Proceed dings of the ASME 2011 Internationa Mechanical Engineering Congress & Exposition al n IMECE2011 1 Novembe 11-17, 2011

Denver, Co er 1, olorado, USA A

IMEC CE2011 1-65748 8

DE EVELOPME ENT OF A BELT CONV B VEYOR CO OOLING SY YSTEM FO CONCR OR RETE AGGR REGATES
Khale I.E. Ahmed ed d A. M. S. Hamou uda Mechan nical & Industr Engineering Department, rial Mech hanical & Indu ustrial Engine eering Department, College of Engineerin ng, Colle of Engineering, ege Qatar Universit Doha (2713), Qatar. ty, Qatar Unive ersity, Doha (2 2713), Qatar. kh.ahm med@qu.edu.q qa ham mouda@qu.ed du.qa M. S. Gadala G Mech hanical Engine eering Depart tment, University of British Columb Vancouve BC, Canad bia, er, da. gadala@m mech.ubc.ca observ vation leads to the assumpt o tion that the transition zone might be weakened by chemical p phenomenon du to the rise of ue o the co onstituent temp peratures [8].

ABSTRACT U Using hot aggr regates, in con ncrete producti ion, results in a drop in compressive strength of th produced co e he oncrete. Variou us metho have been proposed for cooling concr ods n r rete aggregates. This paper propose a new desig for a conve es gn eyor system fo or coolin the aggrega during ho seasons. Sim ng ates ot mulation of th he heat flow during the cooling process over th conveyor is t he analy yzed with the objective of un o nderstanding th effect of th he he variou design par us rameters and achieving min nimum coolin ng time w the least possible powe A finite ele with er. ement model fo or the new design is proposed and discussed. Ch p d hallenges facin ng nume erical simulatio are addresse in this paper The results of on ed r. o the fi inite element analysis of the new design ar presented fo a re or variou initial condi us itions and cool ling rates INTR RODUCTION R Ready-mixed concrete man nufacturers, in hot weathe n er region like the Ar peninsula area, are faced with drops in ns rab a d i comp pressive strengt of concrete produced in summer. Hig ths e gh ambie temperatur increase the rate of ev ent res vaporation from m fresh concrete resu ulting in lower effective wa content an r ater nd hence lower effectiv water-ceme ratio per weight [1-6]. As e ve ent w A shown in Fig. 1, a reduction of compressive st c trength has als so been observed on specimens produced unde a controlle p er ed enviro onment and tes in a labora sted atory [7-8]. High temperatur H re speed cement hydr ds ration and the bonding betw ween the cemen nt grains becomes weaker. Theref s w fore, the earl ly-age strengt th increa ases with high curing temp her peratures becau the reactio use on rate is faster, but 28 8-day strength decreases beca ause of the poo or bondi between ce ing ement grains at these elevate temperatures. a ed It is n noted that high temperature aggregates re her e esults in greate er conce entration of calcium hydro c oxide at the interface. This

Fi 1. Effect of ag ig ggregate tempera ature on the 28-d concrete day compressive strength based o the data given by [1] on n

The two classes of hot climate are `hot-wet and `hot-dry'. e e t' The c common denominator is tha heat accele at erates chemica al proces sses and it is vi to protect n ital newly placed c concrete agains st high te emperatures. I hot-dry cond In ditions, evapor rative forces are and, therefore special care must be tak high a e, e ken to preven nt drying out and to retain the req g quired water content in the concre for hydrat ete tion. While th may not b a significan his be nt proble in hot-wet c em conditions wit high humidit the opposite th ty, dange exists, as ra may lead to an excessi er ain ively wet mix x, disturb bing the water balance for hy ydration and str rength gain [9] ].

