SCREW CONVEYOR

BASIC DESIGN CALCULATION

CEMA (Conveyor Equipment Manufacturer Association) Approach

HISTORY & APPLICATION

HISTORY:
The first conveyor as such as designed by
ARCHIMEDES (287 212 BC) for
removing water from the ship and to
raise water from river to farm land
The next technological advancement of
importance in screw conveyor design was
patented on march 29, 1898 by Frank C.
Caldwell.
This construction is now known as the
helicoid flight.

APPLICATION:
Screw conveyor s are bulk material
transporting devices capable of handling
a great variety of materials which have
relatively good flowability.
Flowability is defined in the CEMA
material classification standard and
denotes: the degree of freedom of
individual material particles to move past
each other
This characteristic is important in a screw
conveyor operation as the screw helix.
The many advantages of screw conveyor
is feasibility of nomerous feed and
discharge of the material to be conveyed.
Another used is the blending of several
ingredients to make a finished product or
to make a pre-mix for some product
Screw conveyors may be operated
horizontally, on an incline or vertically.

MATERIAL CODE & BULK MATERIAL CHARACTERISTICS

MATERIAL CODE
A study has been made to
define the characteristic of
bulk materials in terms which
are readily recognized.

Table 2-1
Material Classification Code Chart
Major Class
Material Characteristics Included
Density
Bulk Density, loose
Size
Very Fine
No. 200 sieve (0.0029") and under

Abrasiveness

A200

No. 100 sieve (0.0059") and under

A100

No. 40 sieve (0.016") and under

Fine

A40

No. 6 sieve (0.132") and under

Granular

B6

1/2" and under

C1/2

3" and under

D3

7" and under

D7

over 16" to be spesified

D16

X = actual maximum size

Dx

Irregular

Stringy, fibrous, cylindrical, slabs,etc

Very free flowing

flow function > 10

free flowing

4 < flow function < 10

average flowability

2 < flow function < 4

sluggish

flow function < 2

Midly abrasive
Moderately abrasive
Extremely abrasive

index 1 - 17
index 18 - 67
index 68 - 416

5
6
7

Lumpy

Flowability

Code Designation
Actual, lb/ft3

MATERIAL CODE & BULK MATERIAL CHARACTERISTICS

BULK MATERIAL
CHARACTERISTIC:
A study has been made to
define the characteristic of
bulk materials in terms which
are readily recognized.
The table shows in the first
column the range of density
that is usually experienced in
handling material

The material table is a guide

only. The material code and
the material factor (Fm) are
based on experience of several
conveyor manufacturers.

Table 2-2
Material Characteristic
Material
Ash, black ground

Weight
Material Code Component Series Mat'. Factor Vertical
lb/ft3
105

105B635

1A-1B-1C

2.0

Ashes, coal, dry __ 1.2"

35 - 45

40C1/246TY

3D

3.0

Ashes, coal, dry __3"

35 - 40

38D346T

3D

2.5

Cement, Clinker

75 - 95

85D336

3D

1.8

94

94A10026M

2D

1.4

Cement, Aerated (Portland)

60 - 75

68A10026M

2D

1.4

Coal, Anthracite, sized__1/2"

49 - 61

55C1/225

2A-2B

1.0

Coal, Bitumious, mined

40 - 60

50D335LNXY

1A-1B

0.9

Coal, Bitumious, slack

43 - 50

47C1/245T

2A-2B

0.9

Dolomite, crushed

80 - 100

90C1/236

2D

2.0

Dolomite, lumpy

90 - 100

95Dx36

2D

2.0

Fly Ash

30 - 45

38A4036M

3D

2.0

Gypsum, raw__1"

