SCREW CONVEYOR

BASIC DESIGN CALCULATION

 CEMA (Conveyor Equipment Manufacturer Association) Approach
 HISTORY & APPLICATION
 HISTORY:
 The first conveyor as such as designed by
ARCHIMEDES (287 – 212 BC) for
removing water from the ship and to
raise water from river to farm land
 The next technological advancement of
importance in screw conveyor design was
patented on march 29, 1898 by Frank C.
Caldwell.
 This construction is now known as the
helicoid flight.
 APPLICATION:
 Screw conveyor s are bulk material
transporting devices capable of handling
a great variety of materials which have
relatively good flowability.
 Flowability is defined in the CEMA
material classification standard and
denotes: “the degree of freedom of
individual material particles to move past
each other”
 This characteristic is important in a screw
conveyor operation as the screw helix.
 The many advantages of screw conveyor
is feasibility of nomerous feed and
discharge of the material to be conveyed.
 Another used is the blending of several
ingredients to make a finished product or
to make a pre-mix for some product
 Screw conveyors may be operated
horizontally, on an incline or vertically.
 MATERIAL CODE & BULK MATERIAL CHARACTERISTICS
 MATERIAL CODE Table 2-1
Material Classification Code Chart
A study has been made to Major Class Material Characteristics Included Code Designation
define the characteristic of Density Bulk Density, loose Actual, lb/ft3
Size Very Fine
bulk materials in terms which No. 200 sieve (0.0029") and under A200
are readily recognized. No. 100 sieve (0.0059") and under A100
No. 40 sieve (0.016") and under A40
Fine No. 6 sieve (0.132") and under B6
Granular 1/2" and under C1/2
3" and under D3
7" and under D7
Lumpy over 16" to be spesified D16
X = actual maximum size Dx
Irregular Stringy, fibrous, cylindrical, slabs,etc E
Flowability Very free flowing flow function > 10 1
free flowing 4 < flow function < 10 2
average flowability 2 < flow function < 4 3
sluggish flow function < 2 4
Abrasiveness Midly abrasive index 1 - 17 5
Moderately abrasive index 18 - 67 6
Extremely abrasive index 68 - 416 7
 MATERIAL CODE & BULK MATERIAL CHARACTERISTICS
 BULK MATERIAL
CHARACTERISTIC:
A study has been made to Table 2-2
Material Characteristic
define the characteristic of Weight
Material Material Code Component Series Mat'. Factor Vertical
bulk materials in terms which lb/ft3
are readily recognized. Ash, black ground 105 105B635 1A-1B-1C 2.0 -
Ashes, coal, dry __ 1.2" 35 - 45 40C1/246TY 3D 3.0 V
Ashes, coal, dry __3" 35 - 40 38D346T 3D 2.5 -
The table shows in the first
Cement, Clinker 75 - 95 85D336 3D 1.8 -
column the range of density Cement, Portland 94 94A10026M 2D 1.4 V
that is usually experienced in Cement, Aerated (Portland) 60 - 75 68A10026M 2D 1.4 V
handling material Coal, Anthracite, sized__1/2" 49 - 61 55C1/225 2A-2B 1.0 -
Coal, Bitumious, mined 40 - 60 50D335LNXY 1A-1B 0.9 -

