.

Powder Technology 104 1999 5667

The influence of granular vortex motion on the volumetric performance
of enclosed screw conveyors
A.W. Roberts
)
Centre for Bulk Solids and Particulate Technologies, Uniersity of Newcastle, Callaghan NSW, 2308 Australia
Received 10 November 1997; received in revised form 15 January 1999; accepted 17 January 1999
Abstract
This paper is concerned with the volumetric performance of enclosed screw conveyors with particular reference to the influence of
vortex motion. Vortex motion arises as a result of internal friction, friction between the granular material and surface of the helical blade,
and the infinitely variable helix angle of the helical flight from the outer periphery of the blade to the shaft. The vortex motion, together
with the degree of fill, govern the volumetric efficiency and, hence, the volumetric throughput. An analysis of the vortex motion in
vertical or steeply inclined screw or auger conveyors is presented. It is shown the vortex motion is characterised by the tangential
component of the absolute grain velocity being substantially constant with the radial position of a point on the blade. On this basis, an
expression for the volumetric efficiency is derived. The volumetric throughput can then be predicted. The paper also presents results from
an experimental screw conveyor where it is shown that the analytical predictions correlate very closely to the measured results. q1999
Elsevier Science S.A. All rights reserved.
Keywords: Screw conveyors; Vortex motion; Friction
1. Introduction
Screw conveyors are used extensively in industry for
conveying and elevating bulk materials over relatively
short distances. They are very effective conveying devices
for free flowing or relatively free flowing bulk solids,
giving good throughput control and providing environmen-
tally clean solutions to process handling problems. Yet,
despite their apparent simplicity, the mechanics of the
conveying action is very complex and designers tend to
rely heavily on empirical performance data.
In the early 1960s, detailed experimental studies of the
performance of screw conveyors were undertaken by
w x w x
Roberts and Willis 1 , and by Rehkugler and Boyd 2 .
These researchers used dimensional analysis and dynamic
similarity to predict the performance of geometrically simi-
lar screw conveyors handling grain. Further investigations
w x
performed by Roberts 3 focused on the significant influ-
)
Tel.: q61-249-216067; Fax: q61-249-216021; E-mail:
engar@cc.newcastle.edu.au
ence of granular vortex motion in limiting the throughput
of vertical grain augers. This latter work was based on
experimental investigations performed on a small scale
auger conveyor in conjunction with studies using specially
designed grain vortex test rigs. While the characteristics of
the vortex motion developed within the auger conveyor as
a function of the rotational speed were established, the
formulation of a general theory to predict the vortex
motion, and hence, volumetric throughput was not forth-
coming at that time. There have been several subsequent
studies of enclosed screw or auger conveyor performance,
w x
the work of Rademacher 4 on vertical screw conveyors
being of particular note.
The design of screw conveyors requires a detailed
consideration of the geometry of the screw and the proper-
ties of the bulk material. While experimental data com-
bined with dynamic similarity have provided a basis for
practical conveyor design, the procedure is somewhat lim-
iting in view of the difficulty of examining the influence
on performance of variations of screw geometry. It is only
in more recent years that analytical models to predict the
performance of screw conveying equipment have started to
w x
emerge 5 .
0032-5910r99r$ - see front matter q 1999 Elsevier Science S.A. All rights reserved.
. PII: S0032- 5910 99 00039- X
( ) A.W. RobertsrPowder Technology 104 1999 5667 57
A theory has now been developed to predict the volu-
metric performance of screw conveyors of any specified
geometry. The theory, which is detailed in this paper, is a
w x
development of the early works of Roberts and Willis 1
w x
and Roberts 3 . An analytical model to predict the vortex
motion, volumetric efficiency and, hence, volumetric
throughput of enclosed screw conveyors is presented.