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The Arab peninsula weather conditions are associated with hot weather for approximately eight months per year. The weather fluctuates between summer temperatures that approach 50oC and winter temperatures that sink to 18oC. Relative humidity follows a similar pattern ranging between 5% and 90% from inland to coastal regions, respectively. Ready-mixed concrete manufacturers have to accommodate these extreme highs and lows in climate fluctuation [10]. Aggregate temperature plays a very important role in defining the concrete mix temperature [11]. It is generally believed that the aggregate temperature has to be less than 2oC to have a concrete mix temperature less than 10oC. However, it has been shown that keeping the aggregate temperature about 15oC is adequate in achieving proper results [11-24]. Cooling the concrete aggregate is one of the most effective methods to reduce the concrete mix temperature. Different equipments have been developed for that purpose. Among those are belt conveyors, cooling drums, chilled storage rooms, and a mix of those methods [23-25]. In these equipments, cooled air, liquid nitrogen, chilled water, or ice are used to reduce the concrete mix temperature [19]. Ice and chilled water are usually added to the mix to keep water balance of the concrete mix under control. Liquid nitrogen is sometimes used to reduce the cement temperature with special precautions to avoid concrete aggregate thermal shocks. Cooled air is the preferred candidate, although this requires huge flow rates and extensive cooling systems. Despite the criticality of the previously described problem for concrete makers, there is very little work in the literature to address the numerical or the experimental simulation of the problem and to optimize the cooling facility. Most of the available work presents industrial experiences and developments [23-25] and this is mostly for food cooling systems [26]. The cooling drums are designed on the basis of well mixing the aggregates using radial webs [24]. The cooling process in the existing drums in the market is based on mixing the aggregates to enlarge the contact area between the aggregates and the cooling air. Research shows that cooling drums are very compact, efficient, and provide a high production rate. Cooling drums entail, although, the disadvantages of being quite expensive, consume high mechanical power, and are difficult to maintain. On the other hand, cooling using air jets over belt conveyors, similar to those reported in [14], is the cheapest and simplest method. However, the concrete industry reports long cooling time, low cooling efficiency, large occupied space and a low production rate. Combination between both methods is generally recommended. It was reported that, three-stage cooling of return sand is effective and efficient when flash cooling and premixing are accomplished on a belt conveyor and final cooling is performed in a rotary sand blending, cooling, screening drum [18]. Convection to the cooling air is the main heat transfer

theme in these previous designs. Cooling through the thermal contact between the aggregates and the cold belt conveyor or drum body as well as the mixing process was neither analyzed nor optimized. Cooling aggregates in general is a challenging task due to its low thermal conductivity. Due to the porosity of the concrete aggregates (10%-50%) the thermal conductivity would deteriorate at a very high rate; e.g., the thermal conductivity of limestone decreases by about 70% for a porosity of 10% [2728]. Same behavior applies to sand in which a 25% increase in its porosity results in 52% reduction in the thermal conductivity [32-33]. This level of low thermal conductivity of these materials inhibits heat flux toward the cooler surfaces as the materials porosity increases. The heat flow during the cooling process, either by belt conveyors or drums, needs to be analyzed and optimized to achieve short and optimum cooling time with low cooling power. The main objectives of the current work are; to propose an optimized design for belt conveyors systems to be used in cooling the concrete aggregates and to present a numerical simulation for the cooling process using the finite element method with the objective of optimizing the overall system performance. DEVELOPMENT OF THE PROPOSED DESIGN The current work is focused on sand cooling. The thermal conductivity of sand in general is very low. This requires, for thick sand beds over the conveyor, very long time for the heat flow to be conducted from the deep layer to the cooled sand surface. This problem is explored using a simple finite element simulation model, Fig. 6 for cooling 15cm of sand initially at 45oC by cooled air jet at -15oC for 30 minutes. The sand effective conductivity is assumed 0.5W/m.C [32]. The lower layer is assumed adiabatic while the upper layer is assumed under forced convection with heat transfer coefficient 20W/m2.C and bulk temperature -15oC. This test case is a 1D heat transfer problem. A closed form solution for the surface temperature Ts at sand bed thickness l meters after time t seconds is given by [38] for sand bed with initial temperature Ti, conductivity K, density , and specific heat c as follows;