The material table is a guide Coal, Bitumious, slack 43 - 50 47C1/245T 2A-2B 0.9 -
Dolomite, crushed 80 - 100 90C1/236 2D 2.0 -
only. The material code and
Dolomite, lumpy 90 - 100 95Dx36 2D 2.0 -
the material factor (Fm) are
Fly Ash 30 - 45 38A4036M 3D 2.0 -
based on experience of several
Gypsum, raw__1" 70 - 80 75D325 2D 2.0
conveyor manufacturers.
Limestone, crushed 85 - 90 88Dx36 2D 2.0
Limestone, dust 55 - 95 75A4046MY 2D 1.6 - 2.0
 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. Table Maximum Lump Size
Class 1 Class 2 Class 2
Screw Radial
Pipe OD 10% lumps 25% lumps 95% lumps Ratio
dia. Clearance
(inches) Ratio R=1.75 Ratio R=2.5 R=4.5
(inches) (inches)
Max. Lump (inch.) Max. Lump (inch.) Max. Lump (inch.)
6 2 3/8 2 5/16 1 1/4 3/4 1/2
9 2 3/8 3 13/16 2 1/4 1 1/2 3/4
9 2 7/8 3 9/16 2 1/4 1 1/2 3/4
12 2 7/8 5 1/16 2 3/4 2 1
12 3 1/2 4 3/4 2 3/4 2 1
12 4 4 1/2 2 3/4 2 1
14 3 1/2 5 3/4 3 1/4 2 1/2 1 1/4
14 4 5 1/2 3 1/4 2 1/2 1 1/4
16 4 6 1/2 3 3/4 2 3/4 1 1/2
16 4 1/2 6 1/4 3 3/4 2 3/4 1 1/2
18 4 7 1/2 4 1/4 3 1 3/4
18 4 1/2 7 1/4 4 1/4 3 1 3/4
20 4 8 1/2 4 3/4 3 1/2 2
20 4 1/2 8 1/4 4 3/4 3 1/2 2
24 4 1/2 10 1/4 6 3 3/4 2 1/2
SELECTION OF CONVEYOR SIZE AND SPEED – 1

 CONVEYOR SIZE & SPEED

 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.
 The capacity table (below) gives the capacities in ft3/hour at one revolution per minutes for
various sized and various cross-sectional loading.
 The basis for the Capacity Table is as follows

𝟎𝟎. 𝟕𝟕𝟕𝟕𝟕𝟕𝟕𝟕 𝑫𝑫𝑫𝑫𝟐𝟐 − 𝑫𝑫𝑫𝑫𝟐𝟐 𝑷𝑷 𝑲𝑲 𝟔𝟔𝟔𝟔

𝑪𝑪 =
𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏

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:

𝑸𝑸. 𝑪𝑪𝑪𝑪𝟎𝟎 . 𝑪𝑪𝑪𝑪𝟏𝟏 . 𝑪𝑪𝑪𝑪𝟐𝟐 . 𝑪𝑪𝑪𝑪𝟑𝟑 Special Conveyor Pitch Capacity Factor, CF1
𝑵𝑵 = Pitch Description CF1
𝑪𝑪𝟏𝟏 Standard Pitch = diameter of screw 1
Short Pitch = 2/3 diameter of screw 1.5
Half Pitch = 1/2 diameter of screw 2
Where: Long Pitch = 1 1/2 diameter of screw 0.67
N : Conveyor speed [rpm],
Special Conveyor Flight Capacity Factor, CF2
(≤ recommended max. Rpm) Conveyor Loading
Type of Flight
Q : Required capacity [ft3/h] 15% 30% 45%
Cut Flight 1.95 1.57 1.43
C1 : Conv. Capacity at one rpm (see table below) Cut & Folded Flight NR 3.75 2.54
Ribbon Flight 1.04 1.37 1.62
CFo : Overload capacity factor [110% - 120%]
CF1 : Conveyor pitch factor Special Conveyor Mixing Paddle Capacity Factor, CF3

CF2 : Type of flight factor Standard paddles per pitch set at 45o reverse pitch
None 1 2 3 4
Factor CF3
CF3 : Mixing paddle factor 1 1.08 1.16 1.24 1.32
Compiled by Masda Ehsan
 SELECTION OF CONVEYOR SIZE AND SPEED – 3

SCREW CONVEYOR CAPACITIES SCREW CONVEYOR CAPACITIES

Material Class Degree of Screw Dia. Max. Capacity (ft3/hour) Material Class Degree of Screw Dia. Max. Capacity (ft3/hour)
Code Trough Loading (inches) RPM at max. RPM at one RPM Code Trough Loading (inches) RPM at max. RPM at one RPM