2. The enclosed screw or auger conveyor
The construction and relevant details of the enclosed
screw or auger conveyor are shown in Fig. 1. The power
driven screw flight is supported in bearings and revolves in
a stationary tubular casing; practical limitations require a
liberal clearance between the flight and the casing and this
has been shown to be beneficial rather than detrimental to
performance. The screw flight is allowed to project beyond
the casing at the lower or intake end, this projection being
referred to as the choke. The screw must be immersed
into the feed hopper at least to the level of the lower end
of the casing, otherwise the auger will not elevate the bulk
material.
w x
As has been shown 1 , the volumetric efficiency is
limited by the degree of fill of the conveyor and the vortex
or rotary motion of the material as it is transported by the
screw. As an elevating device, the enclosed screw con-
veyor becomes more efficient at higher rotational speeds
as a result of the reduced rotational speed or vortex motion
of the bulk material. However, this advantage is usually
more than offset by the decrease in fullness of the
conveyor that accompanies higher operating speeds. The
volumetric efficiency for steeply inclined and vertical con-
veyors is quite low as a result of these factors and the
power requirements per unit throughput is high relative to
other types of conveyors.
3. Screw conveyor throughput
The volumetric throughput of a screw conveyor is given
by
QsQ h m
3
rs 1 . .
t V
where, Q smaximum theoretical throughput with con-
t
veyor running 100% full and the bulk material moving
axially without rotation; h svolumetric efficiency.
V
Fig. 1. Enclosed screw or auger conveyor.
( ) A.W. RobertsrPowder Technology 104 1999 5667 58
Fig. 2. Throughput of an enclosed screw conveyor.
Considering all geometrical dimensions of the screw to
.
be fixed ratios of the screw diameter D, then Eq. 1 may
be expressed by
QsGvD
3
h 2 .
V
where,
2 2
1 C D p t
i s
Gs 1q2 y y 3 .
/ /
8 D D D D
.
D screw diameter m
.
D core or shaft diameter m
i
.
p screw pitch m
.
v angular velocity of screw revrs
.
C radial clearance m
.
t thickness of screw blade m
s
The radial clearance C needs to be at least 1.5 times
larger than the maximum particle size in order to prevent
jamming of particles in the clearance space leading to
particle attrition and increased energy loss. To prevent
excessive slip back and loss of efficiency at higher angles
of elevation, the clearance needs to be limited to a maxi-
mum value of about three times the maximum particle
size.
Research has shown that the throughput of an enclosed
screw conveyor is influenced by the rotational or vortex
motion of the bulk material during transportation and the
w x
degree of fill or fullness of the screw 1,3 . As the
rotational speed of the conveyor increases, the rotational or
.
vortex motion decreases up to a limiting value making
for a more efficient conveying action. However, when a
gravity feed system into the screw intake is employed, the
feed rate cannot match the potential conveying capacity,
and a reduction in fullness occurs. The net result is for
the throughput of the screw conveyor to reach a limiting
value as illustrated in Fig. 2.
w x
As shown by Roberts and Willis 1 , the volumetric
efficiency of a screw conveyor is the product of two
components as indicated below:
h sh h 4 .
V VR F
where, h sRotational or vortex efficiency,
VR
h
av
h sFullness Efficiencys 5 .
F
p

h saverage height of material on the screw surface see

av
.
Fig. 3 .
4. Kinematic analysis of conveying actionvertical
conveyors
The mechanics of screw conveyor performance over a
range of inclination angles is quite complex. The convey-
ing action is more readily described in the first instance for
Fig. 3. Mechanics of conveying action in screw conveyor.
( ) A.W. RobertsrPowder Technology 104 1999 5667 59
the case of vertical or steeply inclined, enclosed screw
conveyors. The extension of the theory to account for the
variations in angle of elevation will then be discussed.
The conveying action is depicted in Fig. 3. As the screw
rotates, a particle of bulk solid moves in a helical path of
opposite hand to that of the screw. Referring to the veloc-
ity diagram shown in Fig. 3a, V is the tangential velocity
S
of the screw at the radius considered, V is the relative
R
velocity of the particle with respect to the screw surface
and V is the absolute velocity of the particle. The angle l
A
defines the direction of the absolute velocity and, hence,
the helix angle of the path followed by the particles at the
radius considered.
The limited feed rate into the screw intake will, in most
cases, cause the conveyor to run less than 100% full. The
fullness decreases with increase in speed, the fullness
being indicated by the variation in height h with radius
r relative to the screw pitch p, as illustrated in Fig. 3b.