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The surface temperatures of the sand bed are calculated using the above equations using up to 10 roots of Eq. 1b. These results are compared to finite element solutions using up to 30 elements through the height of the sand. The temperature distribution after 30 minutes through the sand bed thickness is highly nonlinear as shown in Fig. 2. This requires, as shown in Fig. 3, at least 7 elements through the sand bed thickness for the finite element simulation model to converge to the exact solution. As shown in Fig. 2, the most upper layer temperature is severely reduced while the inside layers are still very hot. Furthermore, the average temperature of the sand after 30 minutes cooling is 38.5oC. This reflects the importance of developing special techniques to overcome this cooling problem that arises from the severely low sand bed effective conductivity.
2 o o

Convection,h=20W/m . C,T=15 C

A. Sand Mixing Conveyors with multi-stages are generally recommended [18]. This implies that frequent mixing of the sand within the cooling air enhances the cooling conditions by, randomly, moving out part of the hot sand and moving inside part of the cooled sand. Sand mixing can be simulated in the finite element simulation model with an aided subroutine. In this subroutine, each nodal temperature is reassigned randomly to another node in the sand domain each certain period of time. Figure 4 shows a schematic diagram illustrating the random mixing technique. This technique simulates well mixing of sand before being moved to another stage [34]. Element size smaller than 0.02m (7 elements through the sand bed thickness) shows good result in the 1D test case. However, the mixing technique is examined with three mesh sizes 0.03m, 0.015m, and 0.01m. The nodal temperatures distribution after 30 mixings within 30 minutes for the same boundary conditions of the previous case is presented in Fig. 4. The sand mixing, as shown in Fig. 5, has significantly reduced the average temperature of the sand bed. Results obtained with element size 0.01m (15 elements through sand bed thickness) are appropriate to be considered for the rest of finite element simulations in the current work.

Fig 2. Finite element model and the resulted temperature distribution in deg. C of the first test case

Fig 4. The random reallocation of the nodal temperature and the nodal temperature distribution in deg. oC after 30 mixings B. Effect of Heat Sink Addition Although the mixing has significantly reduced the amount of heat stored in the sand, the final sand temperature after 30 minutes cooling is still high. Adding a heat sink to the belt is then essential. A simple finite element model is used to test adding heat sinks as separators over the belt, Fig. 6. The heat sinks are assumed aluminum walls with height 30cm and width 10cm and the sand height is assumed 25cm. The distance between each two successive walls is investigated between 10cm to 50cm. The sand is assumed initially at 45oC and the cooling boundary conditions are similar to the previous test cases except for the heat sinks sides which are considered symmetry boundary conditions. The cooling time is assumed two hours with no mixing.

Fig 3. Effect of the number of elements through the sand bed thickness and the effect of the number of closed form used roots on the convergence of the final temperature at the surface of the sand bed after 30 minutes cooling

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TemperatureoC Fig 7. Maximum and minimum temperatures vs distance g m m between two h sinks heat PROP POSED COO OLING SYSTE DESIGN EM The proposed co e ooling system is designed based on the m previo results. The plant consists of 8 belt conv ous e s veyors between n which the sand is m h manipulated wi mixing. A ith Also, the belt of o each c conveyor is aid with speci ded ially designed aluminum hea at sinks. M Many conveyo belt shapes are available in the market or t. The be with super cleat is chosen [36-37] to accommodate the elt n design heat sink, Fig. 8. The aluminum heat sink is a U ned , section channel wi inner thin films. The heat sink is n ith n e i suppo orted over the b cleat with a set of inline b belt bolts. A sketch h e nents of the co ooling system for the sand is i of the main compon shown in Fig. 9. The sand mo n oves from the storage to the coolin system thro ng ough conveyor Co. The s r sand is handled throug cooling con gh nveyors C1-C2- 3-C4-C5-C6-C7-C8 ending at -C C a conve eyor Cf which takes it out o the cooling system to the of g onveyors C2, C4, C6, and C8 mixer . It is worth noting that co the y have t same length as the rest of conveyors, however, they run pe erpendicularly to them. The cooling air je are assumed e ets d to flow perpendicula to the belt pa w ar assing through the U channel l. FINIT ELEMENT SIMULATIO MODEL TE T ON T finite elem The ment simulation of the coolin heat transfe n ng er proble is meant to include ma em any factors th are usually hat y ignore in analytica modeling. One of the m ed al most importan nt ll param meters that wil be included in the simu d ulation are the contac resistances b ct between the pa airs; sand-belt, belt-aluminum m, and s sand-aluminum m. Also, the perfectly ra e andom mixing g betwe the hot and cold sand after transferrin from belt to een d ng o belt is included in th model. Fu s the urthermore, the cooling of the e belt b before it return back to be filled with san is included n nd d. Addin the residual heat in the b after this c ng l belt cooling stage is i consid dered. 4

