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Screw Conveyor Engineering Guide PDF
Screw Conveyor Engineering Guide PDF
Engineering
Manufacturing
Conveying Knowledge, Workmanship, Solutions
ENGINEERING GUIDE
Screw Conveyors
ISO 9001
Release Date 4.1.16 Certified
KWS profile
Founded in 1972, KWS Manufacturing Company,
Ltd, is the leader in the design and manufacture
of conveying equipment for the bulk material
handling industry. Our primary Customers are power
transmission distributors, end users, engineering
firms, system suppliers and original equipment
manufacturers (OEMs).
Table Of Contents
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Screw Conveyor Engineering Guide
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Table Of Contents
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The KWS Screw Conveyor Engineering Guide will provide assistance in the design of a screw
conveyor or system, yielding optimum performance and efficiency.
The Engineering Guide provides the necessary information for selecting a screw conveyor in a series
of five steps. These steps are arranged in logical order and are divided into separate sections for
simplicity.
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Screw conveyors are typically designed to convey bulk materials at 15, 30 or 45-percent trough
loading, depending upon material characteristics of the specific bulk material. As a general rule,
trough loading of 45-percent can be used for light, free-flowing and non-abrasive bulk materials.
Trough loadings of 15 and 30-percent are typically used for denser, sluggish and more abrasive bulk
materials.
The inlet of a screw conveyor is always control fed by another device such as:
• Screw Conveyor
• Screw Feeder
• Belt Conveyor
• Rotary Airlock
• Volumetric or Gravimetric Feeder
The recommended location for the drive unit is on the discharge end of a screw conveyor which
pulls the bulk material to the drive end. With this arrangement, each screw section is put in tension
as the bulk material is conveyed toward the discharge of a screw conveyor, reducing wear and
fatigue on the conveyor components.
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The following are design and construction features to consider when designing an inclined screw
conveyor:
• Incline Up to 10-Degrees – Loss in conveying efficiency is minimal on inclines up to
10-degrees. A screw conveyor with U-trough and full pitch screw is sufficient for most
applications. Loss in efficiency can be overcome by increasing the speed of the screw
conveyor, increasing the diameter of the screw conveyor or reducing the pitch of the screw.
• Incline Between 10 and 20-Degrees – Loss in conveying efficiency is typically between 10 and
40-percent on inclines up to 20-degrees. A screw conveyor with U-trough and 2/3-pitch screw
is sufficient for most applications. Loss in efficiency can also be overcome by increasing the
speed or the diameter of the screw conveyor. Additional horsepower is required to overcome
gravity and bulk material fall back.
• Incline Between 20 and 30-Degrees – Loss in conveying efficiency is typically between 10
and 70-percent on inclines up to 30-degrees. A screw conveyor with tubular housing and
reduced pitch screw (1/2 or 2/3) is recommended for most applications. Loss in efficiency can
also be overcome by increasing the speed or the diameter of the screw conveyor. Additional
horsepower is required to overcome gravity and bulk material fall back.
• Incline Between 30 and 45-Degrees – Loss in conveying efficiency is typically between 30
and 90-percent on inclines up to 45-degrees. A screw conveyor with tubular housing and
reduced pitch screw (1/2 or 2/3) and larger diameter is recommended for most applications.
Increasing the speed of the screw conveyor is also required. Additional horsepower is required
to overcome gravity and bulk material fall back.
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Pitch Efficiency
Pitch Efficiencies
The Pitch Efficiency chart shows the relative 1.00
Efficiency
0.50
housings provide the highest conveying efficiency.
0.40
Angle of Incline
The Horsepower Factor 2
(Fi) is incorporated into the 1.9
1.7
horsepower calculations
Incline afactor (Fi)
1.6
to compensate for the
1.5
additional horsepower 1.4
1.1
fall back.
1
0 5 10 15 20 25 30 35 40 45
Angle of Incline
TSHP (i) = Total Shaft HP for Inclined Screw MHP = Material HP (HP required to move the
Conveyor material)
FHP = Friction HP (HP required to drive the Fi = Incline Factor
conveyor empty) e = Drive Efficiency (Typical value of 0.88 is
used for a shaft mount reducer/motor)
* If calculated Material Horsepower is less than 5HP it should be corrected for potential overload.
Use the Corrected Material HP Chart.
Upset Conditions
Screw conveyors located on inclines over 10-degrees must be designed to start and operate under upset
conditions. An upset condition is caused when normal flow in an inclined screw conveyor is interrupted
and the bulk material inside the conveyor slips back to the lower end, filling up the conveyor. Additional
horsepower is required to restart and convey the bulk material because the conveyor will temporarily
experience 100-percent trough loading. Please consult KWS Engineering for the proper design of inclined
screw conveyors for upset conditions.