At the outer periphery of the screw adjacent to the casing
the height is h . Normally in the case of screw conveyors,
o
h decreases towards the central region of the screw. How-
ever at low speed of operation and low angles of elevation
high filling efficiencies are possible.
.
The velocity diagram depicted in Fig. 3 a is shown in
more detail in Fig. 4. The screw velocity at the radius r
is defined by
V srv 6 .
S
. .
where vs p n r 30 sangular velocity of screw; Ns
rotational speed in revrmin.
The helix angle a of the screw at the radius r is
given by
p
y1
astan 7 .
2p r
where pspitch.
The helix angle of the screw increases from a at the
o
outer periphery of the screw to a at the core or shaft.
i
Hence the helix angle l of the path of particles of bulk
material decreases from l at the outer periphery to l at
o i
the core. The helix angle l is such that
l- 908 y aqf 8 . .
s
f is the friction angle for bulk solid on screw surface.
s
As a consequence of the vortex motion established
within the bulk material, internal shear between concentric
Fig. 4. Velocity diagram for granular particle.
layers occurs. In the case of free flowing granular materi-
als, the internal shear is readily generated; this is not the
case with cohesive and fibre-like materials which do not
convey well in vertical or steeply inclined screw or auger
conveyors.
The motion of bulk particles relative to the screw
surface is defined by the relative velocity V which is
R
given by
V sin l
S
V s 9 .
R
sin aql .
The magnitude of the relative velocity depends primar-
ily on the frictional resistive force provided by the con-
veyor casing. This force depends mainly on the casing
friction coefficient and the normal force on the inner
casing surface as imposed by the centrifugal force of the
rotating granular material.
The absolute velocity V is the vector addition of V
A S
and V . That is,
R

V sV qV 10 .
A S R
The magnitude of the absolute velocity is given by,
V sin a
S
V s 11 .
A
sin aql .
The absolute velocity V has two components, the
A
useful conveying component V and the wasteful rota-
L
tional component V . V and V , respectively, are given
T L T
by
V sV sin l and V sV cos l 12 .
L A T A
hence,
V sin a cos l
S
V s 13 .
T
sin aql .
5. Dynamic analysis of conveying actionvertical con-
veyors
The forces acting on particles in a screw conveyor are
shown in Fig. 5. The velocity components are also shown.
As indicated in Fig. 5b, a particle at the outer periphery in
contact with the stationary casing exerts a force DF
N
against the casing, mainly as a result of the centrifugal
pressure. The centrifugal pressure gives rise to the normal
pressure p acting at the casing. A frictional drag force
n
DF sm DF acts in a direction opposing the absolute
D c N
velocity as indicated in Fig. 5a. Here m is the coefficient
c
of friction for the granular particles on the casing surface.
At an arbitrary radius r, the forces on a particle are as
depicted in Fig. 6. Due to internal shear, a drag force DF
D
is assumed to act as indicated, where the internal friction
coefficient m replaces the casing or boundary friction
g
coefficient m . The force component DF is the resultant
c R
( ) A.W. RobertsrPowder Technology 104 1999 5667 60
Fig. 5. Forces acting in vertical conveyor.
force due to sliding on the screw surface. DF is the axial
A
component of the particle weight of bulk material on the
screw surface.
The drag force DF has two components:
D
DF stangential component, which when combined
DT
with the radius and integrated over the screw surface
provides the restraining torque resistance.
DF saxial component, which is the component re-
DA
quired to slide the material along the conveyor casing.
The components of the force DF are:
R
DF stangential component which is equal to DF
RT DT

DF sAxial component which is equal to DF q

RA DA
.
DF and which provides for the forward motion of the
A
bulk solid in the conveyor. The load acting on the thrust
bearing is equal in magnitude to the summation DF
RA
of the axial forces along the screw.
In the case of a horizontal screw conveyor with no
weight component, only frictional drag, then DF f0 and
A
DF sDF . The path of the particles is such that
R D
ls908 y aqf 14 . .
s
6. Stress fields
The normal pressure p at the casing surface is a
n
Janssen type distribution. Since shallow bed conditions
exist on the screw blade, the pressure distribution may be
assumed to be linear as depicted in Fig. 5. Apart from
gravitational influences, the stress field existing in the
screw is very dependent on the speed of rotation.
