F 4.

1
 Flow of Particulate Solids in Bunkers and Flow Problems F 4.2

Funnel or Core Flow Mass Flow Mass Flow with Funnel Flow Effect
(Expanded Flow)
angle of
repose
ϕb 8
8
ϕb 7
3 3 7
2 2 height plug
6
4 4 levels of 6 flow
free bulk 5
5 5 surface 5 velocity
profiles 4
4
6 6 3
7 7 3 2
1 1 2 Θ
8 8 Θ
Θ2 1 11
Θ1

Numbers show the sequence of discharge of bulk layers

Channelling, Piping, Ratholing Bridging, Arching

dead dead
zones zones

Θ
Θ Θ
F 4.3
 F 4.4
Dynamics of Force Balance at Cohesive Powder Bridge

h
Θ
dFT

dFG
dh B slot length l

Θ VF

dFf
W
´ dFV dFV
1
b
´
1

F = 0 = - dFG + dFT + dFV + dFf

dFG = b. g.b.dhB. l Dead weight of powder bridge

dFV = 1'.sin . dhB. cos .2l Wall force

a
dFT = dFG . Force of inertia
g

3 . f .u2 .(1 - ) . b. l. dh
dFf = Eu . B
Drag force of penetrating fluid
4 .d . 2
 Apparatus Design of Silo Hopper to Avoid Bridging
F 4.5
1. Mass Flow

- Avoid Channelling:
Hopper angle = f(wall friction angle W , effektive angle of internal
friction e)
see diagrams F 4.6 and F 4.7

- Avoid Bridging:

1.1 Free Flowing Bulk Solid (avoid machanical blocking of coarse lumps or rocks):

(1a)

(1b)

slot width (1c)

bmin article size

k = 0.6 ... 1.4 shape dependent parameter

1.2 Cohesive Powder (avoid cohesive bridges):

- Effective wall stress at arch: ´= /ff

1 (2)

- Flow factor (diagram F 4.11): ff = f( e, W , ) (3)

= + W (4)
b ·g·b

σc,crit critical uniaxial compressive strength

ρb,crit bulk density at σ1,crit
g gravitational acceleration
´
1 bmin ´
1
 F 4.6
Bounds between Mass and Core Flow
axisymmetric Flow
(conical hopper)

45 effective angle of
internal friction
40
e = 70°
60°
in deg

35 Core Flow
50°
40°
w

30 30°
angle of wall friction

25

20
Mass Flow
15

10

0
0 10 20 30 40 50 60
hopper angle versus vertical in deg

1 1 - sin e - - arc sin sin W

180° - arccos W
2 2 sin e
sin e

select
 F 4.7
Bounds between Mass and Core Flow
Plane Flow
(wedge-shaped hopper)

55 effective angle of
internal friction
50
e = 70°
45 60°
Core Flow
50°
40 40°
in deg

30°
35
w

30
angle of wall friction

25

20
Mass Flow
15

10

0
0 10 20 30 40 50 60
hopper angle versus vertical in deg

50° - e
arc tan
7,73° W
60,5° + 1-
15,07° 42,3° + 0,131° · exp(0,06 · e )

with W e
3° and 60°
 - Conical Hopper (axisymmetric stress field) F 4.8

Cone Pyramid

max max
wall

bmin b
mi
n

shape factor m = 1 [ 3a ]

- Wedge-shaped Hopper (plane stress field)

vertical front walls

max

lm b min
in >3 b min lm
·b in >3
mi
n
·b
mi
n

shape factor m = 0
inclined front walls F 4.9

B
L

1max

2max

1,5
b
mi
n

b min
3b
mi
n
lm
in >6
·b 1,5
mi
n
b
mi
n
 F 4.10
Arching/Flow Criterion of a Cohesive Powder
in a Convergent Hopper
c

uniaxial compressive strength c

unconfined yield strength
'
effective wall stress

'=
1 1 / ff c = a1 · 1 + c,0

c,crit
' c,crit
' c flow

' bmin '

1
1
' c stable arch
c,0

0 major principal stress during

consolidation (steady-state flow) 1
 Ascertainment of Approximated Flow Factor F 4.11

(angle of wall friction W = 10° - 30°)

2
flow factor ff

1,5
conical hopper

wedge-shaped hopper

1
20 30 40 50 60 70
effective angle of internal friction e in deg
F 4.12
 F 4.13
Consolidation Functions of a Cohesive Powder for Hopper Design
for Reliable Flow
b

b,crit

b,st bulk density

bulk density

* b
b,0

1
0
90°
effective angle of internal friction e
angles of internal
friction e, st, i

stationary angle of internal friction st = const.

angle of internal friction i ≈ const.