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KWS Shaftless Screw Conveyors are successfully used throughout the chemical, food, minerals
processing and wastewater treatment industries for conveying everything from catalysts to
dewatered biosolids.
KWS developed the industry standards for shaftless screw conveyors and continues to create
new and improved design standards. Our high strength alloy spirals are the hardest, strongest and
toughest in the industry. For more information regarding shaftless screw conveyors consult the KWS
Shaftless Screw Conveyor Engineering Guide located on our website.
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Screw Feeders
Screw feeders are designed to meter bulk materials and are typically located at the beginning of
a process. Capacity or feed rate can be accurately controlled with screw feeders. Variable speed
drives improve metering accuracy and can provide a wide range of feed rates. Screw feeders are
available in a variety of sizes, lengths, configurations and materials of construction.
The inlet of a screw feeder is always flood loaded (100-percent). A screw feeder is typically mounted
directly to a:
• Hopper – Square or rectangular in shape with sloped bottom and limited storage capacity
• Bin – Square or rectangular in shape with sloped bottom and large storage capacity
• Silo – Cylindrical in shape with cone or mass-flow bottom and large storage capacity
With the screw feeder inlet flood loaded (100-percent), the design of the screw in the inlet area and
the screw speed determine the desired capacity or feed rate.
Most screw feeders are less than 20-feet in length because the use of internal hanger bearings is
not recommended. In most applications a short screw feeder will meter a bulk material to a screw
conveyor for transfer to the next step of the process.
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Screw feeders can be composed of one, two or virtually any number of screws. A screw feeder with
multiple screws is considered a live bottom screw feeder.
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4
7
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Feeder Shroud
Screw feeders must be equipped with a shroud for at least 2 pitches beyond the inlet opening to
prevent flooding of the bulk material past the inlet. The shroud is a curved cover that converts a
standard U-trough into a tubular housing to prevent bulk materials from flooding past the screw.
Extended shrouds, tubular housings or short pitch flights can be utilized for accurate feed rate
control when metering very free flowing bulk materials.
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When designing a screw feeder, every application is unique. For this reason, please consult KWS
Engineering for proper recommendations concerning your particular needs.
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Inlet Length
The inlet length on an inclined screw feeder must be kept to a minimum to prevent the bulk material
from falling back over the top of the flights in the inlet section. Typically, the length of the inlet should
not exceed 2 times the diameter of the screw for an inclined screw feeder.
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Conveyor size, speed and horsepower requirements are directly affected by the following
characteristics of the conveyed bulk material. More specific information will be discussed in the
ensuing pages clarifying several of the factors listed in the Bulk Material Table.
Bulk Density
Conveying capacity for screw conveyors and screw feeders is calculated volumetrically in cubic feet
per hour (ft3/hr). The bulk density of the bulk material is needed in order to convert capacities given
in tons per hour or pounds per hour to cubic feet per hour.
The bulk density column of the Bulk Material Table provides an average bulk density or a range of
bulk densities for each bulk material. Accurate bulk density information is needed for selecting the
proper screw conveyor or screw feeder.
% Trough Loading
Trough loading is a prime factor in determining conveyor size and is based on the maximum depth at
which bulk materials will flow through a screw conveyor without causing undue wear on the conveyor
components, such as screws, hanger bearings, couplings shafts and troughs. The recommended
trough loading is lower for abrasive bulk materials in comparison to non-abrasive bulk materials.
The characteristics explanations and the Bulk Material Table on the following pages contain important
information for the proper design of screw conveyors and screw feeders. Please contact KWS
Engineering for materials not listed in the Bulk Material Table.
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The character of the lump must also be considered when designing a screw conveyor. Some bulk
materials have hard lumps that won’t break up when conveyed by a screw conveyor. Other bulk
materials may have lumps that are fairly hard but degrade when conveyed causing a reduction in
the lump size. Bulk materials that have lumps that are easily broken up when conveyed have no
limitations on conveyor size.
The allowable size of a lump in a screw conveyor is a function of the radial clearance between
the outside diameter of the center pipe and the radius of the inside of the trough, as well as the
proportion of lumps in the mix. The screw conveyor must be able to convey the lumps without
impeding bulk material flow or damaging the conveyor. The lumps must be able to fit in the
clearance between the center pipe and the inside of the trough. Radial clearance is shown below.
Class 1
Class 1 bulk materials are a mixture of lumps
and fines in which not more than 10-percent
are lumps ranging from maximum size to 1/2
of maximum size and 90-percent are lumps
smaller than 1/2 of maximum size.
Class 2
Class 2 bulk materials are a mixture of lumps and fines in which not more than 25-percent are lumps
ranging from maximum size to 1/2 of maximum size and 75-percent are lumps smaller than 1/2 of
maximum size.
