Diseño de Tolvas

Solids Handling
in
The Chemical Company
Dr. Hermann J. Feise1)

DI Thomas Letzelter2)
1) Science Relations
2) Process Systems Engineering
24.09.2012 1
Solids Handling
Storing and Conveying of Bulk Solids
Bulk Solids Characterization

Flow properties
Shear testers
Design of Storage Silos
Gravity fed storage systems
Flow promoting devices
Conveying of Bulk Solids
Screw conveyors, pneumatic conveying
24.09.2012 Dr. Hermann J. Feise, GOH/C Science Relations and Innovation Management 2
Being an Engineer in Industry
The phone call
 4:30 pm a customer calls  What question do you ask?
 A new factory for our product  …

„Powdery White“  …
 Can you design the handling and  …

shipping facilities for us?  …
 …
 YES, ......
 Oh, and we have two grades, the
fine and the instant product.
The Role of Particle Technology
 Merrow (1986): “use of solids in

a process is the most prominent
factor causing delayed start-up”
 Merrow (1998): “things did not

get better”
 delays of up to 18 month
 process predictions of solids
processes are inferior to
fluid - processes
 Particle technology is becoming
increasingly important
Characterization of Bulk Solids:
Bulk Solids are NOT like liquids
 Flow under gravity

 Surface
 Liquid: level
 Bulk solids: angle of repose
 Flow
Gravel Baking powder
 Liquid: incompressible
 Bulk solids: dilatant
 Storgae pressure
 Liquid: hydro static
 Bulk solids: Janssen - effect
Vitamin powder Cement
Bulk Density – Bulk Solids Density
 Flow properties, packaging

 NOT a material constant
Feed hopper
Fülltrichter
 Depends on compaction,
shaking, electro static
conditions...
Knife valve
Bodenklappe
 Tapped density / bulk density =
Hausner number Graded cylinder
Meßbecher
 Different countries – different Prüfgerät zur Schüttdichtebestimmung nach DIN 53466
Device to determine the bulk density acc DIN 53466
standards – different bulk

densities
Bulk Solid Properties
Janssen - Effect
Janssen (1895)
z v A
Hydro static
w U dz
dz
h U dz
w v
h
v + dv) A
g b A dz 
 = lateral stress ratio = h/v

A  
 tan  x U
g  b D  z
x = external or wall friction angle v    1  e A 

  tan  x 4 
U 
U = circumference
 w   h  tan  x
A = cross sectional area
Bulk Solid Properties
Janssen - Effect
z v A
w U dz v
dz
h U dz
v + dv) A
g b A dz 
A   A x z 
 tan  U
g  b
v     e  1
 Reversion of frictional force!   tan  x U  
Force to Convey Millet seed Vertically
through a 45 mm Acrylic Tube
250
Curve (1) Theoretical

200
Curve (2) Experimental
Millet Vcon ? 30 mm/s
150
Force - N
100
50
0 © P. Arnold, U Wollongong
0 100 200 300 400 500
Column Length - mm
Bulk Solid Properties:
Virtual Experiment
1
fc  Cylindrical sample with
fricitonless supports
 Compaction with lateral
support
 Consolidation stress
1
2 2  Bulk solid density b
 ‚shear‘
 No lateral support
 Uni-axial compressive
1 fc strength fc
Consolidation Shear
Ringschergerät
 Current industrial standard
S
Tie Rod  Ring Shear Tester RST-01pc
Guard Roll
 Sample size: 200 bzw. 900ml
N
Lid
 Automatic control
Cross Bar
 ‚unlimited‘ travel
Guard Roll
Shear Cell  Several data points per
sample
Tie Rod
 Suitable for products with
x95< 4 mm
Bulk Material
S  http://www.dietmar-schulze.de/fre.html
Shear Test
Shear test vs. Travel diagram
S Over-consolidated sample
Material flows under dilation
travel
S Well pre-sheared sample
Material flows under
constand volume, no
compaction
travel
S
Under – consolidated sample
Material keeps compaction
N =normal force, S = shear force during shear
travel
Test Evaluation acc. Jenike
i = internal friction angle
e = effective angle of internal friction

Shaer stres c
fc = uniaxial compressive strength
1 = major principal stress (axial)

2 = minor principal stress (radial)
Plastic deformation
E
c Cohesion
i e
2 fc 1
Internal friction angle Normal stress 
Jenike Shear Cell
 Past industrial N
standard
 Sample size: 600 ml

S
 Material requirement:
3 - 15 Liter
 Max. travel <= 5mm

N = normal force, S = shear force
 Suitable for materials
with x95< 4 mm
Walker Ring Shear Cell
 Walker Ring Shaer Tester

N el. Beheizung
TI
u. Isolation
Deckel
 Sample size: 2 Liter
 ‚unlimited‘ travel
S
 Several data points per
Meßhebel (fest)
Produktprobe
sample
Ringzelle
el. Beheizung
 Suitable for products with
u. Isolation x95< 4 mm
Antrieb  Probenbeheizung bis ca.

