling for distance, from the original 100m
up to 150 m. It is immediately evident that over the longer distance the
maximum solids loading ratio is very much less.
When scaling for the size of the pipeline it will again be necessary to adjust
the position of the 'empty line datum' since, in order to maintain similar air
velocities, the mass flow rate will need to be in proportion to the cross-
sectional area of the pipeline. An acceptable degree of accuracy when scaling
for pipe size is obtained on the basis of proportionality between solids mass
flow rate and pipe cross-section.
16
1
14
I/"'; ~ /
.L 0
L 1 /
"" "
solids
loading
12
~"'
ratio I
I/' "'- "'-. )<
~
.L -....., A ""'"
80
.............
3.0
/ ~ ~ >:","",
~ 10
c:
0
.::; f--"
Ql
~ 8
60 7~
/
'>< ~ "- 2.6
~
~ ....... ~ ><....... "- r--...'"'" B
">
(/)
6 .........
'"
E I // .......
Ql
~
<
--
.........
(3 ............... ....... 1.8 (/)
30/
i '-..... ~
:> Ql
u
0 4 ./ 5.
./ .............
-
5.
~o/ ~ 1.4 ~
g
t::>< f-->'" .............. ...............
r-- r--- .............. r....... 1.0
I
--
--_. 's;.
2 ~ Ql
10- >
c:
0
0.02 0.04 0.06 0.08 0.1
ai" mass flow rate (kg/s)
Figure 14.6 Conveying characteristics for PF A. Pipeline: 50 mm diameter. 150 m long (Scaled
from Figure 14.5).
PNEUMA TIC CONVEYOR DESIGN 453
!
~'--.
_7 /
..... I--... !
30
.L ~ .........
solids
II
I7t--- !
h.. /
loading II 17K J".. !'..... /
I"- !'.....
ratio ...... J".. ...... ......
80 1/ N
I
K 1'-.. 3.0
j. I-. I
l"- f<. t'-.. t>< l"-
t/ r----" r-... k 1'-.. 2.6
60 ~
t::>" r---. r- ;/ f-.. i'-... t'-..
- -
40
'""'
/
~
/ r-- r- ~
./
-r--. k:.: l7' ......... r-
K r-l-..
-- .......
- -
1,Q
I- "? I-- f--
J
l'"'- I--
I-- r- l -
- -
I ""'" r-
10
I--
I-.
I-- I-- I--
i
'-0.6
I-- I--
o I
5 10 15 20
air mass flow rate (kg/s)
Figure 14.7 Conveying characteristics for PFA. Pipeline: 75mm diameter, 150m long (scaled
from Figure 14.5, via Figure 14.6).
Thus
(14.11)
and the product mass flow rate scale on Figure 14.5 (or Figure 14.4, depending
upon the conveying distance required) is then adjusted using the relationship
Figure 14.7 shows the result of scaling up from the 50 mm-diameter line to
75 mm by first adjusting the datum condition and then changing the vertical
scale, increasing all product mass flow rates by a factor of2.25; that is, (75/50)2.
The outcome of this somewhat complicated procedure is that, for a specified
bulk solid, the results of laboratory trials have been adapted to yield a set of
conveying characteristics which are vital to the reliable design of a pneumatic
conveying system that is required to transport the same bulk solid at the same
(or greater) rates over a longer distance. The required pipe diameter is
determined and a suitable operating condition can be selected, enabling the
454 BULK SOLIDS HANDLING
air mover to be specified in terms of air flow rate (FAD), delivery pressure and
size of driving motor (i.e. power).
14.5 Notation
Cross-sectional area of conveying line
Diameter of conveying line
Total conveying distance
Mass flow rate of conveying gas (air)
Mass flow rate of conveyed bulk solid
Pressure in conveying line
Atmospheric pressure
Pressure at conveying line inlet
Pressure-drop due to gas (air) alone in conveying line
Pressure-drop due to two-phase (gas/solids) mixture in convey-
ing line
Characteristic gas constant
Temperature (absolute) in conveying line
Atmospheric temperature (absolute)
Temperature at conveying line inlet (absolute)
Temperature in conveying line
Temperature at conveying line inlet
Velocity of gas (air) in conveying line
Volumetric flow rate of air ('free air')
'Pressure loss factor' in equation (14.7)
Solids loading ratio ( = ms/mg)
Density of conveying gas (air)
References
1. Parameswaran, M.A. and Mukesh, D. Computer-aided design of a pneumatic conveyor, Chem.
Engg. World 13 (10) (October 1978) 41-46.
2. Woodcock, c.R. and Mwabe, P.O. An approach to the computer-aided design of dilute-phase
pneumatic conveying systems. Proc. Pneumatech 2 Conf, Canterbury, UK, September 1984.
3. Latincsics, N. Pneumatic conveyors: computer aided design methods. Proc. 10th Annual
Powder and Bulk Solids Conf., Chicago, May 1985.
4. Mills, D. Mason, I.S. and Marjanovic, P. The comparison of pressure drop in horizontal and
vertical dense phase pneumatic conveying. Proc. 3rd Conf. on Pneumatic Conveying, Pecs,
Hungary, March 1985.
5. Mills, D. and Mason, lS. The influence of conveying distance on the performance and air
requirements of pneumatic conveying system pipelines. Proc. Conf. on Reliable Flow oj
Particulate Solids, Bergen, August 1985.
15.1 Introduction
The three preceding chapters have been concerned primarily with pneumatic
conveying by pipeline, and consideration will now be given to a variation on
this technique in which the particulate bulk solid is made to flow along a
channel inclined at a shallow angle. Pneumatic conveying has several
advantages over other methods of transporting bulk solids, but it suffers from
two drawbacks. Firstly, the power consumption is quite high; and secondly,
especially when conveying in dilute phase, the solids velocity is relatively high
and may cause problems as a result of particle degradation and erosive wear of
the pipeline and system components. Both of these difficulties may be
minimized by conveying in dense phase, that is, with a higher ratio of solids to
air, so that the quantity of air used is smaller and the conveying velocity is
lower.
Air-assisted gravity conveying (or 'air-float conveying') can be regarded as
an extreme form of the dense phase method in which the predominant factor
causing flow is the gravitational force on the bulk solid. The technique is
essentially to maintain an aerated state in the bulk solid, from the moment that
it is fed into the upper end of an inclined channel, by the continuous
introduction of air (or other gas) at a low rate through a false bottom, made of
suitable porous material and fitted into the channel (Figure 15.1). Since the
bulk solid is kept 'live' by the trickle-flow of air, it flows freely down the slope,
even when the angle of declination is very small. The quantity of air used is
kept to the absolute minimum necessary to reduce the interparticle forces, and
the frictional forces between the particles and the internal channel surfaces,
sufficiently to allow the bulk material to 'flow'. The general principle of air-
gravity conveying is thus very simple and the method has the big advantage of
being essentially 'workable'; that is, a great deal of latitude is available in the
design of installations, and provided that a few basic requirements are met
they will generally operate without trouble.
It is not known when aeration of a bulk particulate solid was first used as an
aid to conveying, but one of the earliest relevant patents appears to have been
that of Dodge in 1895 [lJ who used air, entering an open channel through slits
in the base, to transport coarse-grained material. However, significant
progress in the gravity conveying of aerated powders was not made until some
thirty years later when it was found that the method provided an excellent
means of conveying cement. The German company Polysius was a pioneer in
the development of air-assisted gravity conveying, but was followed into the
AIR-ASSISTED GRAVITY CONVEYING 457
bulk solid
teed
Figure 15.1 The principle of air-assisted gra vity conveying: an aerated bulk solid flowing along a
channel.
field by the Huron Portland Cement Company of America which obtained the
first British patent in 1949. Huron's plant at Alpena, Michigan, was one of the
first to make extensive commercial use of this method of conveying and
employed 'Airslides', as they came to be called, at various stages of the
production process from grinding mill discharge to finished cement. The third
organization that played a prominent part in developing and establishing air-
gravity conveyors was the Fuller Company which manufactured them under
licence from Huron.