Class 3
Class 3 bulk materials are a mixture of lumps and fines in which not more than 95-percent are lumps
ranging from maximum size to 1/2 of maximum size and 5-percent are lumps smaller than 1/2 of
maximum size.
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Trough Loading
Trough loading is the depth of a bulk material in the trough of a screw conveyor and is measured in
percent when compared to a full trough. A full trough is considered 100-percent full. Recommended
trough loadings of 15, 30 and 45-percent were developed based on the characteristics of bulk
materials. The recommended trough loading for a screw conveyor is a function of the density,
abrasiveness and flowability of a bulk material. For a given capacity, screw conveyor size and speed is
determined by trough loading percentage.
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COMPONENT/BEARING SERIES
COMPONENT SERIES
The recommended component series for bulk materials are listed in the Bulk Material Table. The
alphabetical series codes refer to the minimum construction requirements for a screw conveyor used
to convey a specific bulk material. Series A and B construction can be used for most light, non-
abrasive and free-flowing bulk materials. Series C and D construction are recommended for dense,
abrasive and sluggish bulk materials. Please consult KWS Engineering for further assistance.
Series A
Light Duty Construction – Series A bulk materials such as barley, cocoa beans, fish meal and sawdust
are light, non-abrasive and very free-flowing. Light duty construction is very cost-effective and consists
of the thinnest gauge materials available for screws, troughs and covers. Helicoid screws and angle
flange troughs are recommended for Series A bulk materials.
Series B
Medium Duty Construction – Series B bulk materials such as alfalfa pellets, dry bagasse, activated
carbon and crushed ice are slightly higher in bulk density, have some abrasiveness and are slightly less
free-flowing when compared to Series A bulk materials. Medium duty construction is cost-effective
and consists of slightly heavier gauge materials for screws, troughs and covers. Helicoid screws and
angle flange troughs are recommended for Series B bulk materials.
Series C
Heavy Duty Construction – Series C bulk materials such as alumina fines, spent distiller’s grain,
foundry sand and sodium sulphate are dense, abrasive and sluggish when compared to Series A and
B bulk materials. Heavy duty construction is required to prevent excessive maintenance or downtime
and consists of heavy duty screws, troughs and covers. Sectional screws and formed flange troughs
are recommended for Series C bulk materials.
Series D
Extra Heavy Duty Construction – Series D bulk materials such as adipic acid, blast furnace slag,
cement clinker and lignite coal are very dense, extremely abrasive and very sluggish when compared
to Series A, B or C bulk materials. Extra heavy duty construction is required to prevent excessive
maintenance or downtime and consists of extra heavy duty screws, troughs and covers. Sectional
screws with weld-on hardsurfacing and formed flange troughs are recommended for Series D bulk
materials.
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COMPONENT/BEARING SERIES
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COMPONENT/BEARING SERIES
The recommended bearing series for bulk materials are listed in the Bulk Material Table. The numerical
series codes refer to the minimum requirements for screw conveyor hanger bearings used for a
specific bulk material. Series 1 and 2 bearing materials are used for most non-abrasive bulk materials.
Series 3 and 4 bearing materials are recommended for abrasive and extremely abrasive bulk materials.
Please consult KWS Engineering for further assistance.
Series 1
Hanger bearings manufactured from engineered plastics such as Nylatron, Plastech and UHMW as
well as oil-impregnated wood and ball bearings are recommended for non-abrasive bulk materials.
Series 2
Hanger bearings manufactured from engineered plastics such as Plastech as well as composite
materials such as Gatke and ball bearings are recommended for bulk materials that have some
abrasiveness when compared to Series A bulk materials.
Series 3
Hanger bearings manufactured from bronze and hard iron metals are recommended for bulk materials
that are abrasive when compared to Series A and B bulk materials.
Series 4
Hanger bearings manufactured from ceramic, hard iron, stellite, and hardsurfaced metals are
recommended for bulk materials that are extremely abrasive when compared to Series A, B or C bulk
materials.
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NOTE: Some bulk materials, while they are not corrosive under “normal” conditions, may become
corrosive when heated or in the presence of moisture.
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Highly Corrosive
Highly corrosive bulk materials require the use of corrosion
resistant alloys. Screw conveyors must be fabricated from
alloys not affected by the corrosive product. Typical materials of
construction for highly corrosive products are 304, 310, 316, 410
Copper Sulfate and 430 stainless steels. Also, high nickel alloys such as Inconel,
Monel and Hastalloy may be used.
Mildly Corrosive
Mildly corrosive bulk materials, or bulk materials that have a
tendency to become corrosive under certain conditions, may
require the use of corrosion resistant alloys. Corrosion is a
relative term that is defined by each particular application. Screw
conveyors must be fabricated from alloys not affected by the
Drilling Sludge
corrosive product. Typical materials of construction for mildly
corrosive products are 304 and 316 stainless steels.
