TABLE OF CONTENT

1.0 Introduction 2
2.0 Calculation 4
2.1 Wood Pellets 4
2.2 Torrefied Wood Chips 8
2.3 Torrefied Wood Pellets 12
3.0 Hopper Design 16
4.0 Conclusion 17
5.0 Reference 18
6.0 Appendix 19

1
1.0 INTRODUCTION

The method used to assessed coarse bulk solids physical properties was adapted from
that proposed by Jenike[4] for hopper design incorporating fine materials. The two principal tests
required to be carried out for hopper design according to this procedure are the material shear
test and wall friction shear test. Such tests are used to determine the unconfined yield stress
(), material flow function (ff), angle of internal friction (), effective angle of internal friction (),
and the kinematic angle of wall friction (). From these properties, a hopper is able to be well
sized and designed and the discharge rate from the hopper assessed. The semi-included angle
of the hopper slope () and the hopper flow factor (ff) are able to be determined. From the
effective angle of internal friction and the kinematic angle of wall friction. The stress
corresponding to the critical condition for flow or no flow (crit) is able to be determined from the
material flow function and hopper flow factor, and the minimum outlet diameter () is able to be
determined from the critical flow condition, the semi-included angle and bulk density of the
material.

Actual stress developed < crit = no flow

Actual stress developed > crit = flow occurred

To calculate the slope of hopper wall:

() = 2 +
60

To calculate the minimum outlet diameter for hopper, this equation is used:

()
=

In Craven et al[1], there are six materials of powder tested and four types of wall material of
hopper tested, but for this report, we picked only three materials of powder which are wood
pellets, torrefied wood chips and torrefied wood pellets and one wall material of hopper which is
TIVAR 88 to be used as the main subject for our hopper design.

2
 Figure 1.1 Design Chart for Conical Outlet Hopper

The chart in Figure 1.1 can be used to obtained the flow factor, ff and the semi-included angle.
For example, if the kinematic angle of wall friction is 22o and the effective angle of internal
friction is 40o, then the value of flow factor is 1.29 and the semi-included angle is 20.5o.

The main objective is to design the conical outlet hopper for three material of powders which are
wood pellets, torrefied wood chips an torrefied wood pellets by using TIVAR 88 as the wall
material of hopper.

3
2.0 CALCULATION

2.1 POWDER WOOD PELLET

According to Craven et al[1], the angle of wall friction for wood pellet is 15o , the effective angle of
internal friction is 40o and bulk density, b is 651 kg/m3

Design Chart for Conical Outlet Hoppers

40 2

1.9

= 40o 1.8

30

1.7

1.6
Wall Friction, degrees

Flow Factor, ff
20 1.5

1.4

1.3

10

1.2

1.1

0 1
0 5 10 15 20 25 30 35 40 45
Semi-included angle, degrees

Figure 2.1.1 Design chart for conical hopper for wood pellet

4
Plotting for hopper flow factor and semi included angles

The value of hopper flow factor, ff will effect compacting stress in the hopper, c and stress
developed in the powder,D ;

From the Figure 1.1 value of hopper flow factor we get is 1.5 and the semi included angle is
31.1o.

1.3 Slope of hopper wall, H()

() = 2 +
60

31.1
() = 2 +
60

() = 2.5183

Calculate the value of sigma critical

In order to find the condition under which flow will occur for the poultry powder in the hopper, the
limiting condition flow,

Actual stress developed < crit = no flow

Actual stress developed > crit = flow occured

5
From the graph below,

4.5

3.5

3 1
=

2.5
y

2
y = 0.0354x + 1.0383
1.5

0.5

0
0 2 4 6 8 10 12

Figure 2.1.2 Confined Stress vs Unconfined Stress

To get sigma critical we use simultaneous equation to solve it.

Equation 1 : y = 0.0354x + 1.0383

1
Equation 2 : =

Sub equation 1 into equation 2

1
0.0354x + 1.0383 =

Solve for value x = 1.6447 and sub into equation 1 to get value of y = 1.0965 which is the value
for sigma critical.

y = crit = 1.0965 kN/m2

6
Minimum diameter circular outlet, B

To find the minimum diameter circular outlet, B we determined from calculated of slope of
hopper wall.

()
=

(2.5183)(1.0965 103 )
=
(9.81)(651)

= 0.432

Summarizing, by using a TIVAR 88 with maximum semi-included cone angle, = 31.1o and a
circular outlet diameter of at least 0.432m.

7
2.2 Torrefied wood chips

According to Craven et al[1], the angle of wall friction for torrefied wood chips is 16o, the effective
angle of internal friction is 40o and bulk density, b is 170 kg/m3.

Design Chart for Conical Outlet Hoppers

40 2

1.9

=40o 1.8

30

1.7

1.6
Wall Friction, degrees

Flow Factor, ff
20 1.5

1.4

1.3

10

1.2

1.1

0 1
0 10 20 30 40 50
Semi-included angle, degrees

Figure 2.2.1 Design chart for conical hopper for torrefied wood chips

8
Plotting for hopper flow factor and semi included angles

The value of hopper flow factor, ff will effect compacting stress in the hopper,c and stress
developed in the powder,D ;

From the Figure 2.1 value of hopper flow factor we get is 1.49 and the semi included angle is
30o.

Slope of hopper wall, H()

() = 2 +
60

30
() = 2 +
60

() = 2.5

Calculate the value of sigma critical

In order to find the condition under which flow will occur for the poultry powder in the hopper, the
limiting condition flow,

Actual stress developed < crit = no flow

Actual stress developed > crit = flow occured

9
Form the graph below,

3 1
=
y

2
y = 0.0138x + 1.0659
1

0
0 2 4 6 8 10 12

c
Figure 2.2.2 Confined Stress vs Unconfined Stress

To get sigma critical we use simultaneous equation to solve it.