Although the air-assisted gravity conveyor first came to prominence for the
transport of cement- and this is still one of the main applications - many
other types of material are now handled with relative ease, including such
diverse substances as fly ash, coal dust, plastic and metal powders, alumina
and sand. Typical of the large installations described in some detail in the
published literature are a 50000-tonne storage plant and an 80000-tonne
ship-loading plant, both handling alumina [2J, and a Canadian aluminium
smelter capable of handling 160000 tonnes of alumina per annum [3]. Various
sizes of conveying channel are used in these installations, one of the largest
being a 915 mm-wide channel which transports alumina from a surge hopper
to a main silo at a rate of 1500 tonne/hour [4].
Currently there are a number of different companies marketing air-assisted
gravity conveyors under a variety of different trade names, such as Airslide,
Fluidor, Whirl-Slide, Flow-Veyor and Fluid-Slide. Nevertheless, considering
the advantages that they can offer over other forms of bulk solids transport,
particularly in terms of low power consumption, the use of these conveyors is
not as widespread as might have been expected. To some extent this may be the
result of a lack of confidence on the part of the design engineer, since air-
gravity conveying remains something of an art!
458 BULK SOLIDS HANDLING
(a)
Figure 15.2 Aeration of a particulate material to reduce the natural angle of repose.
materials display a natural angle of repose of around 35° to 40° (Figure I5.2a)
and in order to get such a material to 'flow' continuously, under gravity alone,
on an inclined surface it would normally be necessary for the slope of the
surface to be greater than this angle of repose (Figure I5.2b). Materials
exhibiting some degree of cohesiveness have much larger angles of repose and
often will not flow, even on steeply inclined surfaces, without some form of
assistance, such as vibration of the surface. The introduction of air to a bulk
powder, for example by supporting the powder on a plate made of a suitable
porous substance and allowing the air to flow upwards through it into the
powder, can significantly reduce the natural angle of repose. The powder will
then flow continuously from the plate when it is inclined at a very shallow
angle, which needs only to be greater than the so-called 'fluidized angle of
repose' of the material-for most free-flowing powders, around 2°_6°
(Figure 15.2c). This phenomenon of fluidized flow can form the basis of a
simple and reliable method of bulk solids transport if a channel is constructed
having a porous base through which air can flow from some form of plenum
chamber (Figure 15.1). It is of course an essential requirement that sufficient
460 BULK SOLIDS HANDLING
air flows into the powder in the channel to cause it to flow and therefore the
porous base must be of high enough resistance to ensure that when part of it is
clear of powder the remainder is not starved of air (Figure 15.3a). The other
essential condition to be met is that the downward slope is sufficient to permit
a steady continuous flow of the fluidized powder. Provided that these
conditions are satisfied, the air-assisted gravity conveyor would normally
prove to be a trouble-free and very economical method oftransporting a wide
range of powdered and granular bulk solids.
The appearance of the flowing aerated powder in the channel can depend
upon a number of properties that together might be termed the 'flow ability' of
the material, and also to some extent on the roughness of the channel surface.
Thus, a very free-flowing dry powder having a relatively low natural angle of
repose (that is, good 'flowability') would be likely to fluidize well, and in this
plenum charmer
air
1r 't<l~'ft3(.
',:. {.:.'~
.~
. ,~f
·;;.·.}i1i':"' __ .
' . ; '1" , .r -.... ~i~t.,.:·'..."'t~ .. -
(c) Slightly cohesive powders that do
not fluidize well can often be
conveyed if the channel slope is
greater (up to about 10 0 ). The
powder effectively slides on a layer
of air trapped against the top surface
of the distributer.
. I
.,,, 7~ ~;.~$~.~1'~.' .~ _ / ao: ayer
. .- '-..
• •~.~ l1' .. 'II(ir.I.. 'J~_;\:
-- -J,, "'~ ":'"~~l".:'~- '':;'''J':.~~_-,,!-,,~
I. atr
'I["A? -·:lt~ ... ...,:"i'~.
.-'\~K~~:.;:tt. ~
... .~~ ...{
~i\.;
' ..
Figure 15.3 The flow of aerated particulate bulk solids in inclined channels.
AIR-ASSISTED GRAVITY CONVEYING 461
state to flow smoothly along a channel inclined at as little as one or two
degrees to the horizontal (Figure 15.3b). Visual observation of the flowing
powder would show distinct liquid-like characteristics such as a smooth or
slightly rippled surface, a 'plume' set up from a partial obstruction to the flow,
and a 'standing wave' set up from a more substantial obstruction. In contrast, a
powder that is cohesive can show a markedly different behaviour in an air-
gravity conveyor. Very cohesive (sticky) materials are, of course, unsuitable for
conveying in channels in this manner. However, powders that are only slightly
cohesive can usually be conveyed provided that the slope of the channel is
greater; perhaps 6°-10°. Observation of these materials suggests that the
particles are not fluidized, but move virtually as a solid mass sliding along the
channel (Figure 15.3c). Irregular zig-zag cracks in the flowing powder bed and
the craggy appearance of its free surface suggest similarities to the channelling
and slugging behaviour that can occur in stationary fluidized beds-indeed
these cohesive powders could be expected to exhibit just such
characteristics-and the nature of the motion is very much akin to that
occurring in en-masse conveyors (Chapter 9).
It is not clear whether the improved 'flowability' that results from the
continuous aeration of powders results predominantly from the air filtering
through the solid particles and reducing the contact forces between them (thus
causing partial fluidization) or from the formation of air layers between the
bed of particles and the channel surfaces allowing slip to take place with the
consequent sharp reduction ofthe boundary shear stresses. Even with fine free-
flowing powders there is some evidence for the latter effect (for example the
bubbling behaviour of a stationary fluidized bed is almost entirely suppressed
when the bed flows), but it seems probable that the former effect is
predominant with such materials.
porous
mbrane
plenu
cha~1
supply 01 filtered air
solids / '
discharge
I
Figure 15.4 Arrangement of a typical air·gravity conveyor.
channel
porous
membrane
plenum
charrber
(b) A side discharge box, one of the many components that can
easily be built-in to an air-gravity conveying installation
Figure 15.5 Construction of an air-gravity conveying channel.
AIR-ASSISTED GRAVITY CONVEYING 463
Table 15.1 Some features of materials commonly used as the porous distributor in air-assisted
gravity conveyors.
Woven fabric
Cotton Low Light and fairly strong, but has little rigidity
and may need supporting in wide ducts;
performance may deteriorate if fluidizing air
or conveyed solids are moist.
Polyester Low As for cotton, but less susceptible to
moisture; unsuitable for use at elevated
temperatures.
Asbestos Low Particularly useful in high-temperature
applications.
Sintered plastic Medium Has smoother surface and greater rigidity
than woven fabrics; appears very prone to
deterioration through accumulation of
atmospheric dust and fines in conveyed
material which cause decrease in air flow.
Sintered metal High Hygienic (therefore useful in food industry);
gives good fluidization and can be made
with high degree of uniformity; but very
expensive.
Ceramic tiles Medium Perhaps less convenient than other materials
in that tiles must be fitted together and
sealed, but widely used; good fluidization;
ceramic is brittle and subject to impact
damage, but is resistant to high
temperatures.
Woven steel laminate High Qualities similar to sintered metal; resistant
to high temperatures.
Compound materials, Low to medium Combines good fluidization qualities
e.g. filter cloth of fine filter cloth with strength
sandwiched between steel sheets; can be easily made to
perforated steel plates any desired specification to
suit user's application.
conveying system. The presence of the covered top channel renders the
conveyor virtually free from problems of dust leakage, but naturally it would
also operate satisfactorily as an open channel. In this form the device has been
widely employed for flow assisters mounted at the bottom of silos, bunkers,
railway wagons and lorries, and so on, enabling these containers to be made
with a virtually flat base and thus to have a substantially greater capacity.