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Flammability (D)
Flammable bulk materials will burn when oxygen and an ignition
source are present. Screw conveyors can be designed with non-
sparking materials to eliminate a possible ignition source. Pressure
tight troughs or housings with mechanical shaft seals will keep
oxygen from entering the screw conveyor. The inside of the screw
conveyor trough or housing can also be purged with an inert gas
such as nitrogen. Hay
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Explosiveness (H)
Explosive bulk materials will ignite when oxygen and an
ignition source are present. Screw conveyors can be designed
with non-sparking materials to eliminate a possible ignition
source. Pressure tight troughs or housings with mechanical
shaft seals will keep oxygen from entering the screw conveyor.
The inside of the screw conveyor trough or housing can be
Powdered Milk purged with an inert gas such as nitrogen. Explosion venting
is also an option for relieving pressure due to an explosion.
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Hygroscopic (M)
Hygroscopic bulk materials readily absorb moisture and can
become contaminated. Screw conveyors with vapor-tight covers
are required. It also may be necessary to insulate or provide a
jacket for the trough to maintain a consistent product temperature.
Purging the troughs with dry gas or air may also be necessary.
Alum
Interlocks, Mats or Agglomerates (N)
Interlocking bulk materials have a tendency to mat together and
become resistant to being conveyed. Heavier construction with
high torque drives for screw conveyors are required. Intermediate
hanger bearings can create an obstruction to flow so may need to
be eliminated. Shaftless screw conveyors are a good option for
interlocking bulk materials.
Wood Bark
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Grass
Elevated Temperature (R)
Hot bulk materials are encountered in many phases of bulk material
processing. Screw conveyors should be designed and manufactured
with heavy-duty construction and may require 304, 316 or even high-
temperature stainless steel alloys. Hot materials can be cooled with
KWS Thermal Processors that utilize jacketed troughs and hollow-
Activated Carbon
flight designs.
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Capacity is defined as the weight or volume per hour of a bulk material that can be safely and
feasibly conveyed using a screw conveyor. Screw conveyor diameter is determined by multiple
factors including capacity.
The following steps are required for proper screw conveyor selection –
1. Calculate required capacity in cubic feet per hour (ft3/hr).
2. Select the recommended trough loading percentage from the Bulk Material Table for the
specific bulk material to be conveyed.
3. Select the screw conveyor diameter that corresponds with the recommended trough loading
and is less than the capacity at maximum RPM from the Capacity Table.
4. Calculate actual conveyor speed by dividing the required capacity by the capacity at 1-RPM
from the Capacity Table.
NOTE: Maximum speeds shown in the Capacity Table are not intended for every application and
were developed for non-abrasive, free-flowing bulk materials. KWS recommends lower
screw conveyor speeds for most industrial applications. A larger screw conveyor diameter
will be required for lower screw conveyor speeds.
Maximum lump size must also be considered when designing a screw conveyor. Please refer to the
Bulk Material Lump Size section for further information.
The Capacity Table is only intended for designing control fed screw conveyors. Conversely, screw
feeders are flood loaded at the inlet and require special design considerations. Please refer to the
Screw Feeder section for further information.
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Selection Capacity (SC) is the capacity adjusted for special pitch or modified flights used in the
process of selecting the screw conveyor diameter for the application.
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Example
A screw conveyor is required to transport 10 tons per hour of unslaked lime with a bulk density of
60 lbs/ft3. The unslaked lime also needs to be mixed in transit using cut and folded flights. The
conveying distance is 15-feet, so short (2/3) pitch screws will be used to ensure proper mixing. The
recommended trough loading percentage from the Bulk Material Table is 30A.
For proper selection of screw conveyor diameter and speed, the actual capacity must be adjusted for
the cut and folded flights and short pitch using the Capacity Factors for Special Pitches and Modified
Flights. As stated above, the adjusted capacity is defined as Selection Capacity (SC).
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The Capacity Factor for cut and folded flights with 30-percent trough loading is 3.75.
Therefore:
SC = 1.50 X 3.75 X 333 ft3/hr
SC = 1,873 ft3/hr
The Selection Capacity will be used to select the proper screw conveyor diameter and speed from
the Capacity Table. With a recommended trough loading of 30A, the Selection Capacity must be
less than the maximum capacity given in the Capacity Table. A 16-inch diameter screw conveyor
will convey 2,496 cubic feet per hour at the maximum recommended speed of 80-rpm.
The actual screw conveyor speed is calculated by dividing the Selection Capacity by the capacity at
1-rpm.
1,873/31.2 = 60-rpm
60-rpm is the correct speed for a 16-inch diameter screw conveyor with cut and folded flights and
short pitch for conveying and mixing 333 cubic feet per hour.