Fig. 6. Forces acting on Granular particle in contact with screw surface.
( ) A.W. RobertsrPowder Technology 104 1999 5667 61
6.1. Low speeds of rotation
At low speeds, the stress field is assumed to be active
with the major principal pressure acting almost vertical. In
view of the motion of the bulk material and low bed
depths, hFD, the vertical pressure may be assumed to be
hydrostatic. That is the pressure distribution is triangular
.
Fig. 5 . That is pressure p at the free surface is zero.
n
p sgh 15 .
v
where, gsr gsbulk specific weight; rsbulk density;
hsheight of bulk solid at radius considered.
The lateral or normal pressure is given by
p sk p 16 .
n j v
where k s0.41.0, the higher values being more relevant
j
at higher conveying speeds.
6.2. High speeds of rotation
At high speeds where the centrifugal inertia effects
dominate, the stress field switches to a passive state with
the major principal pressure equal to the lateral or normal
pressure acting in a horizontal direction. In this case the
pressure distribution for p is constant.
n
6.3. Intermediate speeds of rotation
In this case the pressure distribution is a combination of
the above.
7. Force components
7.1. Low speed operation
Considering an annular segment of bulk solid of weight
DW, then for the active state of stress, the lateral normal
force is given by
DN sk DW 17 .
a s
.
where k s2k h prD . h is the Fullness as defined
s j F F
.
by Eq. 5 and is the pitch to diameter ratio.
7.2. Centrifugal pressure
.
At any radius r, Fig. 4 , the absolute velocity of the
particles is and the particles move in a curved path of
A
radius of curvature equal to the maximum radius of curva-
ture of an ellipse. This is illustrated in Fig. 7. The of radius
of curvature R of the equivalent ellipse is
c
a
2
R s 18 .
c
b
Fig. 7. Ellipse defining curvature of particle path at radius considered.
.
where assemi major axis of the ellipsesrr cos l ;
bssemi minor axissr. Hence,
r
R s 19 .
c 2
cos l
Considering an annular segment of bulk solid of weight
DW, then the centrifugal force DN is given by
c
DWV
2
A
DN s
c
R g
c
or
DWV
2
cos
2
l
A
DN s 20 .
c
rg
From Fig. 4,
V sV cos l. 21 .
T A
Hence,
DWV
2
T
DN s . 22 .
c
rg
Noting that
tan a
V s V 23 .
T S
tan aqtan l
.
and that V srv then Eq. 21 becomes
S
2 2
tan a rv
DN sDW 24 .
c
tan aqtan l g
7.3. General case of combined pressure
The general case involves a combination of the above
two cases. That is,
2 2
tan a rv
or DNsDW k q 25 .
s
5
tan aqtan l g
( ) A.W. RobertsrPowder Technology 104 1999 5667 62
8. Absolute path of motion defined by l
8.1. General expression
From Fig. 6, it follows that
DF DF
A D
s
sin b sin aqf .
s
.
where bs908 y aqf ql
s
The axial force component is given by
DF sk DW 26 .
A F
The coefficient k takes into account the frictional
F
support of the boundary walls. It may be estimated from
k s 1ym k 27 . .
F b s
where m sboundary friction coefficient. At an internal
b
boundary, m sm . At the casing, m sm .where m s
b g b c c
friction coefficient at the casing; m sfriction coefficient
g
developed at an internal boundary.
Noting DF sm DN, where DN is defined by Eq.
D g
.
25 , it may be shown that
2 2
rv tan l k sin aqf .
F s
s 1q yk 28 .
s
g tan a m cos aqf ql .
g s
It should be noted that m is a kinetic friction coeffi-
g
cient since there is dilation of the bulk material and
relative motion between particles.
For a given radius r and angular velocity v, the path
for the particles defined by the angle l may be deter-
mined.
8.2. Helix angle l of particle path at outer periphery
o
At the outer periphery with the particles in contact with
.
the casing, Eq. 26 becomes
2
tan l k sin a qf .
o F o s
N s 1q yk 29 .
S s
tan a m cos a qf ql .
o c o s o
where subscript o denotes outer periphery and m s
c
casing friction. N is the specific speed defined by
S
v
2
R
o
N s 30 .