Where the conveyor is covered it is necessary for the top channel to be
adequately vented through suitable filters. With short conveyors it may be
sufficient to rely on the air escaping with the powder from the outlet end of the
channel and then through the vent system of the discharge hopper, if one is in
use. If the conveying system is long, or if there is a possibility of the channel
outlet becoming choked with powder, it is better to vent from two or more
points between the inlet and the outlet. It is likely to prove useful to have
inspection or access ports fitted at convenient positions along the duct,
464 BULK SOLIDS HANDLING
especially in the region of the inlet and outlet and in other positions where
blockage may occur. In any case it is advisable to have a means of physically
cleaning out the channel since it is a peculiarity of air-gravity conveyors that
when the solids feed is reduced the flow becomes unstable and then stops.
Thus, the base of the channel cannot be completely cleared of the conveyed
material simply by shutting off the feed.
The air-gravity conveyor may operate with flooded feed from a hopper
where precise control of the solids flow rate is not required. The system is then
effectively self-regulating and, with free-flowing powders, there should be little
risk of the conveying channel becoming choked provided that its slope and the
flow rate of fluidizing air are sufficient. Alternatively, the supply may be from
some form of metering device such as a rotary valve or screw feeder. Another
commonly used technique for obtaining some measure of flow control is to fit a
gate or baffie in the conveying duct, close to the inlet from the hopper. Placing
a flow-regulating gate near the outlet end of the conveyor is generally not
advisable as the whole channel could well fill with powder backing up from the
gate. Problems would then occur with venting of the fluidizing air and with
erratic flushing of the powder under the gate as it opens. However, provided
that care is taken over the design of the venting arrangement and also of the
method of discharge control, the choke-fed air-assisted gravity conveyor can
prove to be a very useful device, allowing material to be drawn at will from any
of a number of outlets in what is effectively, a long fluidized header-tank. Solids
flow control at the inlet end, although basically more reliable, does present a
problem on long channels because of the considerable delay between making
an adjustment to the control gate and seeing the effect ofthis adjustment at the
lower end ofthe channel. In fact, where it is important to control the solids flow
rate within relatively close limits it becomes almost essential to install some
form of buffer hopper close to the discharge point.
Air-gravity conveyors are available from a number of manufacturers as a
range of standard bolt-together components which include straight and
curved sections of various widths along with 'accessories' such as flow
diverters, inlet and discharge ports, gate valves and scrap traps. One such
component-a flow diverter-is illustrated in Figure 15.5b.
Controlling the location at which a bulk solid is discharged from an air-
assisted gravity conveyor is likely to be much more satisfactory than
controlling the rate of discharge. Using appropriate bends, diverters and outlet
ports it is possible to construct quite complex systems. Figure 15.6 illustrates
an ingenious but simple solution to the problem of automatically controlling
the feed of materials to a stockpile. An overhead air-gravity conveyor
discharges the fluidized bulk solid down each of a succession of outlet spouts
until the rising level of the stockpile causes them to become blocked.
It has been stated that air-gravity conveyors are usually trouble-free in
operation, and whilst this is true, there are one or two ways in which problems
may arise. One potential source of trouble is the porous membrane that forms
AIR-ASSISTED GRAVITY CONVEYING 465
bulk solids feed
.1 e.g. from belt conveyor
Figure 15.6 An air-assisted gravity conveyor feeding a stockpile through multiple discharge
spouts.
the base of the conveying channel. There are many examples of installations in
which the same membrane has been in use continuously for a number of years,
but in other cases replacement is necessary at quite frequent intervals. There is
probably little that can be done about blinding of the pores in the top surface
of the membrane, but precautions can be taken against deterioration of the
underside by ensuring that the main air supply is adequately filtered.
A further precaution concerns the need for the porous membrane to
withstand a certain amount of iII-usage. It appears to be common practice for
operatives to attempt to relieve suspected blockages with the aid of an iron bar
or similar implement wielded against the outside of the channel or prodded
through an inspection port, with the not uncommon result that the porous
distributor is cracked (in the case of ceramic tiles) or punctured (woven fabrics).
Blockage of the conveying duct is unlikely to occur unless the porous
distributor is damaged or the nature of the conveyed material changes
drastically (for example, becoming wet), both of which would tend to cause
local, or complete defluidization of the flowing solid. Erratic flow in the
conveying channel is unlikely to be caused by the air-gravity conveying system
itself, unless the slope is too shallow or the bed depth is too great. It is more
probable that the feed to the channel would be at fault, for example, as a result
of arching in the hopper supplying the air-gravity channel.
nature of the bulk solid being handled. Attempting to convey at a slope less
than this optimum value can result in the depth of the bed of bulk material in
the channel increasing excessively, even to the point where the channel
becomes completely blocked. Conveying at slopes greater than the optimum
value should not cause any problems, but does not yield any significant
advantage and does not make the best use of available headroom.
However, this optimum slope is not easy to predict without undertaking
tests with samples of the material in a small-scale channel. In general, for free-
flowing materials a slope of around 3° should be sufficient, but more cohesive
powders may require 7° to 10° to ensure continuous trouble-free operation.
where ra is the operating aspect ratio, re is the expansion ratio of the conveyed
AIR-ASSISTED GRAVITY CONVEYING 467
6000
150
,,,',', d'",~
4000 kg/m 3
~
~
4000 ~
30~ I
li'l
o 100
.c
......
Q)
E
g 80
II 2~
/ VII
Q) 60 0
~ 2000
~
g
40 0
II /
If)
If)
to 10~
E
300
:Q /
;'1/
1000
"'0
/
II
If)
20 0
500
100
1/V
6 VI/ /
2
//;V/
o /II
l- F
0.2 0.4 0.5 0.8 1.0
channel width (m)
Figure 15.7 Chart giving the approximate relationship between conveying capacity and channel
width for air-gravity conveyors operating at an aspect ratio of 0.5.
material (that is, the ratio ofthe bulk density of the unfluidized material to that
of the suspension) and Us is the average solids velocity along the channel.
Taking suitable average values of the quantities Us> ra and r e , and introducing
the particle density Pp in place of the bulk density Pb' a convenient 'rule-of-
thumb' may be proposed as
b~ 1.6(;;yI2 (15.2)
where ms in kg/s and Pp in kg/m 3 gives b in metres. This relationship has been
used to plot the chart, Figure 15.7, which provides a quick reference for
determining the approximate channel size for a given application. (It should be
noted, however, that normal industrial practice would be unlikely to permit
the widest channels to operate at an aspect ratio as high as 0.5, and caution
should be exercised in this respect when using the above equations or chart.)
468 BULK SOLIDS HANDLING
.€o
~ 10 ~~--~----+-~~~~~~~~L------r--~
offi
1ii group A
~
! /1
MI IMUM FLUIDIZING
VELOCITY
20 50
mean particle diameter ( /Lm)
Figure 15.8 Minimum fluidising velocity and terminal velocity for a bed of particles fluidized
with air at normal ambient conditions.
normal ambient. Also shown on this chart are approximate values of U t , the
terminal velocity of particles in free fall in still air. For a particulate bulk solid
of known particle size and density, Figure 15.8 allows a fairly reliable estimate
to be made of the minimum fluidizing velocity and, using the diameter of the
smallest particles in the material, the air velocity can be predicted at which
these fine particles may begin to be carried upwards from the surface of the
bed. Approximate ranges of the types of fluidization behaviour, as given by
Geldart's classification (Figure 3.13), are also shown on Figure 15.8, super-
imposed on the lines corresponding to the minimum fluidization condition,
thus helping to provide a useful prediction of the likely behaviour of a
particulate bulk solid in an air-assisted gravity conveyor.
R
470 BULK SOLIDS HANDLING
For a more detailed discussion of the various aspects of the design of air-
assisted gravity conveyors the reader is directed to [5].
