Bulk Solids Handling

Bulk Solids Handling: Equipment Selection and Operation Edited by Don McGlinchey 2008 Blackwell Publishing Ltd. ISBN: 978-1-405-15825-1

Bulk Solids Handling

Equipment Selection and Operation
Edited by

Don McGlinchey
Reader Centre for Industrial Bulk Solids Handling Glasgow Caledonian University UK

c 2008 by Blackwell Publishing Ltd Blackwell Publishing editorial ofces: Blackwell Publishing Ltd, 9600 Garsington Road, Oxford OX4 2DQ, UK Tel: +44 (0)1865 776868 Blackwell Publishing Professional, 2121 State Avenue, Ames, Iowa 50014-8300, USA Tel: +1 515 292 0140 Blackwell Publishing Asia Pty Ltd, 550 Swanston Street, Carlton, Victoria 3053, Australia Tel: +61 (0)3 8359 1011 The right of the Author to be identied as the Author of this Work has been asserted in accordance with the Copyright, Designs and Patents Act 1988. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, except as permitted by the UK Copyright, Designs and Patents Act 1988, without the prior permission of the publisher. Designations used by companies to distinguish their products are often claimed as trademarks. All brand names and product names used in this book are trade names, service marks, trademarks or registered trademarks of their respective owners. The publisher is not associated with any product or vendor mentioned in this book. This publication is designed to provide accurate and authoritative information in regard to the subject matter covered. It is sold on the understanding that the publisher is not engaged in rendering professional services. If professional advice or other expert assistance is required, the services of a competent professional should be sought. First published 2008 by Blackwell Publishing Ltd ISBN: 978-1-4051-5825-1 Library of Congress Cataloging-in-Publication Data Bulk solids handling : equipment selection and operation / edited by Don McGlinchey. 1st ed. p. cm. Includes bibliographical references and index. ISBN-13: 978-1-4051-5825-1 (hardback : alk. paper) ISBN-10: 1-4051-5825-5 (hardback : alk. paper) 1. Bulk solids handlingEquipment and supplies. I. McGlinchey, Don. TS180.8.B8B853 2008 621.8 6dc22 A catalogue record for this title is available from the British Library Set in 10/12 pt Times by Aptara Inc., New Delhi, India Printed and bound in Singapore by C.O.S. Printers Pte Ltd The publishers policy is to use permanent paper from mills that operate a sustainable forestry policy, and which has been manufactured from pulp processed using acid-free and elementary chlorine-free practices. Furthermore, the publisher ensures that the text paper and cover board used have met acceptable environmental accreditation standards. For further information on Blackwell Publishing, visit our website: www.blackwellpublishing.com

Contents

Contributors Aims and Scope Acknowledgements

xi xii xiii 1 1 3 3 3 3 3 5 8 8 10 10 11 11 11 11 13 15 16 20 20 22 23 24 25 27 27 27 29 29 29
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1 Bulk powder properties: instrumentation and techniques NAYLAND STANLEY-WOOD

1.1 Introduction 1.1.1 Density 1.1.2 Particleparticle bonding 1.1.3 Particle packing 1.1.4 Flowability 1.1.5 Variables contributing to bulk powder properties 1.2 Particle and powder densities 1.3 Determination and protocol for bulk density 1.3.1 Aerated bulk density 1.3.2 Poured bulk density 1.3.3 Tap density 1.3.4 Fluidised bulk density 1.3.5 Compressed and compact bulk density 1.4 Flow properties from powder bulk densities 1.4.1 Hausner ratio 1.4.2 Carrs percentage compressibility from bulk densities 1.4.3 Compacted bulk density 1.4.4 Ergun particle density 1.4.5 Application of the Hausner ratio to uidised powder systems 1.4.6 Floodability 1.4.7 Flowability 1.4.8 Dispersibility or dustiness 1.4.9 Permeability 1.4.10 Wall friction tester 1.5 Powder angles 1.5.1 Poured and drained angles 1.5.2 Static angle of repose of a heap 1.5.3 Angle of fall 1.5.4 Angle of difference 1.5.5 Dynamic angle of repose

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CONTENTS

1.6 Bulk powder ow properties from internal angles and shear 1.6.1 Failure properties 1.6.2 Flowability and failure 1.6.3 Failure function from shear tests 1.6.4 Jenike effective angle of internal friction 1.7 Instrumentation for the measurement of tensile strength and cohesion 1.7.1 Cohesiveness and tensile strength 1.7.2 Split cell and lifting lid (vertical shear) instruments for tensile strength and cohesiveness 1.7.3 Direct measurement of cohesion 1.7.4 Uniaxial compression 1.8 Bulk power correlations 1.8.1 Relationships between cohesion and tensile strength 1.8.2 The inuence of particle characteristics on bulk powder properties 1.8.3 Overview of the instrumentation and techniques available for the determination of bulk powder properties References
2 Hopper/bin design JOHN W. CARSON