The resulted te emperature dis stribution of the sand bed afte er 2 hou cooling is presented in Fig 6. Cooling conditions hav urs p g. ve been significantly enhanced for sa ands close to th cooling air or he o e alls. Reducing the distance between the hea g b at to the aluminum wa sinks significantly reduces the maximum temper r rature, as show wn in Fig 7. g.

Fig 5. Maximum, minimum, and average temperatures of the d d ng nd d g sand bed vs coolin time with an without sand mixing using various mesh densities.
Convection,h=20W/m . C,T=15 C
2 o o

Fi 6. Finite element model an the resulted temperature ig nd n distribution in deg. oC of the sand and the heat sink

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eleme model calcu ent ulates the sand output avera temperature d age at dif fferent input t temperatures and different conveyor bel lt speeds The used t s. thermal proper rties of the san rubber belt nd, t, and al luminum fins a shown in Table 1. are S5: Alluminum Fins a rubber supe cleat interna Surfaces and er al

S2

S1

S3

F 8. Rubber belt with super cleat and alum Fig b r minum fins

S4
Fig 10. Th repeated patt he tern of the conveyor Table 1: Thermo phy ysical properties of the coolin system ng compo onents Thermal Specific heat De ensity Con nductivity K Cp (k kg/m3) (W/m.C) (J/kg.C) 1.2 0.025 1012 Air 1800 0.5 835 S Sand 1522 0.16 2010 R Rubber 2700 273 876 Alu uminum

he and uations B. Th governing a boundary conditions equ The first law of th e hermodynamics states that thermal energy is conser rved. Specializ zing this to a differential c control volume gives the three-dim mensional cond duction equatio that may be on n written in the form:

c
F 9. Schema drawing of the proposed belt conveyor Fig atic f b sand cooling system components d s A. T simulation model of one belt The n e Figure 10 sho ows the dimen nsions of the belt width, san b nd heigh heat sinks dimensions. Al the figure shows a detaile ht, lso s ed finite element mode that simulate each belt of the eight belts. el es t The finite element mode assumes that the room e el t m erature and th convection heat transfer coefficient ar he re tempe well controlled. Th assumed ro he oom temperatu is -15oC an ure nd ssumed heat tr ransfer coeffici ient is 40W/m2.C. The finit te the as

T = q + q B t

(2)

The above equa e ation may be written in the following e g expan nded form for 2 approxima 2-D ation:

T T T + q B = kx + ky (3) t x x y y whe kx, ky are the thermal co ere onductivities in the x- and yn y directi ions, respectiv vely (W/m.oC), T is the tempe erature (oC), qB is the internal rate of heat generati per unit volume (W/m3), ion 3 is the material density (kg/m ), c is the specific heat of the ial and materi (J/kg. oC), a t is time (sec).