A-15 45% 6 165 368 2.23 A-35 E-15 30% 6 120 180 1.49
A-25 9 155 1,270 8.20 A-45 E-25 9 100 545 5.45
B-15 12 145 2,820 19.40 B-35 E-35 12 90 1,160 12.90
B-25 14 140 4,370 31.20 B-45 E-45 14 85 1,770 20.80
C-15 16 130 6,060 46.70 C-35 16 80 2,500 31.20
C-25 18 120 8,120 67.60 C-45 18 75 3,380 45.00
20 110 10,300 93.70 D-15 20 70 4,370 62.50
24 100 16,400 164.00 D-25 24 65 7,100 109.00
D-35
D-45

Material Class Degree of Screw Dia. Max. Capacity (ft3/hour) Material Class Degree of Screw Dia. Max. Capacity (ft3/hour)
Code Trough Loading (inches) RPM at max. RPM at one RPM Code Trough Loading (inches) RPM at max. RPM at one RPM
A-16 D-16 30% 6 60 90 1.49 A-17 D-17 15% 6 60 45 0.75
A-26 D-26 9 55 300 5.45 A-27 D-27 9 55 150 2.72
A--36 D-36 12 50 645 12.90 A-37 D-37 12 50 325 6.46
A-46 D-46 14 50 1,040 20.80 A-47 D-47 14 50 520 10.40
B-16 E-16 16 45 1,400 31.20 B-17 E-17 16 45 700 15.60
B-26 E-26 18 45 2,025 45.00 B-27 E-27 18 45 1,010 22.50
B-36 E-36 20 40 2,500 62.50 B-37 E-37 20 40 1,250 31.20
B-46 E-46 24 40 4,360 109.00 B-47 E-47 24 40 2,180 54.60
C-16 C-17
C-26 C-27
C-36 C-37
C-46 C-47
COMPONENT GROUP
NORMAL SERVICE HEAVY SERVICE
Component Group 1A, 1B and 1C Component Group 2A, 2B, 2C and 2D
Regular flights and regular trough Regular flights and heavy trough
Thickness, US standard Thickness, US standard
Screw Dia. Coupling Dia. Screw Dia. Coupling Dia.
gauge or inches gauge or inches
(inches) (inches) (inches) (inches)
Trough Cover Trough Cover
6 1 1/2 16 ga. 16 ga. 6 1 1/2 14 ga. 16 ga.
9 1 1/2 14 ga. 14 ga. 9 1 1/2 10 ga. 14 ga.
9 2 14 ga. 14 ga. 9 2 10 ga. 14 ga.
12 2 12 ga. 14 ga. 12 2 3/16 14 ga.
12 2 7/16 12 ga. 14 ga. 12 2 7/16 3/16 14 ga.
14 2 7/16 12 ga. 14 ga. 14 3 3/16 14 ga.
16 3 12 ga. 14 ga. 16 3 3/16 14 ga.
18 3 10 ga. 12 ga. 18 3 3/16 12 ga.
20 3 10 ga. 12 ga. 20 3 3/16 12 ga.
24 3 7/16 10 ga. 12 ga. 24 3 7/16 3/16 12 ga.

EXTRA HEAVY SERVICE

Component Group 3A, 3B and 3D
Regular flights and heavy trough
Thickness, US standard
Screw Dia. Coupling Dia.
gauge or inches
(inches) (inches)
Trough Cover
6 1 1/2 14 ga. 16 ga.
9 1 1/2 10 ga. 14 ga.
9 2 10 ga. 14 ga.
12 2 3/16 14 ga.
12 2 7/16 3/16 14 ga.
14 3 3/16 14 ga.
16 3 3/16 14 ga.
18 3 3/16 12 ga.
20 3 3/16 12 ga.
24 3 7/16 3/16 12 ga.
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)

