HOPPER GEOMETRY

LOADER HOPPER CALCULATION REPORT

1.) PARAMETERS FOR DESIGN and METHOD

zinc
1.1.) Bulk material :
: concrete
1.2.) Bulk Material Density γ : 2,2 t/m3
1.3.) Angle of Repose θ : 30 °
1.4.) Material and Wall Friction Coefficient µ : 0,3
1.5.) Particule Size : -50 mm
1.6.) Geometry for Construction
1.6.1.) Vertical Wall Height H1 : 0 mm
1.6.2.) Hopper Wall Height H2 : 3310 mm
1.6.3.) Longer Wall Lenght b : 2002 mm
1.6.4.) Shorter Wall Width a : 3812 mm
1.7.) Working Temp. : 25 °
1.8.) Decision of Bunker or Silo 416
A=axb= : 7,631624 m
2

H1(3,3 m)≥1,5A1/2 : 4,1438091 m

So it is a square HOPPER

1.9.) Overpressure Factor Cd : 1,2

1.10.) Calculation is Janssen's Method

2.) DESIGN of SILO WALS and STRUCTURAL MEMBERS

2.1.) Material Qulality : S235

2.1.1.) Minimum Yield Stress f y,k : 235 Mpa
2.1.2.) Ultimate Stress f u,k : 360 Mpa
2.1.3.) Modulus Elasticty E : 210000 Mpa
2.1.4.) Shear Modulus G : 80769 Mpa
2.1.5.) Poisson's Ratio V : 0,3
2.1.6.) Allowable Stress Ϭa : 141 Mpa
2.1.7.) Allowable Stress ԏa : 94 Mpa

2.2.) Material Qulality : S275

2.2.1.) Minimum Yield Stress f y,k : 275 Mpa
2.2.2.) Ultimate Stress f u,k : 430 Mpa
2.2.3.) Allowable Stress Ϭa : 165 Mpa
2.2.4.) Allowable Stress ԏa : 110 Mpa

2.3.) Material Qulality : S355

2.3.1.) Minimum Yield Stress f y,k : 355 Mpa
2.3.2.) Ultimate Stress f u,k : 530 Mpa
2.3.3.) Allowable Stress Ϭa : 213 Mpa
2.3.4.) Allowable Stress ԏa : 142 Mpa
 2.4.) Bolting Material Qulality : 8.8
2
2.4.1.) Minimum Yield Stress f y,k : 800 N/mm
2.4.2.) Ultimate Stress f u,k : 640 N/mm
2

2.4.3.) Allowable Stress Ϭa : 320 N/mm

2

2.4.4.) Allowable Stress ԏa : 192 N/mm

2

3.) SEISMIC DATA for SITE (Assumed)

0,3g

4.) LIVE LOAD for SILO QLL : 200 Kg/m2

5.) CRITICAL LOAD COMBINATION

5.1.) QDL=Dead Load( Self weight of silo and local self weight of belt conveyor)
5.2.) QEL= Seismic Load
5.3.) QML= Material load
5.4.) QLL= Live load
5.4.) Combination

LC1=1QDL+0,8QML +0,3QLL

6.) CALCULATION VERTICAL WALL PRESSURE

6.1.) Laterial pressure Coefficient (K factor)

: 0,33

Rankine Method

6.2.) Pressure on Silo Walls, Janssen's Formula

6.2.1.) Pv : Vertical Pressure at depth Y from top

6.2.2.) Ph : Horizantal Pressure at depth Y from top

6.2.3.) Ra : Hydraulic radius for shorter wall ''a''

: 0,953 m

6.2.4.) Rb : Hydraulic radius for shorter wall ''b''

2,953 m

: 0,738 m
6.2.5.) Pn : Normal Pressure at depth Y from top

Sin74 0,9612617
cos74 0,2756374
αa,b : Wall angles

Pdes : CdxPn

6.3.) Calculation Critical Walls ''a'' Pressure

P TOP=CD*PN

All points are calculated for walls at Table-1

TABLE-1
Y(Depth) Pv Ph Pn Pdes
POINT
(m) (t/m2) (t/m2) (t/m2) (t/m2)
P1 0 0,00 0,00 0,00 0,00

P2 0,3 0,65 0,22 0,25 0,30

P3 1,265 2,61 0,87 1,00 1,20

P4 3,31 6,15 2,05 2,36 2,83

7.) CALCULATION VERTICAL WALL THICKNESS

7.1) (Between Point 1-Point3)

We will use Large Deflection Theory

L span (Vertical stiffning Distance) : 60 cm

2
Pav=(P3+p4)/2 Average pressure at wall : 0,20 kg/cm
t (Plate Thickness) : 0,8 cm

7.1.1) Tensile Force at plate (S)