The general bou e undary conditio that may be applied to ons o Equati (2) may tak one of the f ion ke following form ms:

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No heat flow (adiabatic or natural boundary): This boundary condition is called the adiabatic or natural boundary condition, and may be expressed as:

[K h ] is the additional thermal conductivity matrix due to

convection B.C. given by:

T = 0 , on surface Si n

(4)

[K h ] is the additional thermal conductivity matrix due to

convection B.C. given by:

[K h ] = S h[N s ]T [N s ]dS ; [K h ] = S h[N s ]T [N s ]dS ;

(11c)

Convection heat exchange: When there is a convective heat transfer on a part on the body surface, Si, due to contact with a fluid medium, it can be written as:

(11d)

T kn = h(Ts T f ) , on surface Si n

(5)

is the heat flux vector due to input surface flux B.C. given by:

{Q}S

where h is the convection heat transfer coefficient, which may be temperature dependent (non-linear), Ts is the surface temperature on Si and Tf is the fluid temperature, which may be constant or a function of boundary coordinate and / or time and kn is the thermal conductivity in direction n. Prescribed temperature (Dirichlet BC): The temperature may be prescribed on a specific boundary of the body. The prescribed temperature may be constant or a function of boundary coordinate and/or time: T = Ts ( x, y, z, t ) , on surface Si (6) As seen in Fig. 10, half of the belt is considered for the simulation model due to the symmetry. The boundary conditions applied to this simulation are defined for the four surfaces S1, S2, S3, and S4 as follows:

{Q}s = S q s [N s ]T dS ;
{Q}h =
hTec N s dS ;

(11e)

h and, finally, {Q} is the heat flux vector due to convection B.C. given by:
S

[ ]

(11f)

It should be noted that Equation (11) doesnt involve radiation boundary conditions and internal heat generation which are not a factor in the current simulation. Time discretization of equation (11) using the -method results in the following final equation to be solved for the linear transient simulation:
t +t 1 c h QS + Qh K c + K h K + K + t C T=

) [

(12)

T y

= hS1 TS1 T
S1

(7)

K
K K

T n
T x T n

S4

= hS4 TS4 T
=0

(8)

where is a constant which is between 0 and 1 depending on the solution method used. The following methods are used frequently: = 0 explicit Euler forward method. = implicit trapezoidal rule. = 1 implicit Euler backward method. The current analysis is solved using the implicit Euler backward method. C. The simulation model of the whole plant Figure 11, shows the simulation model of the eight conveyers. The model shows eight belts with sand and another eight belts without sand. The upper model is for the working belts and the lower model is for the returning belts. Each belt is solved for a load step with time that depends on the belt speed, and then the sand temperatures are calculated, randomized and then are applied as initial conditions for the next belt in the next load step. Also, the temperatures of the belt and aluminum fins nodes are calculated and applied to the returning belt and aluminum fins as initial condition for the next load step. Adding, the calculated temperatures of the returning belt are calculated and then applied to the loaded conveyor as initial condition for the next load step. Each belt transfers the calculated temperatures to the next till the last belt, while the first belt gets new sand set with a Tin (Fig. 11). The surface of the sand, the bottom of the belt, and the surrounding areas of the aluminum fins are loaded with forced

Due to Symmetry

(9)

S2 ,3

= hS5 TS5 T
S5

(10)

Following the normal finite element discretization and assembly procedures for Equation (1), the model ends up with the global finite element equations in the form [39-41]:

[C ] {& }+ [[K c ] + [K h ]] {T } = {Q}s + {Q}h T where [C ] is the thermal capacity matrix given by:

(11) (11a)

[C ] = V c[N ]T [N ]dV ; [K c ] is the thermal conductivity matrix given by:

[Kc ] = V [B]T [K ][B]dV ;

(11b)

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conve ection bounda ary conditions. The par rtitions of th he simul lated pattern are consider red adiabatic. The resulte ed tempe eratures are the considered for the next con en f nveyor. Ac ccording to [2 35], the contact therma resistance is 26, c al estim mated to be 200W/m2.C between the san and rubbe nd er, 600W 2.C betwee the aluminu fins and the rubber, an W/m en um t nd 800W 2.C between the sand and aluminum fins. W/m d RESULTS AND DISCUSIONS D The cooling plant is te ested for inp put sand wit th tempe eratures vary from 10oC to 60oC with step of 5oC. Thes f 6 p se tempe eratures are sim mulated at coo oling times; 8, 16, 32, 48, an nd 80 m minutes. Figure 12 shows th temperature distribution of he e o the sa over the 8 belts due to 2 minutes coolin time for eac and ng ch belt. This short tim is not enou for the bel to release th me ugh lt he gaine heat during the return strok This residu heat and th ed t ke. ual he short cooling time reduce the coo r oling rate of the sand resultin ng in tem mperature drop of 30oC at the last stage. Figure 13 show p F ws