𝑳𝑳. 𝑵𝑵. 𝑭𝑭𝒅𝒅 . 𝑭𝑭𝒃𝒃

𝑯𝑯𝑯𝑯𝒇𝒇 =
𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏

𝑪𝑪. 𝑳𝑳. 𝑾𝑾. 𝑭𝑭𝒇𝒇 . 𝑭𝑭𝒎𝒎 . 𝑭𝑭𝒑𝒑

𝑯𝑯𝑷𝑷𝒎𝒎 =
𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏

𝑯𝑯𝑯𝑯𝒇𝒇 + 𝑯𝑯𝑯𝑯𝒎𝒎 𝑭𝑭𝑭𝑭

𝑯𝑯𝑯𝑯 =
𝒆𝒆

Where:
C : Equivalent design capacity [ft3/h], e : Drive efficiency
L : Total length of conveyor [ft] N : operating speed [rpm]
Fb : Hanger bearing factor Fm : Material factor
Ff : Flight Factor Fo : Power overload factor
Fd : Conveyor diameter factor
 HORSEPOWER REQUIREMENT (HORIZONTAL SCREW CONV.)
Hanger Bearing Factor, Fb Flight Factor, Ff
Component Group Bearing Type Fb Conveyor Loading
Type of Flight
Group A Ball 1.0 15% 30% 45% 95%
Group B Babbit 1.7 Standard 1.0 1.0 1.0 1.0
Bronze Cut Flight 1.10 1.15 1.20 1.30
Wood Cut & Folded Flight NR 1.50 1.70 2.20
Group C Plastic 2.0 Ribbon Flight 1.05 1.14 1.20 -
Nylon
Teflon Paddle Factor, Fp
Group D Chilled hard iron 4.4 Standard paddles per pitch set at 45o reverse pitch
Hardened alloy sleeve None 1 2 3 4
Fp 1 1.29 1.58 1.87 2.16
Screw Diameter Factor, Fd
Screw Dia. (inch) Fd Mechanical Efficiencies of Speed Reduction Mechanisms
4 12 Approximate
Type of Speed Reduction Mechanism
6 18 Efficiencies
9 31 V-belts and sheaves 0.94
10 37 Precision roller chain on cut tooth sprockets, open guard 0.93
12 55 Precision roller chain on cut tooth sprockets, oil tights casing 0.94
14 78 Single Reduction helical or herringbone eclosed gear reducer or gearmotor 0.95
16 106 Double Reduction helical or herringbone eclosed gear reducer or gearmotor 0.94
18 135 Triple Reduction helical or herringbone eclosed gear reducer or gearmotor 0.93
20 165 Low ratio (upto 20:1 range) enclosed worm gear speed reducers 0.9
24 235 Medium ratio (20:1 to 60:1 ratio range) enclosed worm gear speed reducers 0.7
Compiled by Masda Ehsan Gigh ratio (60:1 to 100:1 ratio range) enclosed worm gear speed reducers 0.5
Note : Contact Gear Reducer Manufacturer for the exact Mechanical Efficiencies
HORSEPOWER REQUIREMENT (HORIZONTAL SCREW CONV.)
HORSEPOWER REQUIREMENT (HORIZONTAL SCREW CONV.)
HORSEPOWER REQUIREMENT (INCLINED SCREW CONV.)
 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
 DISADVANTAGES:
 The capacity, or the maximum available capacity of a given screw conveyor decreases with
increase of incline
 The horse power per-unit capacity increases.
 ADDITIONAL POWER to lift the material, the formula to calculate horsepower to lift the
material as follow:

𝑪𝑪 . 𝑾𝑾 . 𝒉𝒉
𝑯𝑯𝑯𝑯𝒉𝒉 =
𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑 . (𝟔𝟔𝟔𝟔)

𝑯𝑯𝑯𝑯𝒇𝒇 + 𝑯𝑯𝑯𝑯𝒎𝒎 + 𝑯𝑯𝑯𝑯𝒉𝒉 𝑭𝑭𝑭𝑭

𝑯𝑯𝑯𝑯 =
𝒆𝒆

Where:
HPh: Horsepower to lift the material [HP]
C : Equivalent design capacity [ft3/h]
h : actual height of lift [ft]
e : Drive efficiency
PROBLEMS ASSOCIATED WITH INCLINED SCREW CONVEYOR
 Several things can be done to overcome many of the problems associated with inclined screw
conveyor:
 Limit the use of standard screw components to inclines of less than 25o, preferably not
over 15o
 Use close clearance between trough and screw
 Increase the speed over that applicable for a horizontal screw conveyor of the same size
 Use short pitch screws, 2/3 or ½ pitch