Author(s) and
Material handled reference
Cement, fluidized and conveyed on woven canvas belting Avery, W.M. [6]
in a trough inclined at about 4° Nordberg, B. [7]
Hot metallic sulphide dust, fluidized on a porous
medium of refractory aluminium oxide Anon. [8]
Alumina powder in a large Canadian smelting plant,
conveyed on porous tiles at a 2.2° slope.
(Conveying rate about 200 tonnefh in 5OOmm- Bushell, E. and
wide channel.) Maskell, R.C. [3]
Alumina transported on various sizes of air-gravity Leitzel, R.E. and
conveyor in ship loading and unloading plant. Morrisey, W.M. [2]
Rockdust handled in bulk to reduce costs in mining
applications. ('Airslide' with 6° slope) Alston, G.L. [9]
General information; and reference to sodium
tripolyphosphate and silica flour. Anon., EEU A Handbook
[10]
Various bulk solids conveyed on 'airslides' in
self-unloading railroad car. Hudson, W.G. [11]
easiest to convey and will flow well at very shallow slopes. When the supply of
fluidizing air is shut off the bed collapses rapidly and flow stops, so that there
are unlikely to be any problems with air retention. Materials oflarger particle
size and/or high density (Group D) can sometimes be conveyed in the same
manner, but the quantity of fluidizing air tends to become rather large, and
other forms of transport, such as belt conveying, are likely to be more suitable.
Group A generally includes powders of small particle size and/or low density
which should flow well in an air-gravity conveyor; however, as a result of air
retention, the material may have a tendency to continue flowing for a time after
the fluidizing air supply has been shut off. Finally, Group C includes cohesive
powders that are difficult to fluidize satisfactorily because of high interparticle
forces resulting from very small particle size, electrostatic effects or high
moisture content. The dividing line between Groups C and A is very indistinct
and the only way of properly assessing the suitability of doubtful materials for
air-assisted gravity conveying is by practical experiment in a small-scale test
rig. As previously indicated, it may be found that apparently unsuitable
materials will, by a combination of 'flowing' and 'sliding', move continuously
along an inclined channel, provided that the slope and air supply are sufficient.
Although for a given bulk solid, the parameters mainly influencing its flow
behaviour are those that have already been discussed, there are several other
effects which can cause changes to occur during conveying. The most
significant of these are moisture, electrostatic charging and particle segrega-
tion. It is well known that changes in the moisture content of powders can
seriously affect their handling characteristics and this is especially true in the
case of fluidization and fluidized flow. Whilst a small increase in moisture may
472 BULK SOLIDS HANDLING
Figure 15.9 Perforated plate distributor of the type used in the 'Jet Stream' conveyor: the spacing
of the openings, their shape and the percentage of open area may be varied to suit the material
being conveyed. (Typical dimensions are given in mm.)
AIR-ASSISTED GRAVITY CONVEYING 473
porous distributors
high-pressure air
low-pressure air
plenum chamber
air
(c) A combination of porous distributor and directional air-jets
Figure 15.11 Horizontal conveyors using air jets to move the bulk material along the channel.
474 BULK SOLIDS HANDLING
problems arise with backflow of particles into the plenum chamber and
degradation of friable materials as a result of the high velocity of the jets.
Furthermore, the specific energy consumption (that is, the energy consump-
tion per metre length conveyed at a rate of one tonne per hour) is rather high.
Other proposals for horizontal air-float conveying included a stepped air-
gravity conveyor with 'air-lifts' at the end of each downward inclined section
(Figure 15.l0), an air-jet conveyor with forward-facing nozzles at regular
intervals along the channel (Figure 15.11a) and various designs incorporating
inclined slots across the full width of the conveying channel (Figure 15.11b, c).
A number of attempts have been made to operate conveyors of the air-float
type on an upward slope. In fact, the devices mentioned above will move
particulate material up a slight incline, but not very efficiently. More ingenious
systems have been described in the literature which will work on an upward
gradient of around 10°_20° (Figure 15.12), but with the exception perhaps of
some specialized applications, these devices are unlikely ever to be commerci-
ally viable.
Although intended as a variant of the conventional downward-sloping air-
assisted gravity conveyor for handling 'difficult' materials, the 'Pneuslide'
conveyor (Figure 15.l3) is worth mentioning here. This conveyor, which is
plenum chamber
35rrm
dislrilutor
(j) imer pipe
0.<1 • 33 mm
i.<1 · 26 rrm
(jj) outer pipe
0.<1 . 48 rrvn
i.<1 · 40 rrm
Figure 15.13 Cross section of 'Pneuslide' and 'Pneudistributor' [15].
base ofthe channel would normally not exceed 100 mm/s. A simple calculation
then shows that, for example, the maximum power requirement of a 0.5 m-
wide air-gravity conveying channel should be around 250 watts per metre
length. A channel of this width could be expected to have a capacity of at least
500 tonnelh so that the maximum specific power consumption is likely to be in
the region of 0.5 W1m per t/h. Since the air requirement of air-gravity channels
is proportional approximately to their width whilst the conveying capacity is
more nearly proportional to the square of the width, wide channels have a
lower specific power consumption than narrow ones, provided that they
operate at full capacity.
The energy consumption of air-float conveyors operating horizontally or on
an upward incline is less easy to estimate. However, the various forms of air-jet
conveyor could be expected to require the same quantity of air for fluidization
as the air-gravity conveyors, plus an additional air-flow to propel the powder
along the channel. This 'additional' airflow can be several times that required
for fluidization so that the energy consumption of the air-jet conveyors tends
to be rather high.
15.8 Notation
b Width of conveying channel
Solids mass flow rate
Conveying aspect ratio (defined as the ratio of the depth of the
flowing particulate bed to the width of the channel)
Expansion ratio of particulate bed (defined as the ratio of the
bulk density of the unfluidized material to that of the
suspension)
Minimum fluidizing velocity
Terminal velocity of particles in free fall
Average velocity of the conveyed material
Bulk density
References
1. Dodge, J. Verfahren zum FortschafTen von Materialien in Fiirderrinnen mittels Luftdruck
(Procedure for transportation of materials in conveying channels using pressurised air.)
DRP88402, 1895 (German patent).
2. Leitzel, R.E. and Morrisey, W.M. Air-float conveyors. Bulk Materials Handling, Vo1.1, ed.
M.e. Hawk, Univ. Pittsburgh, Sch. Mechn. Eng., 1971,307-325.
3. Bushell, E. and Maskell, R.c. Fluidised handling of alumina powder. Mech. Handling 47(3)
(March 1960) 126-131.
4. Butler, P. No-moving parts conveyor shifts dry powdered solids. Process Engg. August 1974,
65.
5. Woodcock, C.R. and Mason, 1.S. Aspects of the design of air-assisted gravity conveyors for
AIR-ASSISTED GRAVITY CONVEYING 477
the transport of bulk particulate solids. Proc. 71 st Annual AI ChE Conj, Florida, November
1978.
6. Avery, W. Meet the Airslide. Pit and Quarry 41(2) (1949) 62-67.
7. Nordberg, B. Air-activated gravity conveyors. Rock Products, 52, August 1949, 115-124.
8. Anon. Hot dust is conveyed pneumatically from precipitators to furnaces. Eng. and Mining,
J., July 1954,91.
9. Alston, G.L. Advances in rockdusting procedures. Mechanisation, January 1961,46-48.
10. EEUA Handbook No. 15, Pneumatic Handling of Powdered Materials, Constable and Co.,
London, 1963.
11. Hudson, W.G. Why use pneumatic conveyors. Chem. Engg., April 1954, 191-194.
12. Stegmaier, W. Pneumatic chute for the horizontal transport of powdered bulks. Bulk Solids
Technology 2(1) (Spring 1978) 47-55.