80°C
Bulk Solids Properties:
Johanson Hang-Up Indicizer
52.40
Inside Piston
Outer Piston
Die
41.48
44.32 Sample
23* Shear Plane
52.55
Ledge
46.63
Lower Piston
Compaction Lower Punch
Shear
Flow Profiles and Flow Properties
Dead
zone
Flow
channel
Mass Flow Funnel Flow Arching Ratholing
Types of Arching
1
1
Compaction with Jamming with

cohesive products coarse, non
cohesive products
Process Engineering Silo Design
100
Phone call, letter
Seminar, short visit
Book, journal
Feasibility study
Probability of Success [%]
80
60
Pilot plant testing
40
Full scale testing
Shear test
20
0,1 1 10 100 1000 10000 100000
Cost of Method [£]
Quelle: H. Wright, bulk solids handling, 8(1988)5, 627-628
Silo Pressure Profiles
1 = major principal stress

Material 1 = embankment stress
element fc = uniaxial compressive
strength at 1
1
D
Hydrostatic pressure of a liquid
H 1
fc 1
 dmin
h*
1= fckrit
fc, 1, 1
Silo Stresses
a. w b. w
a. Filling state
b. Beginning discharge
c. Mass flow
d. Funnel flow
c. w d. w Quelle: J. Schwedes, TU Braunschweig 1985
Silo Design acc.to Jenike
Representative sample
Mass flow angle
Silo Operating
geometry Wall friction Conditions
µ = tan(x) Shear
Design for
testing Wall material
mass flow
Hopper
angle Storage time
or Bulk solids Friction Flow

density angle function, Storage temperature
Hopper angle b  e,  i time flow humidity
function: .
Pressure fc ÷  1 .
distribution .
in hopper Critical stress conditions
Silo shape
Storage
volume Jenike - Method
(Bulletin 123) Minimum outlet size against
arching and ratholing
Silo Design:
Mass Flow – Funnel Flow Boundaries
DIN 1055: 2005
Hopper wall friction coefficient h = tan x

Hopper wall friction coefficient h = tan x
Funnel
Funnel Flow
Flow
Mass Flow
possible
Mass Flow
possible
Hopper inclanation 

Hopper inclanation 
Axial-symmetric Silo Plane Silo
Quelle: DIN 1055, Beuth Verlag 2005
Silo Design:
Mass Flow – Funnel Flow Boundaries
DIN 1055: 1984
Axial-symmetric Silo Plane Silo
Quelle: DIN 1055, Teil 6; Beuth Verlag 1984
Silo Desgin: Silo Shapes
Axial-symmetric pyramidal plane
D B B
H H
H
ax eben
ax eben
Bmin L Bmin
Dmin
L > 3 * Bmin
steep steep Less steep
Mass Flow Angle*
100
% proportion odf hoppers with mass flow
80
axc
60
40
20
0 
0° 10° 20° 30° 40° c
*STUDY BY TERBORG OF 500 SAMPLES
Hopper angle (axial-symmetric hopper)
Flow Promotion – not this way
© BASF SE, 1999
Silo Design:
Silo Discharge for Mass Flow
Rotary valve  Flow properties

 Storage time
Vibrating hopper
ax
4m
 Silo Shape
30°
Scraper
Live Bottom
15°
0,5 Dmin/D
Silo Design: Minimum Silo Outlet and
Time consolidation
 Mass Flow Silo
 Maximum stoppage time:
3 days (week end)
 Continuous discharge
 Flow promoters
 conveyor Dmin(3 d)
 Flow promoter, Gravity flow
continuous Dmin
 Flow promoter after Flow promoters, short term
prolonged stoppage Discharge device
DAus
 Alternative: Recycling Conveyor
Mechanical Conveying:
Screw Conveyors
 Principle:  Several feed or discharge ports

 Screw helix moves through the  Closed system (inert
material atmosphere)
 50 - 200 rpm  No bends (exception: flexible
screw conveyors)
 Operational conditions
 Single and multiple screws
 L < 6 m, no intermediate bearing
 Additional features
 L < 60 m , intermediate bearing
 Heating, cooling, mixing,
 Horizontal, vertical, homogenizing, degassing …
 tilted (<30°)
Mechanical Conveying: Flexible Screw
Conveyors
 Screw without core (pig tail) rotates in a
flexible casing (plastic hose)
 Advantages
 Low investment cost
 Can manage one bend
 Horizontal or vertical
 Disadvantage
 Low capacity (DN200: 40 m³/h)
 L < 15m; H < 12m
 High rotational speeds
 Wear of casing and helix
(Ermüdungsbruch)
 Incomplete discharge
Mechanical Conveying:
Vibratory Conveyors
 Models
 Electromagnetical vibratory conveyors
– Non balanced mounting
– L < 6m
 Isolated counterbalanced vibratory
conveyor
– Heavy (balancing weights)
– L = 6 - 30 m possible
– Q > 100 to/h
 Products
 Suitable for: hot, abrasive, dusty
 Nor sited for: cohesive, tacky
 Design
 Several feed and discharge ports
 horizontal up to ±5°
 No bends
Material 1 2 3 4 5
Class
Powder Powder Granualr Fibrous, Large Abrasive High
Powder
sluggish sluggish free-flowing flaky, particles solids temp-
sluggish
100 – adhesive fluidizes >100 mesh floccu- Sizes era-
300 (incl. class 3 – 325 > 25 Ib/ft3 lent > 3˝ ture
mesh 1 when mesh
damp)
Belt conveyor
Screw conv.
Flex screw
converyor
Vibratory conv
Drag disc conv