1
c
unconfined yield strength

uniaxial compressive strength

'

c
effective wall stress

c = a1 · 1 + c,0
'=
1 1 / ff

bmin
c,crit
ff = 1
' '
1
1
c,st

c,0 bmin,st
1 = c,st

0 major principal stress during

consolidation (steady-state flow) 1
 Consolidation Functions of Cohesive Powders for Hopper Design F 4.14
b

b,crit

b,st
)n
bulk density

b= b,0
* · (1 +
*
b,0

0<n<1
1
0
effektive angle of internal friction
i

e
90°
, st

( + 0
,

1
e

e = arc sin sin st · - sin ·

angles of internal friction

1 st 0

stationary angle of internal friction st = const.

angle of internal friction i ≈ const.

1
2 · (sin st - sin i)
a1 =
(1 + sin st) · (1 - sin i)
c
'
unconfined yield strength

2 · (1 + sin i) · sin st
c,0 = · 0
(1 + sin st) · (1 - sin i)
effective wall stress

c,0 '= 1 / ff c = a1 · 1 + c,0

1
c,crit = 1 - a1 · ff
bmin

ff = 1 ' '
1
1
c,st

(m+1) · · sin 2( + ) bmin,st

c,crit w
c,0 bmin =
b,crit ·g
c,st

0 major principal stress during consolidation 1

F 4.15
F 4.16
2. Core Flow F 4.17

Avoid channelling (stable funnel)

Hopper angle

2.1 Free Flowing Bulk Solid see 1.1

2.2 Cohesive Powder

a) Maximum approach at filling and

consolidation:
Vertical pressure at filling, F 4.20:
pv 1 ≈ pv = f ( e, W, b, shaft cross section,
silo height) (8a)

c,crit see F 4.19

CF

bC,min

(9a)

G (angle of internal friction i or it) - function, see F 4.22

2. Core Flow - Supplement F 4.18

Avoid channelling (stable funnel)

Hopper angle: W

2.1 Free Flowing Bulk Solid see 1.1

2.2 Cohesive Powder

A - A: Ring stress 1'' at surface of

Channel channel wall

1'' 1 ''

bC,min
A A

bC,min
Two additional options:
c) Flow and radial stress field,
b) Filling, consolidation and F 4.10, Ring stress:
anisotropy1): 1 (8c)
1'' =
ffd
Horizontal pressure at filling, F 4.20:
Flow factor of channelling:
1'' ≈ ph = f ( e, W, b, shaft cross section
silo height) (8b)

(8d)
(9b)

G (Angle of internal friction i or it) - function, see F 4.22

 effective angle of
internal friction
uniaxial compressive strength
st
c
stationary angle of
effective wall stress angle of wall friction angle of internal friction internal friction bulk density

`
1
w and st ρb
i it

c,crit
ct,crit(core

ct,crit(mass
flow)

c,crit(core

flow)
flow)

1́
b

i
e

it

ct
st

core flow hopper

major principal stress

mass flow hopper
c

1
1

1
1

1
Consolidation Functions of Cohesive Powders for Hopper Design

F 4.19
 Calculation of Silo Pressures according to Slice-Element Method
Force Balance F = 0 F 4.20

b · g · dy
Shaft (Filling F):
pv

dy
y
ph ph pW
pW
H

pv + dpv
pv + dpv H*
dy
HTr

pn p
W pW pn
pv dA
· g · dy y
b

Hopper:
Lateral Pressure Ratio = ph/pv versus Effective Angle
of Internal Friction e and Angle of Wall Friction w
F 4.21
D
pv
ph y
H pw pw
1.7 1 + sin e
p =
1 - sin e
1.6
passive soil pressure pw ph pv
1.5

1.4
passive - plastic

1.3 = 0.5 0.1

TGL 32 274/09
e = 32° 4°
1.2
= 0.6 0.1 DIN 1055 part 6
1.1
isostatic pressure ph = pv
1.0
1 - sin2
w=0° = e rough wall =
active - plastic

w e
0.9 1 +sin2 e

w=5° 1 - sin
0.8 e
smooth wall =0
a = 1 + sin w
w=10° e
0.7
w=15°

w=25° w=20°
0.6
w=30° 1 - sin2 w- (1 - sin2 w ).(sin2 e - sin2 w )
0.5 a = 1 +sin2
w=35° w+ (1 - sin2 w ).(sin2 e - sin2 w )
lateral pressure ratio

w=40°
0.4 generally 0 ≤ w ≤ e
w=45°
0.3 w=50°

w=55°
0.2
w=60° 0 = 1 - sin e soil pressure at rest
0.1 w=65°

0
0 10 20 30 40 50 60 70 80 90
effective angle of internal friction e in deg
 F 4.22

Function G( i) to Design a Hopper for Core Flow

10

6
) i

5
function G

0
0 10 20 30 40 50 60 70 80
angle of internal friction i in deg
 F 4.23
Estimation of Minimum Shaft Diameter
Process Parameters and Geometrical Apparatus Parameters
pressures p shaft diameter Dmin

height H
D H heigth H

pW p pv
h

a) Calculation of vertical pressure

(1a) (1b)