13. Shinohara, K. and Tanaka, T. A new device for pneumatic transport of particles. J. Chem.
Engg. of Japan 5(3) (1972) 279-285.
14. Isler, W. An air-slide type conveyor for horizontal and upward inclined transport. Zement-
Kalk-Gips 10 (1960) 482-486 (In German).
15. Singh, B., Callcott, R.G. and Rigby, G.R. Flow of fluidized solids and other fluids in open
channels. Powder Technol. 20 (1978) 99-113.
16. Woodcock, c.R. and Mason, J.S. Air-float conveying of particulate bulk solids. Proc. Int.
Symp. on Fine Particles Processing, Las Vegas, February 1980.
16.1 Introduction
Hydraulic conveying of bulk solids, or 'slurry transport', involves the
conveyance of solid particles in suspension in a moving liquid. Although the
majority of commercially viable slurry pipelines have been constructed to
carry mineral particles in water, almost any combination of solids and liquids
could be possible provided, obviously, that the solid material is not dissolved
or affected in some other unacceptable manner by the carrying liquid. High-
tonnage, long-distance transportation of coal, iron, copper, phosphate,
limestone and various other minerals in hydraulic pipelines is now a well-
established commercial alternative to other modes of bulk solids transport
such as lorries, railway trains and barges.
The essential elements of a general hydraulic conveying system are
illustrated in Figure 16.1. Initially the bulk solid must be prepared, and this
may involve several stages of size reduction by milling and grinding, followed
by mixing with water (or other liquid) to an appropriate consistency. The
slurry is then held in storage tanks, and agitated to keep the solid particles in
suspension, before being pumped into the pipeline. Depending upon the length
of the pipeline, additional pumping stations may be required at intermediate
points. At the reception terminal it is usually necessary to remove most, if not
all, of the carrying liquid in a 'de-watering plant', after which the bulk solid
passes on to the next process.
One of the first reported applications of the conveyance of particulate solids
in hydraulic pipelines was in California around 1850 when gold-bearing sand
was lifted through some 10-20 m and flushed down inclined sluice boxes, but it
was some forty years later when a US patent was granted for pumping coal
slurry [1]. A number of short-distance systems were demonstrated soon after
this, and in 1914 the first medium-length slurry pipeline was carrying coal from
Thames river barges to the Hammersmith power station in London, the
distance involved being some 540m [1]. It was not until the 1950s that the
slurry pipeline really began to compete against other forms of transportation
for moving bulk solids at high rates over long distances, and in the next 30
years or so a large number of commercially operated pipelines began working,
ranging in length from a few miles to around 1000 miles, and handling a variety
of different bulk solid materials. Lists of important slurry pipelines have
appeared in several publications, for instance, [1]-[3], and only two
examples, representing landmarks in the development of hydraulic transport
of solids, will be described here.
';,':;:,7:'·· I HYDRAULIC CONVEYING
The first long-distance hydraulic pipeline for the transport of iron ore was
constructed in north-western Tasmania (Figure 16.2a) in the late 1960s to
carry the low-grade ore from the mine site at Savage River, a distance of 53
miles (85 km) to Port Latta on the north coast [4]. The terrain is rugged and
mountainous, rendering other modes of transport impractical, both from a
technical and economic standpoint. The selected route involved crossing
several deep river gorges, including that of the Savage River itself, which
necessitated suspending the 230 mm-diameter pipe 140 m above the river from
a 365 m long catenary. The annual throughput achieved with the pipeline is
about 2.3 million tonnes.
A pioneering development in the hydraulic transportation of coal has been
the 273 mile (437 km) Black Mesa pipeline in Arizona, USA. The pipeline,
which began commercial operation in 1970, is 450 mm in diameter for most of
its length and transports coal at a rate of around five million tonnes per year. It
crosses a high desert plateau and four mountain ranges on its route from the
Kayenta mine in north-eastern Arizona to the destination in the southern tip
of Nevada (Figure 16.2b). Upward gradients are limited to 16%, principally to
avoid problems occurring as a result of particles falling back along the pipe
during shutdowns. Towards the end of the route the pipeline drops some
1070m in 12miles (19km), and in order to absorb the high pressure head
during this rapid descent the pipe diameter is reduced to 300 mm.
Probably the biggest problem facing planners of long-distance pipelines
concerns the acquisition of rights of way. Legal difficulties in this respect have
caused a long delay to one of the most ambitious slurry transport projects ever
proposed, the 1400 mile (2300 km) American ETSI coal slurry pipeline
designed to carry 25 million tonnes per year through a 950 mm-diameter pipe
from Gillette, Wyoming, southwards to the Gulf Coast.
Of considerable interest recently, especially where the use of water presents
insurmountable difficulties, are proposals to develop slurry systems that
would use other liquids. The two combinations receiving greatest attention are
coal-in-oil and coal-in-methanol [2]. There seem to be few problems with the
480 BULK SOLIDS HANDLING
t---':!!~--- -
I
I
Figure 16.2 The routes of two of the world's major slurry pipelines.
16.2.1 Pumps
Quite a wide variety of pumps are available for handling slurries, and a useful
survey of these can be found in [5]. These fall into two main categories:
reciprocating pumps, subdivided into plunger type and piston type, and
rotodynamic (centrifugal) pumps. They each have advantages and disadvan-
tages, the most significant being that the reciprocating type, being a positive
displacement machine, can attain higher pressures (even to the extent of re-
starting flow in a blocked pipeline) whereas the centrifugal pump is capable of
passing much larger particles (up to 100 mm diameter or more) without serious
damage.
The selection of pumps for a slurry pipeline project would be governed by
three factors: the pressure required, the flow rate required and the nature of the
slurry in terms of the size of solid particles and their abrasiveness. Table 16.1,
from [6], summarizes the capabilities of the main classes of slurry pump on
hydraulic pipeline applications. The pressure requirement is the first factor
that dictates the type of pump to be used, since for pressures greater than about
45 bar the centrifugal machines must be ruled out. The choice between plunger
482 BULK SOLIDS HANDLING
(*Note that these maximum flow rates can usually be obtained only at pressures much smaller
than the maximum shown)
valves
I
connecting plunger
rod
Figure 16.3 The elements of a plunger pump.
piston
rod
I
pumps and piston pumps would then depend mainly upon the abrasiveness of
the slurry concerned (with the former being better for highly abrasive
products) and the flow rate required. Costs, however, especially in terms of the
number of pumps required (including those on standby), must be carefully
considered.
The plunger pump (Figure 16.3) and the piston pump (Figure 16.4) are
generally similar in construction. Both have a crankshaft which drives the
plungers or pistons through connecting rods and crossheads. The plunger-type
pumps are necessarily single-acting, but piston pumps may be either single- or
double-acting. Since abrasive particles trapped between the piston and the
HYDRAULIC CONVEYING 483
cylinderwallwouldresultinveryhighratesofwear,itisusualwhen handling such
materials to employ plunger pumps in which the plunger is continuously flushed
with clear water during the suction stroke. Valves are usually of the automatic
type, designed to minimize the effects of erosion and to pass reasonable sized
particles (up to about 1.5 mm).
Figure 16.5 A centrifugal pump for slurry handling (photo courtesy Warman International Ltd).
484 BULK SOLIDS HANDLING
Reciprocating pumps are used on both the Savage River and Black Mesa
slurry pipelines. The former uses four 450 k W triplex plunger pumps, arranged
in parallel, two of them being variable-speed in order to allow some
adjustment of the throughput and to make possible a gradual start after a
shutdown. The maximum working pressure of these machines is 140 bar
(2000 Ibf/in 2 ) and each delivers 88 m 3 /hour. The Black Mesa pipeline has four
pumping stations each equipped with double-acting duplex piston pumps.
One station has four 1300kW pumps, each rated for 320m 3 /hour at 110 bar,
and the others each have three 1120 kW or 1300 kW pumps, delivering
480m 3 /hour at the lower pressure of 76 bar. These pumps transport 670
tonnes/hour of coal at a concentration of 48% by mass, corresponding to a
volumetric flow rate of 960 m 3 /hour [6].
