2 Storage and Conveying of Bulk Solids PDF

ChE-205 Particle Technology
Storage and Conveying of Bulk Solids
Saeed GUL, PhD

Professor and Postgraduate Advisor
Department of Chemical Engineering,

University of Engineering & Technology Peshawar, PAKISTAN
Why we need storage & Convoying
http://www.cementequipment.org/home/cement-production-process-from-a-to-z/
27 September 2018 Dr. Saeed GUL, Department of Chemical Engineering, UET Peshawar, Pakistan 2
Introduction
In the materials processing industries

there are some particulate systems,
such as gravel or ores, which may be
stored outdoors in large piles or heaps
unprotected from the weather.
When taking to process, such
materials may be removed by dragline
or tractor shovel and delivered to a
conveyor.
Since many bulk materials are able to
deteriorate with outside ambient
conditions such as moisture, there is a
need to provide for protection to
these piled particulate systems.
Introduction
Several alternatives that have been

used, like domes and cylindrical
structures with conical tops, are
normally known as silos
The reclaiming systems for these types
of silos are similar to those used in
outdoors storage, that is, draglines,
scraper reclaimers, bucket wheel
reclaimers, and so on
Introduction
In many materials processing industries
different types of solids are to be stored in
confinement, with the intention of being
directly connected to processing lines by
any sort of conveying system. Such type of
storages are generally known as bins or
silos.
Difficulties of flow in particulate systems,
from confined storage, is a well known
operative problem and diverse industries
such as mining, chemical, and food industry
have invested considerable time and money
over the years trying to overcome such
situation.
Outdoors Storage
Systematic study of solids flow behavior in bins and silos to ensure
proper discharge, has been intensive since the formal starting of
Powder, or Particle, Technology as a discipline
Outdoors Storage
 useful when huge amounts of materials need to be in inventory
but direct connection to feed processing lines is somewhat
difficult.
 Estimation of surface area for storage can be done by scaling-up
from small samples of the particulate material, using a property
like its angle of repose.
 environment outdoors conditions may affect the stored piles of
materials, an alternative to protect them would be the use of
storage domes.
 Material reclaiming and feeding to processing lines can be carried
out by manual or mechanized handling.
Bulk storage of fine particles
 Raw materials stored in silos

that hold three to four days
production.
 Homogenization of materials is
carried out in these stores if
needed.
 Material are kept in suspension
in blending siloes.
Confined Storage
Open-yard or structured storage may be only a part of a bulk solids

handling facility. Due to processing requirements, there is normally
the need of having an intermediate storage system which may be
directly connected to a processing line.
In some other cases, the storage capacity would not involve large
tonnages and, therefore, confined storage would be an obvious
choice.
Finely divided solids that are subjected to erosion by wind or rain,

piling cannot be taken as a feasible manner of storage
Therefore, all these particulate systems may be most properly kept in

containers or vessels known also as silos, but alternatively termed as
bins and hoppers
Confined Storage
Silo, Bin and Hopper
A silo is tall and relatively small in diameter, while
a bin is usually not so tall and fairly wide.
A hopper is a small bin with a sloping bottom, for
temporary storage of solids prior to be fed into a
particular process. Normally, the lower part of a
silo in a shape of a cone or inverted pyramid is
also called a hopper.
Generally, all these containers are loaded from

the top and discharged from the bottom.
A major problem in bin design is related to
proper and controllable discharge.
Confined Storage (Silo, Bin and Hopper)
General Considerations:
 Silos, bins, and hoppers used to store these materials vary in
capacity from a few kilos to multiton-capacity vessels.
 Start-up delays and ongoing inefficiencies are common in solids
processing plants.
 An important cause of these problems is the improper design of
bulk solids handling equipment.
 A six-year study of 40 solids processing plants in the United States
and Canada (Merrow, 1988) revealed that 80% of these plants
experienced solids handling problems.
 The study also found that these plants were slow in smoothing
operation, with an average start-up time for some plants averaging
18 months. Once start-up began, performance around 40–50% of
design was commonly observed.
Common Flow problems Silo, Bin and Hopper
The common flow problems in hoppers and silos can
be summarized as follows:
 No flow
 Formation of a stable arch over the outlet, or a
stable cavity called a “rathole”
 Segregation
 separation of fine and coarse particles
 Flooding
 Collapse of a rathole in a bin containing fine
powder, resulting in uncontrollable flow of
material, loss of product and clouds of dust
 Structural failure
 improper design causes collapse of silos
Design Considerations:
 Determination of the strength and flow properties of the bulk
solids for the worst likely flow conditions expected to occur in
practice
 Calculation of the bin, stockpile, feeder, or chute geometry to give

the desired capacity to provide a flow pattern with acceptable
characteristics, in order to ensure that discharge is reliable and
predictable
 Estimation of the loadings on the bin and hopper walls and on the
feeders and chutes under operating conditions
 Design and detailing of the handling plant including the structure