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Capacity Table
Capacity in ft3/hr
Trough Loading Screw Dia. (in.) Max. RPM *
At Max. RPM At 1 RPM
4 69 14.5 0.2
6 60 45 0.8
9 55 150 2.7
12 50 323 6.5
14 50 520 10.4
16 45 702 15.6
18 45 1,012 22.5
20 40 1,248 31.2
24 40 2,184 54.6
30 35 3,728 106.5
15% 36 30 5,532 184.4
4 139 57 0.4
6 120 179 1.5
9 100 545 5.5
12 90 1,161 12.9
14 85 1,768 20.8
16 80 2,496 31.2
18 75 3,375 45.0
20 70 4,375 62.5
24 65 7,085 109.0
30 60 12,798 213.3
30% A 36 50 18,440 368.8
4 69 28 0.4
6 60 90 1.5
9 55 305 5.5
12 50 645 12.9
14 50 1,040 20.8
16 45 1,404 31.2
18 45 2,025 45.0
20 40 2,500 62.5
24 40 4,360 109.0
30 35 7,465 213.3
30% B 36 30 11,064 368.8
4 190 116 0.61
6 165 368 2.2
9 155 1,271 8.2
12 145 2,813 19.4
14 140 4,368 31.2
16 130 6,071 46.7
18 120 8,112 67.6
20 110 10,307 93.7
24 100 16,400 164.0
30 90 28,800 320.0
45% 36 75 41,490 553.2
NOTE: Maximum speeds shown in the Capacity Table are not intended for every application and
were developed for non-abrasive, free-flowing bulk materials. KWS recommends lower
screw conveyor speeds for most industrial applications. A larger screw conveyor diameter
will be required for lower screw conveyor speeds.
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The calculations included in the KWS Screw Conveyor Engineering Guide are for control fed screw
conveyors only. The horsepower calculations for screw feeders require additional considerations.
Please consult KWS Engineering for screw feeder applications.
Horsepower is defined as the power required to safely and feasibly convey a bulk material a fixed
distance in a screw conveyor. The horsepower required to drive a screw conveyor is called Total
Shaft Horsepower, or TSHP. TSHP is a function of the characteristics of the bulk material being
conveyed and the friction inherent in the screw conveyor. It is very important to design a screw
conveyor with sufficient horsepower in order to prevent downtime and loss of production.
Properly defining the bulk material to be conveyed is very important because material characteristics
such as bulk density, abrasiveness and flowability all play a role in determining the proper
horsepower for a screw conveyor. TSHP is the sum of Friction Horsepower and Material Horsepower
divided by the drive efficiency. Friction Horsepower is the horsepower required to turn a screw
conveyor when empty. Friction from the bearings, seals and other moving components create
resistance. Sufficient horsepower is required to overcome the friction. Material Horsepower is the
horsepower required to convey the bulk material the full length of the screw conveyor. The Friction
and Material Horsepower calculations are shown below:
Equation Nomenclature:
FHP = Friction HP (HP required to drive MHP = Material HP (HP required to convey bulk
conveyor empty) material)
DF = Conveyor Diameter Factor CFH = Conveyor Capacity (ft3/hr)
HBF = Hanger Bearing Factor W= Bulk Density (lbs/ft3)
L = Conveyor Length (feet) MF = Material Factor (From Bulk Material Table)
S = Conveyor Speed (RPM) CP = Capacity (lbs/hr)
TSHP = Total Shaft HP
e = Drive Efficiency (Typical value of 0.88 is
used for a shaft mount reducer/motor)
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The Diameter Factor (DF) is an empirical value determined over many years of testing and represents
the frictional resistance of the weight of the screw for various screw diameters.
The Hanger Bearing Factor (HBF) is an empirical value determined over many years of testing
and represents the frictional resistance of the hanger bearing for various types of hanger
bearing materials.
The Material Factor (MF) is an empirical value determined over many years of testing and
represents the frictional resistance of the bulk material being conveyed. Please note that as the
bulk density increases, typically the Material Factor increases because denser bulk materials are
more difficult to convey. Material Factors for many materials can be found in the Bulk Material
Table.
The drive unit for a screw conveyor is typically designed with a gear reducer and motor. The
drive unit for a screw conveyor is not 100-percent efficient. There are frictional losses in the gear
reducer and belt/chain reduction. Drive efficiency (e) is typically between 85 and 95-percent.
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The calculated horsepower of a screw conveyor may need to be adjusted so the drive unit will have
more horsepower and torque available to overcome an upset condition such as a minor choke in the
inlet or a large lump being conveyed. The Corrected Material Horsepower Factor, sometimes called
the Overload Factor, is used to increase the Total Shaft Horsepower (TSHP) of a screw conveyor
when the calculated Material Horsepower (MHP) is less than 5-HP. Increasing the TSHP allows the
screw conveyor to overcome most upset conditions, reducing downtime and loss of production.