S
g
where R souter radius; gsgravitational acceleration;
o
vsangular velocity.
.
In the limit, as N `, l s908 y a qf . That is,
S o o s
l approaches a constant value.
o
9. Comparison between predicted and measured results
The predicted performance is compared with the experi-
w x
mental results obtained by Roberts and Willis 1 using a
model auger handling millet seed. Fig. 8 shows a compari-
son between the measured and predicted values of l . The
o
agreement is considered to be quite satisfactory.
10. Characteristics of vortex motion in vertical convey-
ors
In order that the path, defined by l, of the particles at
each radius r be determined, a knowledge of the rotational
or vortex motion of the particles is necessary. That is, the
.
velocity component V sf r needs to be determined.
T
The cross-sectional profile of bulk material on a screw
surface is illustrated in Fig. 9. Considering an element of
material at radius r, it follows that for equilibrium, the
radial pressure s must balance the centrifugal pressure.
r
That is
ds rV
2
r T
s , 31 .
dr r
rsbulk density
The general relationship for vortex or rotational motion
is
V r
n
sC sConstant 32 .
T v
where nsvortex index.
.
Vortices in which the index n of Eq. 32 is greater
than y1 have the characteristic of a higher angular veloc-
ity of the grain near the axis of rotation than at the outer
.
periphery. For values of n- y1 , the angular velocity is
higher at the outer periphery than near the centre. For the
auger conveyor the value of n is important in providing an
indication as to whether reverse or negative flow occurs
near the core.
Fig. 8. Comparison between predicted and measured path helix angles.
u s908; f s188; f s258; psD; k s0.9.
s c s
( ) A.W. RobertsrPowder Technology 104 1999 5667 63
Fig. 9. Pressures acting on bulk element in vortex motion.
.
Substituting for V from Eq. 32 and solving yields
T
rC
2
v
s ss y 33 .
r o 2 n
2nr
Under vortex conditions, a passive state of stress exists
within the bulk mass. This means that s is the major
r
stress or pressure, while s , the vertical pressure, is the
z
minor component. It is assumed that for the shallow bed
conditions prevailing in the screw conveyor, s is equal to
z
the hydrostatic pressure. That is
s sg z 34 .
z
Also,
s sK s . 35 .
z v r
Hence,
g z
s s , 36 .
r
K
v
where gsr gsbulk specific weight; K svortex pres-
v
sure coefficient.
w x
It was shown 3 that K s0.32 for millet seed and
v
0.375 for wheat. In general it may be assumed that K
v
ranges from 0.3 to 0.4.
By making the appropriate substitutions from the above
equations, it can be shown that the variation in height h
with radial direction across the screw surface is given by
K C
2
v v
hsz y , 37 .
o 2 n
2ngr
where
s K K C
2
o v v v
z s sh q 38 .
o o 2 n
g 2ngR
o
w x
Roberts 3 showed that when grain is rotated on an
impeller having four blades of pitch equal to that of a
.
screw, a free vortex is formed. That is, ns1 in Eq. 32 .
This means that the velocity increases towards the core or
shaft of the conveyor flight in a similar way to the increase
in helix angle in this direction. As a result of the rotational
velocity increase with decrease in radius, considerable
slipping back of bulk particles may occur in the central
region of the screw. The condition for slip is defined by
V )V for the region defined by radii r-r -R . No
T S s o
conveying action occurs in this region. r defines the
s
radius at which slip just commences. For the whole of the
screw to be fully active, the shaft radius R should be such
i
that R )r .
i s
However, analysis of the actual vortex motion in the
screw or auger conveyor showed that the characteristic
vortex formed was a function of conveyor speed, changing
from a forced vortex with nsy1 at low auger speeds to
a constant tangential speed vortex with ns0 at the higher
auger speeds. That is,
For low speed V sC r 39 .
T v
For high speed V sC . 40 .
T v
..
Generally the vortex with ns0 Eq. 40 dominates. It
is considered that the full immersion of the screw con-
veyor choke in reducing grain slip in the central region of
the screw is the main factor in restricting the vortex
motion; this in effect enhances the performance. Under
w x
these conditions Roberts 3 showed that for R sR r3,
i o
there was no slip and the whole of the screw surface was
active.