and equipment.
Confined Storage
Types of Silos
From a standpoint of flow patterns there are basically
three types of flow in symmetrical geometry :
(1) Mass flow, ( 2) Funnel flow, (3) Expanded flow
Mass flow
sufficiently steep and smooth to
cause flow of all the solids in the bin
without stagnant regions during
discharge. Recommended for
cohesive materials, for materials
which degrade with time, for fine
powders, and for particulate
systems which need to be prevented
from segregation.
Confined Storage
Funnel flow
Funnel flow occurs when the hopper is not
sufficiently steep and smooth to force the bulk
solid to slide along the walls. It is also observed
when the outlet of the bin is not fully effective, due
to poor feeder or gate design.
The diameter of such channel approximates the
largest dimension of the effective outlet. Flow out
of this type of bin is generally erratic and gives rise
to segregation problems.
Funnel flow has the advantage of providing wear
protection of the bin walls as the material flows
against stationary material.
Suitable for coarse, free-flowing, non degrading
solids when segregation is unimportant.
Confined Storage
Expanded flow
 In expanded flow bins the hopper combines
characteristics of mass flow and funnel flow.
 The higher part of the hopper operates in funnel
flow while the lower operates in mass flow.
 Funnel-flow bins provide the wall protection of
funnel flow, along with the reliable discharge of
mass flow.
 Expanded flow is ideal where large tonnages of
bulk solids need to be stored and is particularly
suitable for storing large quantities of bulk solids
while maintaining acceptable head heights.
Confined Storage
Feeders for Discharge Control
A feeder is a device used to control the flow of bulk solids from a bin.
Any feeder must be selected to suit a particular bulk solid and the
range of feed rates required.
It is particularly important to design the hopper and feeder as an
integral unit, in order to ensure that the flow from the hopper is fully
developed with uniform draw of material from the entire hopper
outlet
Most common types of feeders:
 Belt or apron feeder
 Screw feeder
 Vibratory feeder
 Star feeder
Careful considerations should be taken in selecting
a feeder for a particular application.
Confined Storage
Belt or apron feeders
Apron feeders and belt feeders are used extensively for
heavy duty mineral processing operations.
Apron feeders are capable of extracting materials from
bins, hoppers and even stockpiles. They can transfer
materials across a short distance at a highly controlled
rate of speed.
Belt feeders are designed to carry material across
longer distances, and they are able to extract material
from bins and hoppers via a loading chute. Belt
feeders allow for volumetric control of materials, but
they cannot be used in operations which require an
extremely low rate of material flow.
Apron feeders are well suited for handling wet and
lumpy material while belt feeders are used small dry
materials
Confined Storage
Screw feeders
A screw feeder is a screw that is mounted
directly under the opening of a hopper. The
product in the silo therefore rests on a part of
the screw.
A screw feeder is used for the feeding of
powders from a (wedge shaped) hopper. The
reasons for this are:
 An even withdrawal of the powder is well
possible, resulting in mass flow.
 The screw is closed, so there is no risk of
pollution of the powder or surroundings.
 The screw can be made well resistant
against for example high temperature,
aggressive environment, etc.
Confined Storage
Vibratory feeders
In a vibratory feeder, there is an inclined
pan with different sort of motion located
below a hopper opening.
 A vibratory feeder uses vibration to
"feed" material to a process or
machine.
 Vibratory feeders use both vibration
and gravity to move material.
 Gravity is used to determine the
direction, either down, or down and
to a side, and then vibration is used to
move the material.
 They are mainly used to transport a
large number of smaller objects.
Confined Storage
Star feeders
 Provide highly uniform withdrawal a long a slot
hopper opening.
 The rotational speed control the discharge rate.
 Typically, the feeder dispenses to a pneumatic
conveying system because the air tight seal of the
feeder prevents countercurrent process air from
flowing up through the material bed, thus,
interrupting feeding.
 Unsuitable for friable materials, which can be
sheared by the rotating paddles, or materials with
large particles, which can jam the paddles.
Confined Storage
Bulk Solids Conveying
Introduction
Handling of particulate solids in processing industries is concerned
with movement of materials in different cases such as from supply
point to store or process, between stages during processes, or to
packing and distribution.
The movement of
materials is a crucial
activity which adds
nothing to the value
of the product, but
can represent an
added cost if not
managed properly.
Introduction
For this reason, responsibility for material handling is normally vested
in specialist handling engineers, and many manufacturing industries
adopt this procedure.
When a specific materials handling department is not provided, the
responsibility for efficient handling of materials falls on the production
manager and his/her staff.
It is important, therefore, for production executives to have a sound
knowledge of the fundamentals of good handling practice
Conveying System can broadly be classified in 03 types

1. Mechanical conveying
2. Pneumatic conveying
3. Hydraulic conveying
Mechanical conveying
 Belt conveyors
 Chain conveyors
 Scraper conveyors
 Apron conveyors
 Bucket elevators
 Screw conveyors
Pneumatic Conveying
One of the most important bulk solids handling techniques in a solids
handling plant is the movement of material suspended in a stream of
air over horizontal, inclined or vertical surfaces, ranging from a few to
several hundred meters.
This type of conveying is one of the most versatile,
handling materials that range from fine powders
through small pellets and bulk densities of 16 to
more than 3200 kg/m3.
Hydraulic Conveying
Slurry transport by gravity flow in flumes and pipes has been

common for over 100 years
Short distance hydraulic conveying using slurry pumps developed
during the 20th century, mostly in the mining industry.
In the 1950’s long distance pipeline slurry transport was introduced

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ChE-205 Particle Technology

Storage and Conveying of Bulk Solids

Saeed GUL, PhD

Department of Chemical Engineering,

In the materials processing industries

Several alternatives that have been

 Raw materials stored in silos

Open-yard or structured storage may be only a part of a bulk solids

Finely divided solids that are subjected to erosion by wind or rain,

Therefore, all these particulate systems may be most properly kept in

Generally, all these containers are loaded from

 Calculation of the bin, stockpile, feeder, or chute geometry to give

 Design and detailing of the handling plant including the structure

Conveying System can broadly be classified in 03 types

Slurry transport by gravity flow in flumes and pipes has been

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