30 30 31 34 36 37 37 38 41 44 53 54 57 59 62 68 68 69 74 76 76 78 78 79 79 79 82 82 82 85 85 89 91 92 93 93

2.1 2.2 2.3 2.4 2.5 2.6

Fundamentals Flow patterns Arching Ratholing Flow rate Segregation 2.6.1 Sifting 2.6.2 Dusting (particle entrainment) 2.6.3 Fluidisation (air entrainment) 2.7 Importance of outlet and outlet region 2.8 Aerated versus non-aerated 2.9 Selection criteria 2.9.1 How to set bin size 2.9.2 Flow pattern selection 2.9.3 Inlets and outlets 2.9.4 Inserts 2.9.5 Cylinder geometry 2.9.6 Materials of construction 2.9.7 Type of feeder and valve 2.9.8 Safety and environmental considerations

CONTENTS

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2.10 Operational aspects 2.10.1 No ow or erratic ow 2.10.2 Flow rate problems 2.10.3 Particle segregation 2.10.4 Excess stagnant material 2.10.5 Structural concerns 2.10.6 Process problems 2.10.7 Abrasive wear and attrition 2.10.8 Feeder problems References
3 Silo and hopper design for strength J. MICHAEL ROTTER

93 94 94 94 95 95 97 97 98 98 99 99 99 99 101 102 103 103 103 106 107 110 113 114 114 116 117 122 124 125 125 125 129 131 132 132 132 135 135 135

3.1 Introduction 3.2 Why pressures in silos matter 3.2.1 General 3.2.2 Classications of silos 3.2.3 Metal and concrete silos 3.3 Pressures in silos: basic theory 3.3.1 Early studies 3.3.2 Janssen silo pressure theory for vertical walls 3.3.3 The lateral pressure ratio K 3.3.4 Pressures in hoppers 3.3.5 Simple structural concepts for cylinders 3.3.6 Variability of the properties of stored solids 3.4 Pressure changes during discharge of solids (emptying) 3.4.1 First discoveries and explanations 3.4.2 A better understanding 3.4.3 Pressure observations during emptying 3.4.4 The importance of ow patterns during discharge 3.4.5 Eccentric discharge and its consequences 3.5 Structural damage and its causes 3.5.1 Introduction 3.5.2 Steel and aluminium silos 3.5.3 Concrete silos 3.6 Design situations 3.7 Concluding remarks Acknowledgements References
4 Pneumatic conveying DAVID MILLS AND MARK JONES

4.1 Introduction 4.1.1 System exibility

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CONTENTS

4.2

4.3

4.4

4.5

4.6

4.1.2 Industries and materials 4.1.3 Modes of conveying Conveying system types 4.2.1 Open systems 4.2.2 Positive pressure systems 4.2.3 Negative pressure (vacuum) systems 4.2.4 Staged systems 4.2.5 Shared negative and positive pressure systems 4.2.6 Dual vacuum and positive pressure systems 4.2.7 Batch conveying systems 4.2.8 Mobile systems 4.2.9 Closed systems 4.2.10 Innovatory systems System components 4.3.1 Pipeline feeding devices 4.3.2 Gassolid separation 4.3.3 Air supply 4.3.4 Air compression effects 4.3.5 Power requirements 4.3.6 Pipelines and valves Conveying capability 4.4.1 Pipeline bore 4.4.2 Conveying distance 4.4.3 Pressure 4.4.4 Conveying air velocity 4.4.5 Particle velocity 4.4.6 Material properties 4.4.7 Dense phase conveying 4.4.8 Sliding bed ow 4.4.9 Plug ow 4.4.10 Dilute phase conveying Conveying system design 4.5.1 Conveying air velocity 4.5.2 Compressor specication 4.5.3 Solids loading ratio 4.5.4 The air only datum 4.5.5 Acceleration pressure drop 4.5.6 Scaling parameters 4.5.7 Scaling model 4.5.8 Scaling procedure Troubleshooting 4.6.1 Material ow rate problems 4.6.2 Pipeline blockage 4.6.3 Conveying limits 4.6.4 Air leakage

136 136 137 138 138 138 140 140 141 141 144 145 146 148 149 157 159 162 163 164 170 171 171 171 171 172 172 172 173 175 176 178 179 180 180 181 182 182 183 186 187 187 187 188 190