11. Vortex performance results
In order to illustrate the various vortex parameters,
consider the case of a vertical enclosed screw conveyor
( ) A.W. RobertsrPowder Technology 104 1999 5667 64
elevating grain. The conveyor is 0.15 m diameter with a
pitch also equal to 0.15 m. The conveyor operates at 400
. .
revrmin. From Eq. 30 , N s13.4. Hence from Eq. 29 ,
S
.
l s36.138. Using Eq. 28 the values of l at various
o
radii may be computed, the values being plotted in Fig. 10.
Also shown in Fig. 10 is the variation in screw helix angle
a with radius.
. .
Knowing l, as well as a, Eqs. 6 and 13 may be
used to determine the rotational velocity components V
S
and V , respectively, as a function of radius. V and V
T T S
are plotted in Fig. 11. As can be observed, V decreases
T
slightly at smaller radii near the shaft or core, but is
otherwise substantially constant. The application of Eq.
.
32 indicates that the vortex index nfy0.1, this value
. .
being used in Eqs. 37 and 38 to determine surface
.
profile hrh sf r , which is also shown in Fig. 11. It is
o
worth noting that because V is virtually constant, then the
T
assumption that ns0 is quite reasonable and confirms
previous predictions.
12. Vortex efficiency
.
The vortex efficiency, defined by Eq. 4 , provides a
measure of the volumetric throughput of a conveyor run-
ning 100% full. Referring to Figs. 3 and 4, the vortex
efficiency is defined as
2 V
R
L o
h s rdr 41 .
H
VR 2 2
V R yR
. R
Lt o i i
V is constant for a given screw geometry and speed.
Lt
There is a need to evaluate V as a function of r. This
L
requires a knowledge of l as a function of r. This may be
achieved using the vortex theory previously discussed.
Fig. 10. Screw helix angle a and particle path angle l versus radius.
D spitchs0.15 m; D s0.05 m; Ns400 revrmin; k s0.9; f s188;
o i s s
f s258.
g
Fig. 11. Screw and particle velocity components. D spitchs0.15 m;
o
D s0.05 m; Ns400 revrmin; K s0.4; k s0.5; f s188; f s258,
i v s s g
h s0.125 m.
o
12.1. General relationship for h
VR
For a given value of the vortex index n, the helix
angle l of the particle path at any radius r may be
.
determined. Hence, the distribution of lsf r may be
established for a given value of n . It may be shown that
. .
from Eqs. 13 and 32 ,
V C sin a cos l
T v
s s
nq1
V sin aql vr .
S
C tan a
v
s
nq1
tan aqtan l vr
From which,
nq1
vr
tan lstan a y1 42 .
C
v
At the outer periphery, lsl , rsR and asa . Hence,
o o o
tan a qtan l
o o
nq1
C svR s . 43 .
v o
tan a
o
.
The equation defining lsf r becomes
nq1
r tan a qtan l
o o
tan lstan a y1 . 44 .
/ /
R tan a
o o
From Fig. 4 it may be deduced that,
V tan l
L
s 45 .
V tan aqtan l
Lt
( ) A.W. RobertsrPowder Technology 104 1999 5667 65
Fig. 12. Comparison between predicted and measured vortex efficiencies.
u s908; f s188; f s258; psD; k s0.9; DrD s3.33.
s c s c
.
Substituting in Eq. 39 gives
2 tan l
R
o
h s r dr 46 .
H
VR 2 2
tan aqtan l R yR
. R
o i i
.
where tan l is defined by Eq. 44 .
12.2. Non-dimensional ratio form
.
Eq. 44 may be expressed in non-dimensional ratio
form as follows:
2 tan l
z
o
h s z dz 47 .
H
VR 2 2
tan aqtan l z yz
. z
o i i
nq1
z tan a qtan l
o o
tan lstan a y1 , 48 .
/ /
z tan a
o o
where, zsrrp, z sR rp, z sR rp
o o i i
12.3. Aerage ortex efficiency
.
Assume zsrrpsz , where z s R qR r2 ps
av av o i
.
z qz r2.
o i
.
From Eq. 21
nq1
R tan a qtan l
av o o
tan l stan a y1
av av
/ /
R tan a
o o
49 .