Centrifugal pumps (Figure 16.5) are more commonly used and tend to be
the automatic choice for short-distance applications and on in-plant oper-
ation where the relatively low maximum working pressure (about 50 bar, for
multiple pumps in series) does not prove to be a limitation. In order to
minimize wear, centrifugal pumps are commonly lined with rubber, and this
places a restriction on the impeller speed and the particle size of a slurry, since
large particles travelling at high velocities can have sufficient inertia to cut the
rubber lining. Pumps for coarse-particle slurries are lined with wear-resistant
metal alloys and can operate at higher heads since greater impeller tip-speeds
are permissible. However, the need to pass large particles means that these
pumps are designed with impellers and casings having wide flow passages, and
the hydraulic efficiency tends therefore to be low.
A typical application of centrifugal pumps is on the Waipipi Iron Sands
project in New Zealand, which includes a 6.4 km land pipeline followed by a
2.9 km undersea section. There are three pumping stations, having ten
centrifugal pumps distributed amongst them, ranging in capacity from
190kW, 520m 3 /hour up to 600kW, 1460m 3/hour. The smaller pumps,
arranged five in series in the main booster station and three in series on a
concentrator barge, have a maximum discharge pressure of 28 bar, whilst the
larger ones, mounted six in series on a ship-loading station, are rated at 46 bar
[6].
A system that has been developed for handling very abrasive slurries is
based on the use of 'lock-hoppers' (Figure 16.6). These allow conventional
multistage pumps to develop high heads with clear water whilst the slurry is
switched in and out of the lock-hoppers by sequenced valves. Another device
which has the same general objective of feeding the solids into the pipeline
downstream of the main or primary pumps, so allowing these to work with
clear water, is the jet pump (Figure 16.7). The driving fluid, from a conventional
primary pump, flows at high velocity through the central nozzle and entrains
solids-laden fluid, mixing with it in the throat section. In order to obtain a
reasonable delivery pressure, the flow rate of the driving fluid is likely to be of
the same order as the entrained flow.
HYDRAULIC CONVEYING 485
slu-ry from
to rrai1skny
water r9l\rn
Figure 16.6 A lock-hopper system for use with abrasive slurries. Note: system is illustrated with
valves b, c, e and h open, and valves a, d, f and g closed so that lock-hopper A is discharging slurry
into the pipeline under the action of high-pressure water being supplied through valve e. Lock-
hopper B is filling through valve c. All the valves are reversed when lock-hopper A is empty of
slurry and lock-hopper B is full.
driVing__
/
........J::-/--r"""'
7··ng.---tubei'/- - - - -
''-.. . .-----"---
fluid "- delivered
0:-
fluiL-
etfkJen
out
evacuated segnents
caked soids
scraper blade
surface of the bowl by centrifugal sedimentation. The liquid leaves the bowl
over a weir-plate at the cylindrical end whilst the solids leave from the opposite
end, propelled by the rotation of the screw relative to the bowl. Adjustment of
the position of the weir plate allows the depth of the water layer in the bowl to
be altered, greater depth giving a clearer effiuent but increasing the fines
content and the moisture content of the de-watered solids.
The basket centrifuge or screen-bowl centrifuge is somewhat similar, but the
rotating cylindrical bowl is constructed of fine mesh, typically of 200-1000 pm
aperture size. Slurry enters the bowl axially at one end and is distributed over
the inside surface of the cylindrical screen. It is propelled along the bowl, either
by the action of a rotating screw conveyor or by an axial oscillation applied to
the bowl. The de-watering mechanism is thus essentially filtration, with the
fine particles that pass through the mesh being returned to the bowl for further
processing, and the caked solids being thrown off at the discharge end of
the bowl.
Vacuum and pressure filtration, particularly the former, are commonly-
used ways of removing the water from a conveyed slurry. They offer a
HYDRAULIC CONVEYING 489
somewhat more gentle approach to the recovery of the solids and are therefore
better for fragile materials. The simplest form is the rotary drum filter in which
the filter cloth covers the surface of a cylindrical drum arranged with its axis
horizontal. The interior of the drum is evacuated as it rotates slowly with
about one-third of its surface immersed in the slurry to be de-watered. Liquid
passes through the filter and is collected in a filtrate tank whilst the solids cake
on the surface of the drum is progressively dried as the drum turns
(Figure 16.9). After about three-quarters of a revolution the de-watered solids
cake is removed from the drum by means of a scraper knife or by a temporary
reversal of air flow through one segment of the filter.
There are many variations on the theme of filtration, with the filter cloth
being arranged on plates or discs, for example, but their principle of operation
is basically the same.
pumps, and long distance oil and gas pipeline construction techniques, rather
than the development of new hardware to suit the slurry. Thus, a fundamental
understanding of slurry flow behaviour in a stable and controlled environment
was the basis upon which advances in the technology of slurry pipelines were
made.
The economics of slurry pipelines are 'site-sensitive' and so it is difficult to
generalize. One major variable in comparing transport alternatives is the
overall conveying distance. Since pipelines can often take a fairly direct route,
they are usually significantly shorter than rail or road routes which have more
severe grade and construction restrictions, or barge routes which have obvious
length and location restraints. In addition, generalized comparisons are
difficult where existing alternative transport modes are available. Some
general observations which can be made are as follows.
Annual tonnage. A throughput of one million tonnes per year (about 115 tlh
on continuous operation) or more is likely to be necessary iftransport by a new
slurry pipeline is to be competitive with other transport modes. However, for
certain applications, such as transporting high-value minerals such as copper
from remote locations, annual throughputs of only a few thousand tonnes can
be commercially viable.
Terrain and location. Slurry pipelines are often selected as the best mode of
transport where the terrain is difficult and the location is remote. Pipelines are
easier to construct in remote areas than roads and railways since they have less
restrictive grade requirements and can be installed at rates of several
kilometres per day by conventional long-distance pipeline construction
techniques. Also, since the pipeline can be buried and pumping stations can be
spaced 50-100 miles apart, remote operations and maintenance are relatively
simple.
,
.~
8
.~
solids concentration -
Figure 16.10 General form of relationship between slurry viscosity and solids concentration.
particular, the modes of flow that they exhibit when pumped through
pipelines, is crucial to the successful design of hydraulic conveying systems. As
mentioned previously, two distinct flow regimes can be conveniently
identified-homogeneous flow (non-settling slurries) and heterogeneous flow
(settling slurries). These have been described in more detail in Chapter 3
(section 3.7.1) and at this point the reader should refer back to that and the
following sections for a discussion of the modelling of the different modes of
flow and the use of these models for the prediction of pressure-drops in
flowing slurries. The various correlations given, and the associated charts,
should enable pressure-drops to be determined with sufficient confidence at
least for a preliminary design study.
In practical slurry pipeline systems the critical variables, which are to some
extent interrelated, are the pumping velocity and the solids concentration. The
viscosity of the slurry is clearly dependent upon the concentration of solids,
but in general the form of the relationship is not linear (Figure 16.10). The
optimum working concentration for slurry pipelines is likely to be around the
'knee' of the curve in order to balance the requirements of maximum solids
throughput and lowest pumping power. The pumping velocity will also
influence the power requirement and for this reason, as well as to minimize
problems of erosive wear, the velocity should be kept reasonably low.
However, the velocity must not be so low that the solids begin to settle out of
suspension (assuming that the system is being designed on the basis of
homogeneous flow).
References
1. Zandi, I and Gimm, K.K. Transport of Solid Commodities via Freight Pipeline (Freight
Pipeline Technology; Volume 2). US Department of Transportation, Report No. DOT-TST-
76T-36, July 1976.
2. Link, J.M., Pouska, G.A. and Kirshenbaum, N.W. Mineral slurry transport-an update.
Proc. Int. Symp. on Fine Particles Processing, Las Vegas, February 1980,282-298.