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4.6.5 Performance monitoring 4.6.6 System optimising 4.6.7 Erosive wear 4.6.8 Particle degradation References Nomenclature
5 Screw conveyors LYN BATES

191 192 193 195 196 196 197 197 199 201 203 204 205 206 209 209 210 211 211 211 217 218 219 219 221 221 221 226 228 230 232 235 236 239 240 240 241 243 244

5.1 5.2 5.3 5.4 5.5 5.6

Introduction Classes of screw equipment Standard screw conveyor features The many operating benets of screw conveyors General limitations of screw conveyors Screw conveyor capacity 5.6.1 The effect of machine inclination 5.7 Power requirements 5.7.1 Empty running 5.7.2 Power to transport material 5.7.3 Conveyors subjected to ood feed conditions 5.8 Screw feeders 5.8.1 Hopper discharge screws 5.9 Power needs of screw feeders 5.10 Dispensing screws 5.11 Special screw feeders References
6 Trough conveying DON MCGLINCHEY

6.1 Introduction 6.2 The chute 6.2.1 Operational problems 6.3 Vibratory conveyors 6.3.1 Estimation of solids ow rate 6.3.2 System choices 6.3.3 Mount 6.4 Air slides 6.4.1 Selection considerations 6.4.2 Air requirement 6.4.3 Maintenance and troubleshooting 6.5 Chain and ight conveyors 6.5.1 En masse conveyor 6.5.2 En masse conveyor design considerations

CONTENTS

6.5.3 En masse conveyor performance calculations 6.5.4 En masse conveyor applications 6.6 Summary References Nomenclature Further reading
7 Small-scale bulk handling operations ANDREW COWELL

245 246 246 248 248 249 250 250 251 251 256 260 265 272 274 279 279 284 285 287

7.1 Introduction 7.2 Equipment 7.2.1 Aeromechanical conveyors 7.2.2 Bag dump stations 7.2.3 Bulk bag dischargers 7.2.4 Bulk bag llers 7.2.5 Drum dumpers 7.2.6 Flexible screw conveyors 7.2.7 Sack llers 7.2.8 Small volume batch conveyors 7.3 Summary References
Index

Contributors

L. Bates J.W. Carson A. Cowell M. Jones D. McGlinchey D. Mills J.M. Rotter

Ajax Equipment Ltd, Milton Works, Mule Street, Bolton, BL2 2AR, UK Jenike & Johanson, Inc, 400 Business Park Dr., Tyngsboro MA 01879, USA School of Engineering and Computing, Glasgow Caledonian University, Cowcaddens Road, Glasgow, G4 0BA, UK Division of Mechanical Engineering, The University of Newcastle, Callaghan Campus, Callaghan, NSW 2308, Australia School of Engineering and Design, Glasgow Caledonian University, Cowcaddens Road, Glasgow, G4 0BA, UK Pneumatic Conveying Consultant, 9 Cherry Orchard, Old Wives Lees, Canterbury, Kent, CT4 8BQ, UK Institute for Infrastructure and Environment, School of Engineering and Electronics, University of Edinburgh, Edinburgh, EH9 3JL, Scotland, UK Selwood, Brock Road, St Peter Port, Guernsey, GY1 1RB, UK

N. Stanley-Wood

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Aims and scope

The readership is expected to be engineers, scientists and technologist, most likely process operators and chemical engineers or mechanical engineers or physicists. They may be young engineers or role changers with little formal education in bulk solids handling who have responsibility for handling, storage, processing or production involving particulate materials. The topics covered by the book will include the characterisation of individual particles and bulk particulate materials, silo design for strength and ow, pneumatic conveying systems, mechanical conveying, small-scale operations. Belt conveying will not be covered in this volume. The material in the book will provide an overview and discuss the limitations and applications of the technology. Guidance will be given on making appropriate equipment choices. Operational issues will be discussed and will include example calculations and case studies. The book aims to provide the reader with the breadth of knowledge to give a good general understanding of the major technologies involved in the storage and handling of particulate materials from large grains to ne cohesive materials. This will place the reader in a better position of being able to diagnose solids handling and storage problems in industry and to deal with experts and equipment suppliers from an informed standpoint. The material contained in the book is designed to be equally applicable to engineers and scientists working in a broad spectrum of industries, for example agriculture, agrochemicals, cement, construction, food, bulk and ne chemicals industries, minerals and metals, petro-chemicals, pharmaceuticals, plastics, pigments, power generation and waste handling.

xii

Acknowledgements

I wish to thank all the authors who made such signicant contributions to this book. I thank all at Wiley-Blackwell for their advice and help in bringing the book together. I would also like to thank colleagues at Glasgow Caledonian University for their support and time.

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