.
or from Eq. 25
nq1
z tan a qtan l
av o o
tan l stan a y1
av av
/ /
z tan a
o o
50 .
1
tan a s . 51 .
av
2pz
av
It may be shown that
tan l
av
h s 52 .
VRav.
tan a qtan l
av av
13. Predicted and experimental results
Fig. 12 shows the comparison between the measured
and predicted values of the vortex efficiency. The approxi-
.
mate solution given by Eq. 50 is in reasonably close
agreement with the more rigorous solution given by the
. .
numerical integration of Eq. 45 . Eq. 29 is easier to
apply and its application is recommended. The good agree-
ment between the experimental and predicted values of the
vortex efficiency lend confidence in the theory presented.
Fig. 13 shows the measured Fullness h , the predicted
F
vortex efficiency h and a comparison between the mea-
VR
sured and predicted volumetric efficiencies h for the
V
model auger used in the original research of Roberts and
w x w x
Willis 1 and Roberts 3 . Again, the close agreement
between the measured and predicted values gives support
to the theory presented in this paper. Knowing the volu-
metric efficiency, the throughput can be computed using
. .
Eqs. 1 4 .
14. Operation of conveyors at various elevation angles
The foregoing analysis concentrates on the vortex mo-
tion in vertical screw or auger conveyors. The analysis for
operation at any elevation angle u is more complex. In
.
general it may be postulated that Eq. 28 for determining
the vortex characteristics will have the following more
general form,
2 2
rv tan l k f u sin aqf . .
F 1 s
s 1q yk f u .
s 2
g tan a m cos aqf ql .
g s
53 .
. .
where the functions f u and f u need to be deter-
1 2
mined. In all cases it may be assumed that the vortex index
Fig. 13. Comparison between predicted and measured volumetric effi-
ciencies. u s908; f s188; f s258; psD; k s0.9; DrD s3.33.
s c s c
( ) A.W. RobertsrPowder Technology 104 1999 5667 66
n is zero, that is V sconstant over all radii for each
T
conveyor speed.
15. Special case of horizontal conveyor
For horizontal screw conveyors, the evidence suggests
.
that the angle bs0 Fig. 4 . That is, the helix angle of the
path is independent of the screw speed and is given by
ls908 y a qf 54 . .
o s
As an approximation, this relationship may also be
assumed for screw conveyors operating at low angles of
elevation up to say, us208. This simplifies the analysis.
.
The vortex efficiency may be obtained from Eq. 47
and expressed in the following form
2 1q2pm z
z
s o
h s z 1y dz 55 .
H
VR 2 2 2 2 5
z yz 4p z q1
z
o i i
where, zsrrp, z sR rp and z sR rp. This equation
o o i i
may be solved by numerical integration.
The corresponding approximate expression for the vor-
tex efficiency assumes zsrrpsz . Hence,
av
1q2pm z
s av
h s1y 56 .
VRav 2 2
4p z q1
av
.
Where z is assumed to be z s z qz r2.
av av o i
.
Results obtained from Eq. 56 are shown to compare
very closely with the more rigorous solutions given by Eq.
.
55 .
By way of example, h values computed using Eq.
VR
.
56 for a screw with a core or shaft diameter one third the
screw diameter are plotted in Fig. 14. This graph illustrates
the effect of both pitch to diameter ratio as well as the
influence of screw friction.
Fig. 14. Vortex efficiency as function of prD ratioyDrD s3.33.
c
16. Conclusions
The design of screw conveyors requires a detailed
consideration of the geometry of the screw and the proper-
ties of the bulk material. Whereas in the past, the perfor-
mance of screw conveyors has been based on experimental
studies using dimensional analysis and dynamic similarity
to predict the performance of geometrically screws, the
limitations of this procedure have been recognised. The
analysis and associated methodology presented in this
paper overcome these limitations and provide a more
general basis for screw conveyor performance prediction.
The volumetric performance of enclosed screw convey-
ors with particular reference to the influence of vortex
motion has been investigated. Vortex motion arises as a
result of internal friction, friction between the granular
material and surface of the helical blade, and the infinitely
variable helix angle of the helical flight from the outer
periphery of the blade to the shaft. The vortex motion,
together with the degree of fill, govern the volumetric
efficiency and, hence, the volumetric throughput.