: 223,29 kg

7.1.2) SE Force at plate

I (moment of inertia of the plating per unit width : 0,04 cm4

: 269,66 kg
7.1.3.) Calculation Bending Moment for plate (Mb)

: 48,27 kgcm

7.1.4.) Stress Control for plate

: 731,62854 kg/cm2

Ϭa (1410) ≥ 731,63 So plating is safety side

Selected t=8 mm(S235) Between point1-point 4

8.) CALCULATION FRICTIONAL FORCE at VERTICAL WALLS

: 3,63 m2
Aa =a2/4

: 0,18 m2
Ab =(ab-2Aa)/2

All points frictional forces are calculated for wall ''a'' at Table-2

TABLE-2
Y(Depth) Pva Pvb qa qb
POINT
(m) (t/m2) (t/m2) (t/m) (t/m)
P1 0,00 0,00 0,00 0,00 0,00

P2 0,30 0,65 0,65 0,13 0,01

P3 1,27 2,61 2,61 0,67 0,06

P4 3,31 6,15 6,15 2,25 0,22

9 VERTICAL STIFNNER SECTION CALCULATON on VERTICAL WALLS

wall ''a'' is between ''1'' and '4''

9.1.) Bending Moment at Point 4

β=PC/PB
 P3 : 1,20 t/m2
P4 : 2,83 t/m2
L ( Horizantal stiffnening distance between P 3 and P 4) : 1,8 m
X ( Vertical Stifneers span) : 0,64 m

β : 2,36
So ''α'' is selected : 0,2
Mb=αP6L2x : 0,50 tm

9.2.) Frictional tensile force at Point 4

X ( Vertical Stifneers span) : 1,8 m

qa (Tensile force on wall ''a'') 2,25 t/m
qa4 = qaX 4,0498672 t

9.3.) Cross-Section at Point 7

t (Plate Thickness) : 0,8 cm

IPE 100 profile

2
A1 Cross-Section Area : 10,3 cm
X1 Gravitiy center : 5 cm
4
I1 Moment of inertia : 171 cm

t (Plate 8 mm)
2
A2 Cross-Section Area : 12,16 cm
X2 Gravitiy center : 10,4 cm
4
I2 Moment of inertia : 1,3653333 cm

Xg =(X1A1+X2A2)/(A1+A2) gravity center for section : 7,92 cm

d1=Xg-X1 : 2,92 cm
d2=X2-Xg : 2,48 cm

4
Itotaly=I1+A1d12+I2+A2d22 …...... : 334,97583 cm
3
Wtotaly=Itotaly/Xg 42,28 cm

2
Ϭ=(Ta/Atotaly)+Mb/Wtotaly : 1358,2577 kg/cm

Ϭav (S235 Plate t=8 mm and ıpe 100 profile s275) 1550 kg/cm2

Ϭav (1550) ≥ 1358,3 So section is safety side

 10.) HOPPER LOAD and SUPPORTING LUG SECTION CALCULATON

10.1.) loader hopper dead load ( assumed)

QdL : 4 t

10.2.) Material Load in Silo( Material Self weight in silo)

3
Shell Volume Vshell : 11,13 m
QML( with Cd factor) : 29,39 t

10.3.) Live Load on Silo

Unit live Load : 200 kg/m

2

QLL : 0 t

10.4.) Total Seismic Mass

LC1=1QDL+0,8QML +0,3QLL : 27,51 t

10.5.) Total Seismic load

QEL(X,Y) : 8,25 t

We will use 4 lugs for support.so that for each ssupport lugs load

vertical direction : 8,35 t

laterial direction : 4,13 t

bending moment 100,17 tcm

t (Plate Thickness) : 0,8 cm

t (Plate 8 mm)
2
A1 Cross-Section Area : 12 cm
X1 Gravitiy center : 7,5 cm
4
I1 Moment of inertia : 225 cm

t (Plate 8 mm)
2
A2 Cross-Section Area : 12 cm
X2 Gravitiy center : 0,4 cm
4
I2 Moment of inertia : 0,64 cm

t (Plate 8 mm)
2
A3 Cross-Section Area : 8 cm
X3 Gravitiy center : 14,6 cm
4
I3 Moment of inertia : 0,4266667 cm

Xg =(X1A1+X2A2)/(A1+A2) gravity center for section : 6,61 cm

d1=Xg-X1 : 0,89 cm
d2=X2-Xg : 6,21 cm
d3=X3-Xg : 7,99 cm

4
Itotaly=I1+A1d12+I2+A2d22 …...... : 1209,0617 cm
3
Wtotaly=Itotaly/Xg 182,84 cm

2
Ϭ=(Ta/Atotaly)+Mb/Wtotaly : 808,66659 kg/cm

Ϭav (S235 Plate t=8 mm ) 1450 kg/cm2

Ϭav (1450) ≥ 808,67 So section is safety side