Screw Conveyor Design Calculation

Refer : CEMA Screw Conveyor Section Calculate by moon.near76@gmail.com

APPLICATION :
1 Screw conveyor s are bulk material transporting devices capable of handling a great variety of materials which have relatively good flowability.
2 Flowability is defined in the CEMA material classification standard and denotes: “the degree of freedom of individual material particles to move past each other”
3 This characteristic is important in a screw conveyor operation as the screw helix.
4 The many advantages of screw conveyor is feasibility of nomerous feed and discharge of the material to be conveyed.
5 Another used is the blending of several ingredients to make a finished product or to make a pre-mix for some product
6 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.

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.

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.
 CONVEYOR SIZE & SPEED
1 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.
2 The capacity table (below) gives the capacities in ft3/hour at one revolution per minutes for various sized and various cross-sectional loading.
3 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

SELECTION OF CONVEYOR SIZE AND SPEED – 3

COMPONENT GROUP
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]
N : operating speed [rpm]
Fb : Hanger bearing factor
Fd : Conveyor diameter factor
Ff : Flight Factor
Fm : Material factor
Fo : Power overload factor
e : Drive efficiency ( Ƞ1 . Ƞ2 )

HORSEPOWER REQUIREMENT (INCLINED SCREW CONV.)

1 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
2 DISADVANTAGES : a. The capacity, or the maximum available capacity of a given screw conveyor decreases with increase of incline
b. The horse power per-unit capacity increases.
3 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 ( Ƞ1 . Ƞ2 )

PROBLEMS ASSOCIATED WITH INCLINED SCREW CONVEYOR

Several things can be done to overcome many of the problems associated with inclined screw conveyor :
1 Limit the use of standard screw components to inclines of less than 25⁰, preferably not over 15⁰.
2 Use close clearance between trough and screw
3 Increase the speed over that applicable for a horizontal screw conveyor of the same size
4 Use short pitch screws, 2/3 or ½ pitch
 250 Tph Screw Conveyor Design Calculation
For : PT.SEMEN BIMA Calculate by moon.near76@gmail.com

PT. Semen BIMA Convey bulk horizontally from a chute to a bin at the rate of 250 TpH
The distance from the centre of chute, the centre of the bin is 30 m
Fine the screw diameter, revolution/menit, the drive power & the installed motor power.

Step - 1 :
Get any information of the conveyed material:
W = 60 to 75 lb/ft³
Material code is 68A 100 26M
The component series is 20
The material factor ( Fm ) 1.4

Step - 2 :
Equivalent aerated volume :
Q = 250 TpH
ϒ = 60 lb/ft³
Cfo = 110 %

Q . 10³ = 113636.4 lb/hr

Q =
2.2

Q = 1893.9 ft³/hr ( Normal Capacity )

Q =
ϒ

C = Q . Cfo = 2083.3 ft³/hr ( Equivalent Design Capacity )

Step - 3 :
Determine speed of screw conveyor from the capacity table for screw Ø 20 inch C1 = 62.5 ft³/hr

Q . Cfo = 33.3 rpm

N =
C1

Step - 4 :
Determine conveyor Horsepower
Fm = 1.4 W = 60 lb/ft³
Fd = 165 for screw Ø 20 inch Fb = 4.4 for group D : hard iron hanger bearing.
Ff = 1 for standard flight ƞ1 = 0.94 reducer efficient
Fp = 1 for paddle factor ƞ2 = 0.94 v-belt effeicient

The overall length of screw must be greater than the 30 m ( C to C length )

Use nine standard screw conveyor trough section 12 ft 3.66 m

30 = 98.4 ft 30.0 m
Lo =
0.3048

L = 9 . 12 = 108.0 ft ( Equivalent length L should be > than Lo )

L . N . Fd . Fb = 2.61 HP
HPf =
1000000

C . L . W . Ff . Fm . Fp = 18.90 HP
HPm =
1000000

Fo = 1 for HP ≥ 5 HP

( HPf + HPm ). Fo = 24.35 HP 18.2 kW The nearest largest motor power is 22 kW

HP =
ƞ1 . ƞ2

Torque ( Ʈ ) 63025 . HP = 46035.35 lb.in

Ʈ =
N

716,2 . HP = 523.13 kg.m

Mt =
N

Inclined screw Conveyor

Conveyor Incline angle, h= 15 degree

C.W.h = 0.95 HP
HPh =
33000. (60)

( HPf + HPm + HPh ). Fo = 25.42 HP 19.0 kW The nearest largest motor power is 22 kW
HP =
ƞ1 . ƞ2