An analysis of the vortex motion in vertical or steeply
inclined screw or auger conveyors has been presented.
Because of the dominance of the centrifugal pressure due
to the motion of the screw, a passive state of stress is
generated within the bulk granular material. It is shown the
vortex motion is characterised by the tangential component
of the absolute grain velocity being substantially constant
with the radial position of a point on the blade. On this
basis, an expression for the volumetric efficiency is de-
rived. The volumetric throughput can then be predicted.
17. List of symbols
a semi major axis of ellipse, m
b semi minor axis of ellipse, m
C radial clearance, m
C constant in vortex equation
v
D screw diameter, m
D core or shaft diameter, m
i
g gravitational acceleration, mrs
2
h height of material on screw surface, m
h average height of material on screw surface, m
av
h height of material on screw surface at outer periph-
o
ery, m
. .
k pressure ratio, Eqs. 26 and 27
F
.
k pressure ratio, Eq. 16
j
.
k pressure ratio, Eq. 17
s
K vortex pressure coefficient
v
N rotational speed, revrmin
N non-dimensional specific speed
S
n vortex index
p screw pitch, m
p normal pressure, Pa
n
( ) A.W. RobertsrPowder Technology 104 1999 5667 67
p vertical or axial pressure, Pa
v
Q volumetric throughput, m
3
rs
Q maximum theoretical throughput, m
3
rs
T
R mean radius of screw, m
av
R radius of curvature of equivalent elliptical path, m
c
R shaft radius, m
i
R screw radius at outer periphery, m
o
r screw radius, m
r radius at which slip commences, m
s
t thickness of screw blade, m
s
V absolute velocity, mrs
A
V conveying velocity component, mrs
L
V maximum theoretical conveying velocity, mrs
Lt
V relative velocity, mrs
R
V screw velocity, mrs
S
V rotating velocity component, mrs
T
.
z coordinate defining depth from surface Fig. 9
.
z constant defined by Eq. 38
o
a helix angle of screw, 8
a helix angle of screw at outer periphery, 8
o
b angle defining absolute velocity in Fig. 4
G non-dimensional screw geometry factor
g bulk specific weight, Nrm
3
DF axial force due to particle weight, N
A
DF frictional drag force due to sliding against casing,
D
N
DF axial component of DF , N
DA D
DF tangential component of DF , N
DT D
DF normal force due to centrifugal pressure, N
N
DF resultant force due to sliding on screw surface, N
R
DF axial component of DF , N
RA R
DF tangential component of DF , N
RT R
DN total normal force on annulus, N
DN normal force on annulus, N
a
DN centrifugal force due to annulus, N
c
DW weight of annular segment, N
z ratio of radius to pitch
z average value of ratio of radius to pitch
av
z ratio of radius to pitch at inner or screw radius
i
z ratio of radius to pitch at outer screw radius
o
h fullness efficiency
F
h volumetric efficiency
V
h vortex efficiency
VR
u angle of elevation of conveyor, 8
l helix angle of particles, 8.
.
l helix angle of particles at inner radius, 8 .
i
l helix angle of particles at outer periphery, 8.
o
m friction coefficient at boundary
b
m friction coefficient at casing
c
m friction coefficient at internal boundary
g
m friction coefficient at screw surface
s
r bulk density, kgrm
3
s radial stress constant, Pa
o
s radial stress, Pa
r
s vertical stress, Pa
z
f friction angle for granular material in contact with
c
casing, 8.
f internal friction angle for granular material, 8.
g
f friction angle for bulk solid on screw surface, 8.
s
v angular velocity of screw, revrs
References
w x . 1 A.W. Roberts, A.H. Willis, Proc. Inst. Mech. Eng. 176 1962 165.
w x . 2 G.E. Rehkugler, L.L Boyd, Trans. Am. Soc. Agric. Eng. 1962 98.
w x . 3 A.W. Roberts, Proc. Inst. Mech. Eng. 178 1964 293.
w x . 4 F.J.C. Rademacher, VDI-Forschungsheft 592 1979 .
w x 5 A.W. Roberts, Trans. Mech. Eng., The Instn. Eng. Aust. ME 20
. 1995 213.