mperature distr ribution of the sand over the 8 belts due to 6 the tem minute cooling tim for each be es me elt. This longe cooling time er helps most of the g gained heat in the belt to b released ou n be ut during the return stro g oke. This is re esulted in temp perature drop of o 45oC a the last stag For very s at ge. slow belt, 10 m minutes cooling g for ea belt, as sh ach hown in Fig. 1 the gained heat has been 14, d n totally released whic is resulted in temperature drop of 52oC at y ch n a the las stage. st F For full view of the pla w ant performan nce, the inpu ut tempe eratures are plotted again nst the final stage outpu ut tempe erature for 7 co ooling rates as shown in Fig. 15. The shown n results are the fin average t s nal temperature a steady state at condit tions after 4 ho ours of operati ion. These res sults have been n summ marized further in Fig. 16 w which shows th effect of the he coolin time on the final average sand temperat ng ture at differen nt input sand tempera atures. This chart defines the required coolin time based o the input tem ng on mperature of th sand and the he recom mmended outpu temperature as indicated in the figure. ut n

Fig 11. Finite element model for the eight conve r eyors showing th loaded convey he yors and the retu urning ones

Fi 12. Tempera ig ature distributio in deg. oC for the results obtained from the finite elem simulation of belt conve ons m ment n eyor cooling sys stem with Tin=55 oC, cooling time tc= 16mi (2 minutes f each belt) = g in for

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ig ature distributio in deg. oC for the results obtained from the finite elem simulation of belt conve ons m ment n eyor cooling Fi 13. Tempera sys stem with Tin=55 oC, cooling time tc= 48mi (6 minutes f each belt) = g in for

Fi 14. Tempera ig ature distributio in deg. oC for the results obtained from the finite elem simulation of belt conve ons m ment n eyor cooling sys stem with Tin=5 oC, cooling time tc= 80min (10 minutes f each belt) 55 n for

Rec commended Zone d

Fig 15. Relation betwe the average output temper R een e rature and the i input temperat ture for differen cooling time tc nt es

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Reco ommended Z Zone

Fig 16. Relation betw ween the coolin time and the final average t ng temperature at different inpu temperatures Ti t ut

NCLUSIONS CON Co ooling concrete aggregates is a crucial factor in hot weathe e er region like the Ar n rab peninsula area to retai the concret in te streng gth. Existing cooling meth hods in the lit terature are no ot optim mized for power and cooling time minimizat t tion. Mo of the exis ost sting designs perform some mixing of th e he aggre egates in a col environment. These desig dont utiliz ld gns ze the fu advantages of proper mix ull xing, free fallin of aggregate ng es and extended belt surface area for heat co t a onvection. Th he presented simulatio in this pape shows signif on er ficant impact of o mixing process on the cooling efficiency. A belt conveyo or the m coolin system des ng sign is propos and analyz using finit sed zed te eleme simulation tools to acco ent n ount and to make use of th m he above factors. e KNOWLEDME ENT ACK This research was supported by a grant fund NPRP08-693-2 N 2290 f from the Qata National Re ar esearch Found dation (QNRF F), Qatar r. REFE ERENCES [1] AC1 Committ 305, Hot weather concr tee reting, revised dAC1 Materials Journal, 88, (4) 417 (1999). s [2] Abbasi, A. F., Al-Tayyib, A. J. Effect of hot weather on , A f o modulus of rupture and splitting tensi strength of ile o m. 1 . concrete, Cem Cont. Res, 15, 233 (1985). [3] Zivkovic, S. D. The effect of increased temperature on D t o fresh and hard dened concrete in Proc. 3rd RILEM Con e, d nf.

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