4.5
3.5
3
Corrected HP
2.5
1.5
0.5
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Calculated HP
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The procedure for calculating Total Shaft Horsepower (TSHP) for screw conveyors with special
flights is identical to that used for standard flights except the Material Horsepower (MHP) must
be multiplied by one or more of the Special Flight Factors (SF). Special Flight Factors are used to
account for the additional horsepower needed to overcome the resistance of the special flights to
the bulk material being conveyed. Special flights are used for chopping up or mixing bulk materials
and additional horsepower is required to perform these functions.
Conveyor Loading
Type
15% 30% 45%
Cut flight 1.10 1.15 1.2
Cut & folded flight X 1.50 1.7
Ribbon flight 1.05 1.14 1.20
Example
Using the previous example, a screw conveyor is required to transport 10 tons per hour of unslaked
lime with a bulk density of 60 lbs. per cubic foot. The unslaked lime also needs to be mixed in transit
using cut and folded flights. The conveying distance is 15-feet so short (2/3) pitch screws will be used
to ensure proper mixing. The recommended trough loading percentage from the Bulk Material Table is
30A. The Special Flight Factor for cut-and-folded flights at 30-percent trough loading is 1.50.
Conveyor Loading
Type
15% 30% 45%
Cut flight 1.10 1.15 1.2
Cut & folded flight X 1.50 1.7
Ribbon flight 1.05 1.14 1.20
The Material Horsepower (MHP) will be multiplied by 1.50 to account for the additional horsepower
needed to overcome the resistance of the special flights to the unslaked lime being conveyed and mixed.
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Torque is defined as the twisting force exerted by the drive unit on the conveyor screw. Torque
is transmitted through the drive shaft of the drive unit to the screw and converted to force
to convey the bulk material. Properly selecting screw conveyor components is important to
minimizing downtime and maintenance.
Full Motor Torque is the maximum torque generated by the drive unit. The equation for Full
Motor Torque is shown below:
Torque is measured in inch-lbs. for screw conveyor components. The torque rating of the
drive shaft, coupling shafts, coupling bolts and conveyor screw must be able to withstand
Full Motor Torque without failing. Every KWS screw conveyor is designed to this criteria with a
minimum safety factor of 5 to 1. The motor on the screw conveyor will stall out before there is a
mechanical failure of a screw conveyor component.
Maximum torque ratings for each screw conveyor component are shown in the Torque
Tables. Maximum torque ratings are based on a safe stress value for the specific material of
construction. The screw conveyor components will have an infinite life under normal operating
conditions.
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There are many different factors to consider when designing a screw conveyor. The purpose of this
example is to provide a step-by-step process that a KWS engineer would follow when designing
a screw conveyor. It is important for the person designing the screw conveyor to understand how
each factor affects the final screw conveyor design.
The screw conveyor for the example is control fed at the inlet by another screw conveyor.
The first step is to look up corn meal in the Bulk Material Table and write down the following
information –
Bulk Material: Corn Meal
Maximum Particle Size: minus 1/8-inch and smaller
Bulk Density: 32 to 40 lbs/ft3
Trough Loading: 30A (30-percent)
HP Factor: 0.5
Component Series: A1-A2
Abrasiveness: I
Corrosiveness: I
Flowability: III
Note – For the example, the additional characteristics provided in the “Note” column of the bulk
material will not be considered in order to simplify the solution. Please refer to the Bulk Material
Factors section for more detailed information.
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Maximum Bulk
Bulk % HP Component
Particle Density Abrasiveness Corrosiveness Flowability
Material Loading Factor Series
Size (in.) (lbs/ft³)
Corn
-1/8 32-40 30A 0.5 A1-A2 I I III
Meal
Now that the characteristics of the bulk material to be conveyed have been determined, the next
step is to calculate the capacity in cubic feet per hour. Always use the lowest bulk density when
calculating capacity in order to get the highest potential volumetric capacity.
The recommended trough loading percentage according to the Bulk Material Table is 30A, or 30-percent.
Using standard full pitch, fill in the blank to calculate the Selection Capacity:
1
1
Nomenclature:
SC = Selection Capacity (ft³/hr)
CFH = Required Capacity in Cubic Feet Per Hour (ft³/hr)
CF = Capacity Factor
The Selection Capacity will be used to select the proper screw conveyor diameter and speed from
the Capacity Table. Using the Recommended Trough % Loading and calculated Selection Capacity,
select the proper conveyor diameter. The Selection Capacity must be less than the maximum
capacity given in the Capacity Table. Fill in the blanks below based on your previous calculations:
Conveyor Diameter: 12” Capacity at Max RPM: 1,161
Capacity at 1 RPM: 12.9
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The Actual Conveyor Speed is calculated by dividing the Selection Capacity by the Capacity at 1-RPM.