3. Zandi, I. Freight pipelines, J. Pipelines 2(1982) 77-93.
4. McDermott, W.F. Savage River Mines, the world's first long distance iron ore slurry pipeline.
In Bulk Materials Handling, ed. M.C. Hawk, U niv. of Pittsburgh School of Engineering, 1971,
216-238.
5. Thompson, T.L., Frey, R.J., Cowper, N.T.; and Wasp, E.J. Slurry pumps: a survey. Proc.
Hydrotransport 2, BHRA Conf., Conventry, UK, September 1972, Paper HI.
6. Wasp, E.J., Kenny, J.P. and Gandhi, R.L. Solid-Liquid Flow Slurry Pipeline Transportation.
Trans Tech. Publications and Gulf Publishing Company, 1979.
HYDRAULIC CONVEYING 493
7. Baker, P.J., Jacobs, B.E.A. and Bonnington, S.T. A Guide to Slurry Pipeline Systems. BHRA
Fluid Engineering, 1979.
8. Duckworth, R.A., Pullum, L., Addie, G.R. and Lockyear, C.F. The pipeline transport of coarse
materials in a non-Newtonian carried fluid. Proc. Hydrotransport 10, BHRA Cone.,
Innsbruck, October 1986, 69-88.
9. Davies, G. Coal slurry fuels get closer. The Chemical Engineer, January 1986, 17.
10. Sauermann, H.B. Recent developments in hydraulic pipelines. Materials Handling News,
April 1982, 18-24.
Bain, A.G. and Bonnington, S.T. The Hydraulic Transport of Solids by Pipeline. Pergamon,
Oxford, 1970.
Baker, PJ., Jacobs, B.E.A. and Bonnington, S.T. A Guide to Slurry Pipeline Systems. BHRA Fluid
Engineering, 1979.
Wasp, E.J., Kenny, J.P. and Gandhi, R.L. Solid-Liquid Flow Slurry Pipeline Transportation. Trans.
Tech. Publications and Gulf Publishing Company, 1979.
s
17 Capsule transport
17.1 Introduction
In the preceding chapters (12-16) of this book, various aspects of the
transportation of bulk particulate and granular materials in pipelines have
been discussed. The concept was that if the bulk solid were to be fed
continuously into a gas or a liquid flowing steadily along a pipeline, the
particles would be conveyed by the fluid to the outlet end where they could be
disengaged from the carrier fluid in a suitable separation unit. An alternative
approach to the pipeline transportation of bulk solids, especially in cases
where, for some reason, it is undesirable for the conveyed material to come
into contact with the carrier fluid, is to enclose the bulk solid in cylindrical or
spherical capsules, of diameter only slightly less than that of the pipeline, and
then use the gas or liquid to propel these capsules from one end of the pipeline
to the other.
The term 'capsule transport' is used here to mean any system that involves
the transportation of cargo (usually, but not necessarily, bulk solid) in capsules
propelled by fluid moving through a pipeline. This definition could encompass
the familiar systems, often seen in department stores, hospitals and factories, in
which documents and small samples are transported in cylindrical containers
through small-diameter pipes, usually operating under a vacuum. The
definition could be extended to include the case where the bulk material is pre-
formed (for example, by sintering) into relatively large solid cylinders or
spheres. Although the mechanism of transportation is very similar, these solid
cylinders or spheres should not, of course, be called 'capsules'.
Of the two distinct methods of capsule transportation-by gas (usually air)
and by liquid (usually water)-it was the former that was developed first and
was the first to be used commercially. Pneumatic capsule systems were first
built and demonstrated in England in the 1820s, although it was more than ten
years earlier, in 1810, that George Medhurst, an English engineer, had
suggested this method for the conveyance of letters and goods at high speed
through small-diameter pipes [1]. The first experimental system is believed to
have been that of John Vallance, which comprised a wheeled carriage 5t feet
(1.7 m) wide and 22 feet (6.7 m) long, running on rails through a tube 8 feet
(2.4m) in diameter and 150 feet (46 m) long. Considerable development of the
concept of pneumatically-propelled capsules for the conveyance of goods and
personnel was undertaken during the mid-19th century by the Pneumatic
Despatch Company [2]. They were responsible for laying an experimental
CAPSULE TRANSPORT 495
Figure 17.1 An experimental pneumatic capsule pipeline laid alongside the River Thames,
London, in 1861 [3] (Illustrated London News).
tube, some 400 metres in length, along the bank of the River Thames at
Battersea in London (Figure 17.1). This tube was moved and extended to
550 m to run underground between Euston Station and a nearby post office,
carrying parcels in the wheeled capsules at speeds of about 7.5 metres/second
(Figure 17.2).
Various similar tunnels were constructed in London for the conveyance of
parcels and, in August 1864, a full-size passenger-carrying pneumatic railway
was demonstrated at Crystal Palace in London (Figure 17.3). Passengers were
conveyed in a wheeled carriage through a tunnel approximately 3 m in diameter
and 550 m long [2] but, since the journey was undertaken in darkness, the
effect of claustrophobia must have been considerable! Shortly after this a
similar underground system was constructed in New York with the intention
of ,demonstrating the practicability of passenger conveyance by the pneumatic
method' [2]; however, it is doubtful whether fare-paying passengers were ever
carried.
There was little further progress towards the development of a pneumatic
capsule pipeline for the transport of passengers, but the Pneumatic Despatch
Company, and later the Post Office, built up a system of tunnels under London
for carrying letters and parcels. A similar system using a 450 mm-diameter pipe
2 km in length, has been operating in Hamburg, West Germany, since 1962,
and others have been developed in France, Japan and the USA [1].
In the use of pneumatic capsule pipelines for the transport of bulk solids the
Soviet Union seems to have made the most impressive progress. Systems either
in operation or under consideration (in 1978) included one for carrying ore at a
rate of four million tonnes per year over a distance of 6 km, and another to
transport broken stone a distance of 50 km at 2.4 million tonnes per year [6].
In Georgia in the Soviet Union there is a commercially-operated system
carrying gravel in trains of six capsules which travel at 15 m/s through a one-
metre diameter pipeline [1]. This pipeline was 2.2 km in length, but a second,
some 50 km long and having a capacity of 2 million tonnes per year, was under
construction in 1980.
A system in Japan, consisting of a 600 mm diameter pipeline 1.4 km in
~
\0
0\
t:C
c:::
r
~
~
r
S
en
:I:
~
tl
r
Z
Cl
Figure 17.2 Wheeled capsules used in an early form of pneumatic pipeline for the transport of
parcels [4] (Illustrated London News).
(')
>
-a
e
r'
tTl
;d
>
z
~...,
.j:>.
\0
Figure 17.3 A pneumatically-propelled passenger-carrying 'capsule' demonstrated at Crystal --.J
Perhaps because it has been recognized that the wheels are almost
invariably the weakest part of the capsule there have been attempts to
eliminate them. One of the most interesting proposals is a system of magnetic
suspension so that there is no physical contact between the capsules and the
pipeline. The planned propulsion system in this case involves linear induction
motors, but the use of air to drive the capsules might be a feasible alternative
[9].
In general, bulk solids would be carried in closed capsules with automatic
loading and unloading. In a conventional capsule fitted with a long curved lid,
a useful arrangement is to fit one ofthe guide wheels at each end of the capsule
to the lid. This serves to keep the lid firmly shut whilst the capsule is in the
pipeline and provides a convenient means of opening the lid at the loading and
unloading stations.
The air seal is usually provided by a flexible skirt mounted between the
wheel assembly and the capsule body. This is slightly smaller than the internal
diameter of the pipeline in order to provide maximum aerodynamic thrust
with minimum friction of the capsule against the pipe wall. The aerodynamic
thrust, and therefore the velocity of the capsule, is clearly a function of the
proportion of the pipe cross-section occupied by the capsule and its flexible
skirt. In an interesting recent development, the seal was provided by an end-
plate fitted to the capsule, this end-plate being specially constructed to allow
the opening and closing of ports by remote control. In this way the
'effectiveness' of the seal can be adjusted, giving some measure of external
control of the capsule velocity [10].