70 - 80

75D325

2D

2.0

Limestone, crushed

85 - 90

88Dx36

2D

2.0

Limestone, dust

55 - 95

75A4046MY

2D

1.6 - 2.0

Cement, Portland

SELECTION OF CONVEYOR SIZE AND SPEED 1

MAXIMUM LUMP SIZE

The Allowable size of a lump in a screw
conveyor is a function of the radial
clearance between the outside diameter
of the central pipe and the radius of the
inside of the screw trough.
Table Maximum Lump Size
Screw
dia.
(inches)
6
9
9
12
12
12
14
14
16
16
18
18
20
20
24

Pipe OD
(inches)

Radial
Clearance
(inches)

2 3/8
2 3/8
2 7/8
2 7/8
3 1/2
4
3 1/2
4
4
4 1/2
4
4 1/2
4
4 1/2
4 1/2

2 5/16
3 13/16
3 9/16
5 1/16
4 3/4
4 1/2
5 3/4
5 1/2
6 1/2
6 1/4
7 1/2
7 1/4
8 1/2
8 1/4
10 1/4

Class 1
Class 2
Class 2
10% lumps
25% lumps
95% lumps Ratio
Ratio R=1.75
Ratio R=2.5
R=4.5
Max. Lump (inch.) Max. Lump (inch.) Max. Lump (inch.)
1 1/4
3/4
1/2
2 1/4
1 1/2
3/4
2 1/4
1 1/2
3/4
2 3/4
2
1
2 3/4
2
1
2 3/4
2
1
3 1/4
2 1/2
1 1/4
3 1/4
2 1/2
1 1/4
3 3/4
2 3/4
1 1/2
3 3/4
2 3/4
1 1/2
4 1/4
3
1 3/4
4 1/4
3
1 3/4
4 3/4
3 1/2
2
4 3/4
3 1/2
2
6
3 3/4
2 1/2

SELECTION OF CONVEYOR SIZE AND SPEED 1

CONVEYOR SIZE & SPEED

In order to determine the size and speed of a screw conveor, it is necessary first to establish
the material code number. This Code number controls the cross-sectional loading that should
be used.
The capacity table (below) gives the capacities in ft3/hour at one revolution per minutes for
various sized and various cross-sectional loading.
The basis for the Capacity Table is as follows

.
=

Where:
C : Capacity [ft3/hour.rpm]
Ds : Diameter of screw [inches]
Dp : Diameter of pipe [inches]
P : pitch of screw, [inches]
K : percent trough loading

SELECTION OF CONVEYOR SIZE AND SPEED 2

In order to determine the conveyor speed can

be calculated by the formula:

. . . .

Where:
N : Conveyor speed [rpm],
( recommended max. Rpm)
Q : Required capacity [ft3/h]
C1 : Conv. Capacity at one rpm (see table below)
CFo : Overload capacity factor [110% - 120%]
CF1 : Conveyor pitch factor
CF2 : Type of flight factor
CF3 : Mixing paddle factor

Special Conveyor Pitch Capacity Factor, CF1

Pitch
Description
Standard
Pitch = diameter of screw
Short
Pitch = 2/3 diameter of screw
Half
Pitch = 1/2 diameter of screw
Long
Pitch = 1 1/2 diameter of screw

CF1
1
1.5
2
0.67

Special Conveyor Flight Capacity Factor, CF2

Conveyor Loading
Type of Flight
15%
30%
Cut Flight
1.95
1.57
Cut & Folded Flight
NR
3.75
Ribbon Flight
1.04
1.37

45%
1.43
2.54
1.62

Special Conveyor Mixing Paddle Capacity Factor, CF3

Standard paddles per pitch set at 45o reverse pitch
None
1
2
3
4
Factor CF3
1
1.08
1.16
1.24
1.32
Compiled by Masda Ehsan

SELECTION OF CONVEYOR SIZE AND SPEED 3

SCREW CONVEYOR CAPACITIES

Material Class
Degree of
Screw Dia. Max.
Capacity (ft3/hour)
Code
Trough Loading (inches) RPM at max. RPM at one RPM
A-15
A-25
B-15
B-25
C-15
C-25