Fill in the blanks below:
Capacity Table
Capacity in ft3/hr
Trough Loading Screw Dia. (in.) Max. RPM *
At Max. RPM At 1 RPM
4 139 57 0.4
6 120 179 1.5
9 100 545 5.5
12 90 1,161 12.9
14 85 1,768 20.8
16 80 2,496 31.2
18 75 3,375 45.0
20 70 4,375 62.5
24 65 7,085 109.0
30 60 12,798 213.3
30% A 36 50 18,440 368.8
Maximum Bulk
Bulk % HP Component
Particle Density Abrasiveness Corrosiveness Flowability
Material Loading Factor Series
Size (in.) (lbs/ft³)
Corn
-1/8 32-40 30A 0.5 A1-A2 I I III
Meal
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Calculating Horsepower
Friction Horsepower
A 12-inch diameter screw conveyor was selected in Step 2 of the example. The Diameter Factor (DF)
selected from the Diameter Factor Chart (HP Section) is 55 for a 12-inch diameter screw conveyor.
Diameter Factor Chart (DF)
Dia. Factor Dia. Factor Dia. Factor Dia. Factor
4 12 12 55 18 135 30 377
6 18 14 78 20 165 36 549
9 31 16 106 24 235
Since the bulk material to be conveyed is corn meal, a wood hanger bearing is selected for the
application. The Hanger Bearing Factor (HBF) selected from the Hanger Bearing Factor Chart
(HP Section) is 1.7 for a wood hanger bearing.
Hanger Bearing Factor Chart (HBF)
Bearing Type Bearing Factor Bearing* Class
Ball, Roller, or none 1.0 2
Bronze, or Wood 1.7 2
Plastic, Nylon, UHMW, or Teflon 2.0 3
Hard Iron, or Stellite 4.4 4
Nomenclature:
DF = Conveyor Diameter Factor HBF = Hanger Bearing Factor
L = Conveyor Length (ft) S = Conveyor Speed
Material Horsepower
The capacity (CP) given in the example is 25,600 lbs. per hour. Please note: Do not use Selection
Capacity (SC) to calculate horsepower. The screw conveyor length is 16-feet.
The Material Factor (MF) or HP Factor for corn meal is 0.5 from the Bulk Material Table.
Nomenclature:
MF = Material Factor CP = Capacity (lbs/hr)
The calculated Material Horsepower (MHP) is 0.21-HP and must be corrected since it is less than
5-HP. Using the Corrected Material HP Chart below, locate 0.21-HP on the horizontal axis of the
chart, draw a line vertically until it intersects the curved line, then move horizontally to determine the
Corrected Material Horsepower of 0.5-HP.
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4.5
3.5
3
Corrected HP
2.5
1.5
0.5
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
0.21 Calculated HP
Fill in the blanks and calculate Total Shaft Horsepower (TSHP) by summing the Friction Horsepower
(FHP) and the Corrected Material Horsepower (MHP) as follows:
Drive efficiency (e) for a typical screw conveyor drive unit with shaft-mounted reducer and V-belt
drive is 88-percent, or 0.88.
Total Shaft Horsepower (TSHP) is typically rounded up to the next commonly available motor size.
The most commonly available motor size for the example would be 1-HP. The drive unit selected for
the example is 1-HP at 60-rpm. The speed of the drive unit is typically rounded to the closest 5-rpm
increment.
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Maximum Bulk
Bulk % HP Component
Particle Density Abrasiveness Corrosiveness Flowability
Material Loading Factor Series
Size (in.) (lbs/ft³)
Corn
-1/8 32-40 30A 0.5 A1-A2 I I III
Meal
The torque rating of the drive shaft, coupling shafts, coupling bolts and conveyor screw must be
greater than Full Motor Torque for proper design.
A 12-inch diameter screw conveyor was selected for the example. The minimum standard shaft size
for a 12-inch diameter screw conveyor is 2-inch diameter. The corresponding pipe size is 2-1/2-inch
schedule 40 pipe with 5/8-inch diameter coupling bolts. The materials of construction of the screw
conveyor is carbon steel.
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Maximum torque ratings for each screw conveyor component are shown in the Torque Tables below.
Maximum torque ratings are based on a safe stress value for the specific material of construction. The
screw conveyor components will have an infinite life under normal operating conditions.
The torque rating of the screw conveyor components from the Torque Tables:
The torque rating of each screw conveyor component is much higher than the Full Motor Torque
generated by the drive unit. The screw conveyor in the example is designed properly and will function
many years with minimal maintenance or downtime.
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Maximum Bulk
Bulk % HP Component
Particle Density Abrasiveness Corrosiveness Flowability
Material Loading Factor Series
Size (in.) (lbs/ft³)
Corn
-1/8 32-40 30A 0.5 A1-A2 I I III
Meal
The recommended Component Series for corn meal is A as listed in the Bulk Material Table. Corn meal
is a light, non-abrasive and free-flowing bulk material.