Equation 1 : y = 0.0138x + 1.0659

1
Equation 2 : =

Sub equation 1 into equation 2

1
0.0138x + 1.0659 =

Solve for value x = 1.6216 and sub into equation 1 to get value of y = 1.0883 which is the value
for sigma critical.

y = crit = 1.0883 kN/m2

10
Minimum diameter circular outlet, B

To find the minimum diameter circular outlet, B we determined from calculated of slope of
hopper wall.

()
=

(2.5)(1.0883103 )
=
(9.81)(170)

= 1.6314

Summarizing, by using a TIVAR 88 with maximum semi-included cone angle, = 30o and a
circular outlet diameter of at least 1.6314m.

11
2.3 Torrefied wood pellet

According to Craven et al[1], the angle of wall friction for torrefied wood pellet is 17o, effective
angle of internal friction is 40o and bulk density, b is 677 kg/m3

Design Chart for Conical Outlet Hoppers

40 2

1.9

=40o 1.8

30

1.7

1.6
Wall Friction, degrees

Flow Factor, ff
20 1.5

1.4

1.3

10

1.2

1.1

0 1
0 10 20 30 40 50
Semi-included angle, degrees

Figure 2.3.1 Design chart for conical hopper for torrified wood pellet

12
Plotting for hopper flow factor and semi included angles

The value of hopper flow factor, ff will effect compacting stress in the hopper,c and stress
developed in the powder,D ;

From the Figure 2.1 value of hopper flow factor we get is 1.48 and the semi included angle is
28o.

Slope of hopper wall, H()

() = 2 +
60

28
() = 2 +
60

() = 2.4667

Calculate the value of sigma critical

In order to find the condition under which flow will occur for the poultry powder in the hopper, the
limiting condition flow,

Actual stress developed < crit = no flow

Actual stress developed > crit = flow occured

Form the graph below,

13
 2

1.75

1.5 1
=

y 1.25

0.75
y = 0.0329x + 0.1077
0.5

0.25

0
0 2 4 6 8 10 12 14 16
c

Figure 2.3.2 Confined Stress vs Unconfined Stress

To get sigma critical we use simultaneous equation to solve it.

Equation 1 : y = 0.0329x + 0.1077.

1
Equation 2 : =

Sub equation 1 into equation 2

1
0.0329x + 0.1077 =

Solve for value x = 0.1676 and sub into equation 1 to get value of y = 0.1132 which is the value
for sigma critical.

y = crit = 0.1132 kN/m2

14
Minimum diameter circular outlet, B

To find the minimum diameter circular outlet, B we determined from calculated of slope of
hopper wall.

()
=

(2.4677)(0.1132 103 )
=
(9.81)(677)

= 0.0421

Summarizing, by using a TIVAR 88 with maximum semi-included cone angle, = 28o and a
circular outlet diameter of at least 0.0421m.

15
3.0 HOPPER DESIGN

Wall Material of Hopper: TIVAR 88

Material of Powder: Wood Pellets

Semi-Included Angle: 31.1o

Minimum Outlet Diameter of Hopper: 0.432m

Figure 3.1 Hopper Design for Wood Pellets

Wall Material of Hopper: TIVAR 88

Material of Powder: Torrefied Wood Chips

Semi-Included Angle: 30o

Minimum Outlet Diameter of Hopper: 1.6314m

Figure 3.2 Hopper Design for Torrefied Wood Chips

Wall Material of Hopper: TIVAR 88

Material of Powder: Torrefied Pellets

Semi-Included Angle: 28o

Minimum Outlet Diameter of Hopper: 0.0421m

Figure 3.3 Hopper Design for Torrefied Wood Pellets

16
4.0 CONCLUSION

This report has presented the conical hopper design parameters, for three types of bulk solids:
wood pellets, torrefied wood chips and torrefied wood pellets based on the specified physical
properties and direct shear test data. The results obtained cover the range of wall friction angles
12 29[o]. The wall material of hopper is TIVAR 88.

Recognized worldwide as the premium lining material for bulk material handling, TIVAR 88 is
noted for its performance in promoting bulk solids flow of cohesive or non-free flowing materials
due to its low surface friction. TIVAR 88 liners are the perfect solution when you need to reduce
or eliminate arching, ratholing and erratic material flow challenges in bins, bunkers, hoppers and
chutes, railcars, etc. [3]

Simulations have also been carried out to study the interrelationships between the design
parameters and the physical properties of the powders, and correlations for such study were
also obtained. The data presented in this work will enhance the efficient design of conical
hoppers for handling any of the three powders considered.

The designs of hopper obtained are later compared to the designs of hopper obtained by using
software called Conical Outler Hopper Calculator in the second report.

17
5.0 REFERENCE

1. Craven, J. M., Swithenbank, J., & Sharifi, V. N. (2015). Investigation into the Flow Properties
of Coarse Solid Fuels for Use in Industrial Feed Systems. Journal of Powder Technology,
2015, 1-12. doi:10.1155/2015/786063
2. Rhodes, M. J. (2008). Introduction to particle technology. Chichester, England: Wiley.
3. TIVAR 88. (n.d.). Retrieved May 14, 2017, from
http://www.quadrantplastics.com/en/products/engineering-plastics/moderate-80-c/tivar-R-
uhmw-pe-family-of-products/tivar-R-88.html
4. Jenike A.W. (1965). Storage and flow of solids. Bull. 123, Eng. Expt. Sta., Utah State
University.

18
6.0 APPENDIX

19