. AeroMech
Drag chain c.
Redler conv
Bucket elevator
Plastic elevator
Belt Conveyor
Drag chain conveyor

Feeder / Conveyor
Drag disc conveyor
Screw conveyor
Vibratory conveyor
Aeromechanical conveyor
Flexible screw conveyor

Screw feeder without intermediate bearings
30 Conveying60distance [m] 100 150
Pneumatic Conveying Principle
Product
Discharge
air
PI
Pressureized
air
Ambient air Feed port

Silo with
filter unit
Geldard diagram of fluidization
10000
Diagram acc. to Geldart, boundaries acc. to Molerus
Group D
Density differnce (s – F) [kg \ m3]
5000
2000
Group A
1000 Group B
500 Group C
200
100
10 20 50 100 200 500 1000 2000 5000
Mean particle size dp [µm]
Pneumatic Conveying States
Horizontal Conveying
Dense Phase Conveying
Dichtstromförderung Lean Phase Conveying
Dünnstromförderung
pressure‐
Saug-or vacuum conveying
oder Druckförderung
Druckförderung Instabiler stabiler Förderbereich

Stable plug flow Instable/
Kolben- Stable dispersion flow
Dünen- / Flugförderung
stabiler
(bezogener Druckverlust/Längeneinheit)
Vollrohr-/Kolben- plug
Dünen-
Solids conveying rate
Gutdurchsatz
log(log) relative pressure drop, p/l
flow . . . .
. MS3MS2MS1MS0= 0
MS = 0
ruhende
Granular
Schüttung
bed at rest
Leerlaufkurve
Air only
. . .
MS3 > MS2 > MS1
pmin
f) b)
d)
c)
e) a)
vmin v*
(log) mean gas velocity, v
log (mittlere Gasgeschwindigkeit)
Pneumatic Conveying:
Air flow controller
 Dense phase conveyor (Roto-

Conveyor or pressure vessel Fa. Waeschle
system)
p [mbar]
 Laval nozzle with variable nozzle
geometry
 Almost constant air flow rate
(ideal pump characteristic) at all
pressure levels up to the supply
pressure
 Suitable for explosion protection Ventilator
areas (no ignition sources) Compressor
Air flow controller
 Can supply systems with various
discharge ports and conveying
distances (routing and run length) Q [m³/h]
Being an Engineer in Industry
The phone call
 4:30 pm a customer calls  What question do you ask?
 A new factory for our product  Product Split, Production capacity

„Powdery White“  Product Data
 Can you design the handling and  Storage Volume, Storage Time
shipping facilities for us?  Packaging (bags, Super Sacks, loose)
 YES, ......  What do you suggest to do?
 Oh, and we have two grades, the  …

fine and the instant product.  …
 …

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Solids Handling

Dr. Hermann J. Feise1)

Bulk Solids Characterization

 A new factory for our product  …

 Can you design the handling and  …

 Merrow (1986): “use of solids in

 Merrow (1998): “things did not

 Flow under gravity

 Flow properties, packaging

standards – different bulk

 = lateral stress ratio = h/v

Curve (1) Theoretical

i = internal friction angle

e = effective angle of internal friction

1 = major principal stress (axial)

 Sample size: 600 ml

 Max. travel <= 5mm

 Walker Ring Shaer Tester

Antrieb  Probenbeheizung bis ca.

Mass Flow Funnel Flow Arching Ratholing

Compaction with Jamming with

0,1 1 10 100 1000 10000 100000

1 = major principal stress

c. w d. w Quelle: J. Schwedes, TU Braunschweig 1985

DIN 1055: 2005

Hopper wall friction coefficient h = tan x

Hopper inclanation 

Axial-symmetric Silo Plane Silo

Quelle: DIN 1055, Beuth Verlag 2005

Axial-symmetric Silo Plane Silo

Quelle: DIN 1055, Teil 6; Beuth Verlag 1984

Axial-symmetric pyramidal plane

© BASF SE, 1999

Rotary valve  Flow properties

 Principle:  Several feed or discharge ports

Drag disc conv

Drag chain conveyor

Drag disc conveyor

Flexible screw conveyor

30 Conveying60distance [m] 100 150

Ambient air Feed port

Druckförderung Instabiler stabiler Förderbereich

 Dense phase conveyor (Roto-

 A new factory for our product  Product Split, Production capacity

 YES, ......  What do you suggest to do?

 Oh, and we have two grades, the  …

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