45%

6
9
12
14
16
18
20
24

165
155
145
140
130
120
110
100

368
1,270
2,820
4,370
6,060
8,120
10,300
16,400

2.23
8.20
19.40
31.20
46.70
67.60
93.70
164.00

Material Class
Degree of
Screw Dia. Max.
Capacity (ft3/hour)
Code
Trough Loading (inches) RPM at max. RPM at one RPM
A-16
A-26
A--36
A-46
B-16
B-26
B-36
B-46
C-16
C-26
C-36
C-46

D-16
D-26
D-36
D-46
E-16
E-26
E-36
E-46

30%

6
9
12
14
16
18
20
24

60
55
50
50
45
45
40
40

90
300
645
1,040
1,400
2,025
2,500
4,360

1.49
5.45
12.90
20.80
31.20
45.00
62.50
109.00

SCREW CONVEYOR CAPACITIES

Material Class
Degree of
Screw Dia. Max.
Capacity (ft3/hour)
Code
Trough Loading (inches) RPM at max. RPM at one RPM
A-35
A-45
B-35
B-45
C-35
C-45
D-15
D-25
D-35
D-45

E-15
E-25
E-35
E-45

30%

6
9
12
14
16
18
20
24

120
100
90
85
80
75
70
65

180
545
1,160
1,770
2,500
3,380
4,370
7,100

1.49
5.45
12.90
20.80
31.20
45.00
62.50
109.00

Material Class
Degree of
Screw Dia. Max.
Capacity (ft3/hour)
Code
Trough Loading (inches) RPM at max. RPM at one RPM
A-17
A-27
A-37
A-47
B-17
B-27
B-37
B-47
C-17
C-27
C-37
C-47

D-17
D-27
D-37
D-47
E-17
E-27
E-37
E-47

15%

6
9
12
14
16
18
20
24

60
55
50
50
45
45
40
40

45
150
325
520
700
1,010
1,250
2,180

0.75
2.72
6.46
10.40
15.60
22.50
31.20
54.60

COMPONENT GROUP

NORMAL SERVICE
Component Group 1A, 1B and 1C
Regular flights and regular trough
Thickness, US standard
Screw Dia. Coupling Dia.
gauge or inches
(inches)
(inches)
Trough
Cover
6
1 1/2
16 ga.
16 ga.
9
1 1/2
14 ga.
14 ga.
9
2
14 ga.
14 ga.
12
2
12 ga.
14 ga.
12
2 7/16
12 ga.
14 ga.
14
2 7/16
12 ga.
14 ga.
16
3
12 ga.
14 ga.
18
3
10 ga.
12 ga.
20
3
10 ga.
12 ga.
24
3 7/16
10 ga.
12 ga.

HEAVY SERVICE
Component Group 2A, 2B, 2C and 2D
Regular flights and heavy trough
Thickness, US standard
Screw Dia. Coupling Dia.
gauge or inches
(inches)
(inches)
Trough
Cover
6
1 1/2
14 ga.
16 ga.
9
1 1/2
10 ga.
14 ga.
9
2
10 ga.
14 ga.
12
2
3/16
14 ga.
12
2 7/16
3/16
14 ga.
14
3
3/16
14 ga.
16
3
3/16
14 ga.
18
3
3/16
12 ga.
20
3
3/16
12 ga.
24
3 7/16
3/16
12 ga.

EXTRA HEAVY SERVICE

Component Group 3A, 3B and 3D
Regular flights and heavy trough
Thickness, US standard
Screw Dia. Coupling Dia.
gauge or inches
(inches)
(inches)
Trough
Cover
6
1 1/2
14 ga.
16 ga.
9
1 1/2
10 ga.
14 ga.
9
2
10 ga.
14 ga.
12
2
3/16
14 ga.
12
2 7/16
3/16
14 ga.
14
3
3/16
14 ga.
16
3
3/16
14 ga.
18
3
3/16
12 ga.
20
3
3/16
12 ga.
24
3 7/16
3/16
12 ga.