The dimensions of the capsules are determined to some extent by the
internal diameter of the pipeline and the radius of curvature of the bends
(Figure 17.6). For any given pipe bend, the extremes of capsule size will range
from a very short capsule with diameter only slightly smaller than that of the
pipe, to a very long capsule of minimal diameter. Obviously neither of these
extremes is practical as the volume in each case approaches zero, but
somewhere between there will be an optimum value of the length/diameter
ratio (or 'slenderness ratio') for which the payload volume of the capsule is a
maximum. It is found [11] that, for a given pipe size and curvature, the volume
of the capsule body is nearly proportional to its length and the body weight is
nearly proportional to the cube of its length. There is therefore a practical limit
Figure 17.6 Relationship between the geometry of the pipeline and that of the capsule.
CAPSULE TRANSPORT 501
on the slenderness ratio that can be used, giving due consideration to the
structural integrity of the capsule, and a value of about 7 is recommended [11].
Except for relatively sharp bends (having a radius of curvature less than about
30 pipe diameters) the length of capsule to give maximum payload volume
would be too great for it to be structurally sound,~and therefore it is usually the
limiting slenderness ratio of about 7 that dictates the dimensions of the
capsules.
Transport rate
(million tonnes per year) Pipeline diameter (mm)
1 600-1000
2 800-1200
5 1000-1400
502 BULK SOLIDS HANDLING
~~f' L,~~~~~~""",,==
Figure 17.8 Flap-gate booster for pneumatic capsule pipeline. Pressure ahead of approaching
capsule causes the flap gate to open automatically. Flap closes after capsule has passed.
advance of it, causes the gate automatically to open so that the capsule passes
through without making physical contact.
Because of the practical limit on the air velocities that can be allowed in the
pipeline there is no advantage in attempting to use very high pressures in order
to reduce the number of L>ooster stations required. Roots-type blowers, or
machines having similar characteristics, are generally employed, providing air
at pressure of 0.5-0.8 bar. The critical aspect of the system design is then, as
explained previously, the spacing of the booster stations to maintain
movement of the required number of capsules at the required \lelocity.
Figure 17.9 A booster station, featuring a capsule by-pass arrangement, for a hydro-capsule
transport system.
Vl
o
--J
508 BULK SOLIDS HANDLING
(17.1)
Capsules will need to be returned to the loading point at the same rate, and
therefore assuming that the outgoing pipeline and the return line are the same
CAPSULE TRANSPORT 509
length,
V2 N 2 v1 N 1
-- -- (17.2)
L L
where N 2 is the number of capsules in the line and V2 is their velocity.
Thus
=Nl( 1 + ~J
i.e.
(17.3)
N=
p
rnA '~(1 + V2VI)
3.6hA mcvl
(17.4)
where hA is the annual hours of system operation (that is, hours/year) taking
account of downtime for regular maintenance, shutdown at weekends, and so
on.
There will also be active capsules passing through the terminals and the
number of capsules thus involved will depend on the proportion of the total
cycle time that is actually spent in the terminals.
Now the time taken for a capsule to travel along the outgoing pipeline is
L L L( VI)
t 1 +t 2 =-+-=- 1+- (17.5)
VI V2 VI v2
Then if the time spent in the loading station is ta and in the unloading station
510 BULK SOLIDS HANDLING
or
rnAtcycle
N tot =----'-'--"-'.':"::"::'" (17.6)
3.6h A mc
The capsule fleet size will exceed this total by some small number to allow
for standby in case of breakdowns.
17.5 Notation
hA Annual hours of system operation (hours per year).
L Length of conveying line
me Mass of cargo in one capsule
rnA Annual throughput of bulk solid (tonnes per year)
rns Effective mass flow rate of bulk solid through pipeline
Nt Number of capsules in outgoing (loaded) pipeline
Nz Number of capsules in return pipeline
Np Number of active capsules in pipeline
N tot Total number of capsules in service
tt Transit time for capsule in outgoing pipeline
tz Transit time for capsule in return pipeline
ta Time spent by capsule in loading terminal
tb Time spent by capsule in unloading terminal
tcycle Total time taken by capsule to navigate whole system (total
cycle time).
References
1. Simper, 1.1. and Baker, PJ. Pneumatic pipeline capsule systems-the future potential. Proc.
Pneumotransport 2, BHRA Conf., Guildford, UK, September. 1973, F4. 31~39.
2. Lee, C.E. The Pneumatic Despatch Company's Railways. Trans. Newcomen Society 45 (1974)
67~88.
3. Illustrated London News, 24 August 1861, 178.
CAPSULE TRANSPORT 511
4. Ibid. 28 February 1863, 213
5. Ibid. 10 September 1864,276.
6. Alexandrov, A.M. Pneumatic pipeline container transportation of goods. Proc. Pneumo-
transport 4, Carmel-by-the-Sea, USA, June 1978, G5. 51-59.
7. Yoshitani, Y. Application of capsule transport system for raw material transport in steelworks.
Proc. Pipeline 78 Seminar, Univ. of Witwatersrand, South Africa, October 1978.
8. Liu, H. Capsule pipelines: potential and research direction. Proc. 4th Int. Symp. on Freight
Pipelines, Atlantic City, USA, October 1982.
9. Marcus, R.D. Pneumatic conveying update. Pneumatic Conveying Manual 1984, suppl to
South Africa Materials Handling News, 2-12.
10. Tsuji, Y., Morikawa, Y. and Seki, W. Velocity control in a capsule pipeline by changing the
area of the end-plate. J. Pipelines 5 (1985) 147-153.
11. Bunce, J.A. Capsules for pneumatic pipelines. Proc. Pneumotransport 4, BHRA Conf., Carmel-
by-the-Sea, USA, June 1978, G1. 1-18.
12. AIRAPID capsule-tube transport system. Brochure, Nippon Steel Corporation and Daifuku
Machinery Works Ltd., Tokyo, Japan.
13. Carstens, M.R. Analysis of a low-speed capsule-transport pipeline. Proc. H ydrotransport 1,
BHRA Conf., Coventry, UK, September 1970, C4. 73-88.
14. Tsuji, Y. Fluid mechanics of pneumatic capsule transport. Bulk Solids Handling 5 (3) (June
1985) 653-661.
15. Farahar, M.A. Transport of aggregates by the pneumatic capsule pipeline. Proc. Pneurno-
transport 3, BHRA Conf., Bath, UK, April 1976, A9 115-126.
16. Jensen, EJ. Capsule pipelining-the system and its potential. Proc. Hydrotransport 3, BHRA
Conf., Colorado, USA, May 1974, G1. 1-11.
17. Ellis, H.S. An analysis of the lift-off of pipeline capsules. Proc. H ydrotransport 4, BHRA Conf.,
Alberta, Canada, May 1976, C1. 1-12.
18. Kruyer, J and White, L.M. Hydrodynamics for the design of a capsule pipeline. Proc.
Hydrotransport 4, BHRA Conf., Alberta, Canada, May 1976, C2. 13-22.
19. Polderman, H.G. Analytical and experimental studies on horizontal and vertical capsule
transport. Proc. Hydrotransport 6, BHRA Conf., Canterbury, UK, September 1979, 169-186.
20. Lazarus, J.H. Hydraulic transport of capsules in pipelines. Proc. Int. Conf. on Pipeline
Transportation of Solids, Univ. of Witwatersrand, South Africa, 1981.
21. Lazarus, lH. Booster pumps for hydraulic transport of capsules in pipelines. Proc.
Hydrotransport 6, BHRA Conf., Canterbury, UK, September 1979, D2. 187-200.
Index
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514 INDEX