The 12-inch diameter by 16-feet long screw conveyor for the example is constructed from carbon steel
with the following construction as selected from the Component Series Table:
Series A
Screw Dia. Shaft Dia. Cover Thickness Screw Number Trough
Helicoid Sectional Thickness (Min.)
4 1” 14 Ga. 4H206 N/A 14 Ga.
6 1-1/2” 14 Ga. 6H304* 6S309 14 Ga.
1-1/2 “ 9H306* 9S309
9 14 Ga. 14 Ga.
2” 9H406* 9S409
2” 12H408* 12S409
12 2-7/16” 14 Ga. 12H508* 12S509 12 Ga.
3” 12H614* 12S612
2-7/16” 14H508* 14S509
14 14 Ga. 12 Ga.
3” 14H614* 14S609
16 3” 14 Ga. 16H610* 16S612 12 Ga.
3” 18S612
18 12 Ga. N/A 10 Ga.
3-7/16” 18S712
3” 20S612
20 12 Ga. N/A 3/16”
3-7/16” 20S712
24 3-7/16” 12 Ga. N/A 24S712 3/16”
30 3-15/16” 10 Ga. N/A 30S816 3/8”
36 4-7/16” 3/16” N/A 36S916 3/8”
Screw: 12H408 helicoid screws with 1/8-inch nominal flight thickness and 2-inch shaft diameter
Trough: TUA1212 angle flange trough with 12-gauge trough thickness
Cover: COV1214UFL flanged cover with 14-gauge cover thickness
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The recommended Bearing Material Series is 1-2 as listed in the Bulk Material Table.
The 12-inch diameter by 16-feet long screw conveyor for the example can utilize several different
hanger bearing materials as selected from the Component Series Table:
Based on a Bearing Material Series of 1-2, the hanger bearings can be Nylatron, Plastech, UHMW,
Wood, Gatke or ball bearing. We are selecting wood for the example because wood hanger bearings
are very cost-effective and durable.
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A
Shaft E F
Screw B C D G H J K L M N P R
Dia. Bolts (Min.)
Dia.
4 1 9’ - 10-1/2” 10 1-1/2 3/8 4-1/2 1 3-5/8 4-5/8 3-3/4 5-3/4 1-7/16 4-7/8 7-3/4 7-1/2
6 1-1/2 9’ - 10” 10 2 3/8 6 1 4-1/2 5-5/8 5 8-1/8 1-1/2 6 9-3/4 10
1-1/2
9 9’ - 10” 10 2 1/2 8 1-1/2 6-1/8 7-7/8 7-1/8 9-3/8 1-5/8 7-5/8 13-3/4 13
2
2 11’ - 10” 2
12 2-7/16 11’ - 9” 12 3 5/8 10-1/2 1-5/8 7-3/4 9-5/8 8-7/8 12-1/4 2 9-3/4 17-1/4 17
3 11’ - 9” 3
2-7/16
14 11’ - 9” 12 3 5/8 11-1/2 1-5/8 9-1/4 10-7/8 10-1/8 13-1/2 2 11-1/4 19-1/4 19
3
16 3 11’ - 9” 12 3 5/8 13-1/2 2 10-5/8 12 11-1/8 14-7/8 2-1/2 12-5/8 21-1/1 21
3 11’ - 9” 3
18 12 5/8 14-1/2 2 12-1/8 13-3/8 12-3/8 16 2-1/2 14-5/8 24-1/4 24
3-7/16 11’ - 8” 4
3 11’ - 9” 3
20 12 3/4 15-1/2 2-1/4 13-1/2 15 13-3/8 19-1/4 2-1/2 16 26-1/4 26
3-7/16 11’ - 8” 4
24 3-7/16 11’ - 8” 12 4 3/4 17-1/2 2-1/4 16-1/2 18-1/8 15-3/8 20 2-1/2 19 30-1/4 30
30 3-15/16 11’ - 8” 12 4 3/4 20-1/2 2-1/2 19-1/2 21-1/2 18-3/8 30 3 22-1/2 38 36
36 4-7/16 11’ - 7” 12 5 3/4 23-1/2 2-1/2 22-1/2 24 21-3/8 36 3 25-1/2 44 43
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Notes
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Notes
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What makes KWS different from other manufacturers?
At KWS we understand the needs and exceed the
expectations of our Customers. As an ISO-9001 certified
company, quality is integrated into every aspect of our
processes. Quality is defined by the Customer, and derived
Design
from the total KWS Customer experience. It’s not just
Engineering
product quality, but quality throughout every step of the
Manufacturing
Sales, Engineering and Manufacturing processes. Quality
starts with our first Customer contact and never ends.
ISO 9001
Certified