HORSEPOWER REQUIREMENT (HORIZONTAL SCREW CONV.)

The horsepower required to operate a horizontal screw conveyor is based on proper

installation, uniform and regular feed rate.
The horse power requirement is the total of the horsepower to overcome conveyor friction
(HPf) and the horsepower to transport the material at specified rate (HPm)
=
=
=

Where:
C : Equivalent design capacity [ft3/h],
L : Total length of conveyor [ft]
Fb : Hanger bearing factor
Ff : Flight Factor
Fd : Conveyor diameter factor

. . .

. . . . .

e : Drive efficiency
N : operating speed [rpm]
Fm : Material factor
Fo : Power overload factor

HORSEPOWER REQUIREMENT (HORIZONTAL SCREW CONV.)

Hanger Bearing Factor, Fb

Component Group
Bearing Type
Group A
Ball
Group B
Babbit
Bronze
Wood
Group C
Plastic
Nylon
Teflon
Group D
Chilled hard iron
Hardened alloy sleeve

Flight Factor, Ff

Fb
1.0
1.7

2.0

Type of Flight

Standard
Cut Flight
Cut & Folded Flight
Ribbon Flight

Compiled by Masda Ehsan

Fd
12
18
31
37
55
78
106
135
165
235

95%
1.0
1.30
2.20
-

Paddle Factor, Fp
4.4
Fp

Screw Diameter Factor, Fd

Screw Dia. (inch)
4
6
9
10
12
14
16
18
20
24

15%
1.0
1.10
NR
1.05

Conveyor Loading
30%
45%
1.0
1.0
1.15
1.20
1.50
1.70
1.14
1.20

Standard paddles per pitch set at 45o reverse pitch

None
1
2
3
4
1
1.29
1.58
1.87
2.16

Mechanical Efficiencies of Speed Reduction Mechanisms

Type of Speed Reduction Mechanism
V-belts and sheaves
Precision roller chain on cut tooth sprockets, open guard
Precision roller chain on cut tooth sprockets, oil tights casing
Single Reduction helical or herringbone eclosed gear reducer or gearmotor
Double Reduction helical or herringbone eclosed gear reducer or gearmotor
Triple Reduction helical or herringbone eclosed gear reducer or gearmotor
Low ratio (upto 20:1 range) enclosed worm gear speed reducers
Medium ratio (20:1 to 60:1 ratio range) enclosed worm gear speed reducers
Gigh ratio (60:1 to 100:1 ratio range) enclosed worm gear speed reducers
Note : Contact Gear Reducer Manufacturer for the exact Mechanical Efficiencies

Approximate
Efficiencies
0.94
0.93
0.94
0.95
0.94
0.93
0.9
0.7
0.5

HORSEPOWER REQUIREMENT (HORIZONTAL SCREW CONV.)

HORSEPOWER REQUIREMENT (HORIZONTAL SCREW CONV.)

HORSEPOWER REQUIREMENT (INCLINED SCREW CONV.)

ADVANTAGES: Inclined screw conveyor is often very desirable as it may solve a conveying
problem with a minimum of equipment and occupy a minimum space
DISADVANTAGES:
The capacity, or the maximum available capacity of a given screw conveyor decreases with
increase of incline
The horse power per-unit capacity increases.
ADDITIONAL POWER to lift the material, the formula to calculate horsepower to lift the
material as follow:
=
=

. .
. ()

+ +

Where:
HPh: Horsepower to lift the material [HP]
C : Equivalent design capacity [ft3/h]
h : actual height of lift [ft]
e : Drive efficiency

PROBLEMS ASSOCIATED WITH INCLINED SCREW CONVEYOR

Several things can be done to overcome many of the problems associated with inclined screw
conveyor:
Limit the use of standard screw components to inclines of less than 25o, preferably not
over 15o
Use close clearance between trough and screw
Increase the speed over that applicable for a horizontal screw conveyor of the same size
Use short pitch screws, 2/3 or pitch