(1c)
1 - sin w - (1 - sin2
2
w
.
) (sin2
e - sin2
w )
a = (2)
1 + sin2 w+ (1 - sin2 ).(sin2 - sin2 ) Filling /Storage
w e w

b) Consolidation function
c (3)

c,0

1
c) Shaft design equation

(4)

or

(5)
 Standard Silo F 4.24

h2
maximum roof loads:
filter load: 6 kN

h3
earthing snow load: 1 kN /m2
gangway:
walking monoload: 1,5 kN
evenly distributed: 0,75 kN/m2 18
Fl 100 x15 d3

detail "Z"

name and rated width of support

level indication

~ TGL 31 - 461

~ TGL 31 - 343
work opening
work opening
TGL 0 - 2501

safety device
output ND 6

carrier eye
lifting arm
filter link

rated
by-pass

reserve
FTFN

volume
input

V
m3 p1 p2 p3 p4 p5 r1 r2 s1 s2 t1 t2
number of

20 B 90
A 250
40 B 110
250 d1) d3
bolts

80 893 x
100 200 200 600 600 150/50 200 B 160 A 300
100 666
160 B 220 3000 3075 24
300 -
320 B 325 5000 5080 36

rated
volume d1) R1 R2 1 2 h1 h2 h3 h4 h5 h7 h9 mass2)
V
[ °] [ °] =30° =30° kg
m3
20 3000 5920 3000 300 1130
40 3000 150 800 1550
8920 6000
775 1050 35 40 325 1820 750
80 3000 13920 11000 2800 2990
200
100 3000 16920 14000 4290 3480
160 5000 11870 7000 300 3875
1750 1550 25 30 420 3200 - 900
320 5000 20870 16000 350 8180

1)
d = vessel outer diameter
2)
total mass for Al Mg 3 ( sS = 2,7 t / m3)
 F 4.25
valid for: consider:

dependency of
Comparison of Models to Calculate the cohesion- hopper flow
less shape condi-

cohesive

pressure
Hopper Discharge Mass Flow Rate

air drag
tions
F 4.26
 Stationary Discharge Flow Rate versus Particle Size for Sand F 4.27

conical mass flow hopper

kb =3, = 1, ffc > 10

1,5
calculated (Tomas)
discharge flow rate vs in m/s

1,4 measured (Carleton)

1,3
b = 0,156 m
1,2
= 10°
1,1
1,0
0,9 b = 0,036 m
= 10°
0,8 b = 0,036 m
0,7 = 15°
0,6 b = 0,0167 m
0,5 = 10°
0,4
0,3
0,2 b = 0,0103 m
= 10°
0,1
0
-2
5 10 2 5 10-1 2 5 10 0
2 5 101 2 5 102
particle size d in mm
F 4.28
F 4.29
 F 4.30
Equipment for Filling of Silos

- to avoid segregation
 F 4.31
Methods to Control the Level of Silos

1. Pressure gauges 2. Mechanical 3. Revolving blade devices

plumb

5. Conductivity measurement

4. Membrane pressure switch 6. Capacity measurement

7. Radiometric measurement 8. Ultra-sonic measurement

 Revolving Blade Level Indicator LS 40
F 4.32

LS 40/A - 0,1 to LS 40/B - 0,25 to

LS 40/A - 3,0 LS 40/B - 6,0

rated length

rated length
normal edition
with protection pipe from
carbon (St) or
stainless steel (N)

LS 40/C - 0,25 to
LS 40/C - 1,0

LS 40/C - 0,4 - 0,14

installation at
inclined wall

blade material installation type

type length in m
0,14 C 0,25 C - 0,25 - 0,14 - N
N 0,5 C - 0,5 - 0,14 - N
1,0 C - 1,0 - 0,14 - N
145

0,25 C - 0,25 - 0,14 - St

St 0,5 C - 0,5 - 0,14 - St
1,0 C - 1,0 - 0,14 - St
0,14 N C - 0,4 - 0,14 - N
St C - 0,4 - 0,14 - St
145
0,4
0,36 N C - 0,4 - 0,36 - N
St bended C - 0,4 - 0,36 - St
360 protection
pipe
∅10

0,11 N C - 0,4 - 0,11 - N

St C - 0,4 - 0,11 - St
110
 F 4.33
Hopper Locks

horizontal gate vertical gate horizontal rotary double rotary

slide-valve slide-valve

ball valve rotary disk valve

discharge chute with lock with swivel chute

claw lever lock
 F 4.34

Hopper gates
Size in mm b1 d1 h1 h2 l1 l2 l3 Mass in
kg
250 250 120 86 1097 982 180 70
315 315 1230 1115 218 92
400 410 315 140 100 1420 1305 265 123
500 515 1630 1515 318 147
630 630 1925 1810 380 221
800 800 400 160 114 2652 2362 465 393
1000 1000 180 132 3100 2810 570 570

Hopper gates with drive

Size in mm h1 h2 l1 l2 l3 Mass P
in kg in kW
250 120 136 1245 905 180 200
315 1450 1045 217 230 0.55
118
400 140 1735 1235 265 260
500 119 2050 1445 317 325
630 2405 1685 380 410 0.75
160 111
800 2915 2025 465 535
1.1
1000 180 101 3530 2435 570 785
b1 see table above