FEEDER LOADS AND POWER REQUIREMENTS

From a design point of view it is important to be able to determine with some accuracy the
loads acting on feeders in
hopper/feeder combinations and the corresponding power requirements. Yet the state of the
art has, in the past, been such that the loads and power requirements could not be
estimated with any degree of precision. For instance Wright has observed that the majority
of formulae published are empirical in nature and derived to predict loads and
corresponding power requirements for feeders used in conjunction with funnel flow
bins. These formulae are inadequate when applied to mass flow bins since, in such cases,
the loads and power requirements are often greatly underestimated. This is largely due to
the fact that in mass flow bins the full area of the hopper outlet is presented to the feeder.
The loads acting on feeders can vary considerably. There are many reasons for this, some
more obvious than others. As indicated by Reisner and Rothe [18], the shape of the hopper
outlet will influence the load on a feeder as illustrated in Figure 27. In Figure 27(a), the full
load (not equal to the hydrostatic head) acts on the feeder. In Figure 27(b) the load is
partly reduced by changing the shape of the hopper. the load is completely
removed from the feeder and only acts on the hopper wall. solution may not be as simple as
that depicted. It is clear that the flow pattern developed in the feeding operation must be
such that uniform, non segregated flow is achieved at all times. The loads acting on feeders
and corresponding power requirements are influenced by several factors. These include the
following:

1-Hopper flow pattern, whether mass flow or funnel flow

2-Flow properties of the bulk solid

3-The chosen hopper shape which in the case of mass flow includes axi-symmetric or
conical, plane flow or transition (combination of conical and plane flow)

4-The actual hopper geometry.

5-The wall friction characteristics between the bulk solid and hopper walls and skirt plates

6-The type of feeder and its geometrical proportions

7-The initial filling conditions when the bin is filled from the empty condition and the flow
condition when discharge has occurred.

The most efficient and reliable feeding performance is achieved by using a mass flow
hopper/feeder combination. For a given bulk solid and hopper/ feeder geometry the load
acting on a feeder varies considerably between the initial load, when the bin is first filled,
and the load either during flow or after flow has stopped. Reisner has indicated that the
initial load can be 2 to 4 times the flow load. However, research has shown that the
variation is much greater than this with the initial loads of the order of 4 to 8 times that of
the flow load. Theoretical predictions show that circumstances can arise whereby the
initial/flow load variations can be much higher than those indicated.

Pressure Distributions in Mass Flow Bins

It is first necessary to examine the pressures acting in mass flow bins under both initial
filling and flow conditions. shows the bin stress fields and corresponding pressure
distributions for the initial filling and flow cases. In each case, pn represents the pressure
acting normal to the bin wall while pv represents the average vertical pressure.

Initial Filling Case

The Janssen curves for the cylinder are shown in Figure 28(a).

(ii) Hopper

Following  Jenike  [37],  the  normal  pressure  acting  against  the  wall  is  related  to  the  average  vertical  pressure  by  a
parameter K such that

Pn
K =                 (8)
pv

From an equilibrium analysis for the hopper the following differential equation is obtained.

dpn npn
  +   = γ K            (9)
dz (ho­z)

Solution of this equation leads to

ho­z   ho   ho­z

   µ   
where n = (m+l) {K (1 + )­ 1}              (11)
tanα

            α = hopper half angle

            hc  = surcharge head acting at transition of cylinder and hopper

            ho = distance from apex to transition

hc  is given by

Qc
hc  =                 (12)
γAc

Qc
where is derived from the Jansen Equation (1)
Ac

That is

Qc γR ­ µKj H/R ­ µKj H/R
= [1­e ] + γhs e                 (13)
Ac µKj    

where Qc  = surcharge force at transition

            Ac  = area of cylinder

            H = height of material in contact with cylinder walls.

For  the  initial  filling  condition  in  the  hopper,  Jenike  [37]  assumes  that  the  average  vertical  pressure  distribution  in
the  hopper  follows  the  linear  hydrostatic  pressure  distribution.  For  this  condition  the  value  of  K  in  (10)  is  the
minimum value. That is

   tanα   
K = Kmin  =                 (14)
µ+tanα

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Since the initial load only ever occurs when the bin is filled from the empty condition without discharge taking place,
it is good practice to always maintain a cushion of material in the hopper [22]. From a practical point of view this is
most desirable in order to protect the hopper surface from impact damage during filling.

Figure 35 ­ Variations in feeder loads with hopper geometry plane­flow bin of example 4.6.1

However there is a further advantage; the material left in the hopper as a cushion, having previously been in motion,
will  preserve  the  arched  stress  field.  The  new  material  being  deposited  in  the  bin  will  initially  have  a  peaked  stress
field. This will provide a surcharge load an the arch field, but the load at the outlet will be of lower order  than  if  the
bin is totally filled from the empty condition. The stress condition and reduced loading is illustrated in Figure 36.

Figure 36 ­ Cushioning in hopper to reduce feeder load

5. FEEDING OF BULK SOLIDS FROM BIN ONTO BELT CONVEYOR

In the handling of bulk solids, belt feeders with skirtplates are commonly used. In other cases dump bins are used in
combination with belt conveyors as illustrated in Figure 37. For design purposes  it  is  necessary  to  determine  the  belt
loads under initial filling and flow conditions and the corresponding drive powers [11].

Figure 37 ­ Schematic arrangement of dump bin and belt conveyor

5.1 Design Equations

5.1.1 Bin and Hopper Surcharge and Corresponding Power

These are determined in accordance with the methods described in Section 4.

5.1.2 Skirtplate Resistance

Assuming steady flow, the skirtplate resistance may be determined as follows:

i.  Hopper Section

Fsph  = µ2 Kv(2Q + ρgBLy) y/B             (40)

ii.  Extended Section (Section beyond hopper)

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Fspe = µ2 Kv ρg(L s ­L)y²              (41)

where:
Q = feeder loads as determined by equation (24)
ρ = bulk density
y = average height of material against skirtplates
Kv = ratio of lateral to vertical pressure at skirtplates g = acceleration due to gravity = 9.81 (m/s²)
B = width between skirtplates
µ2 = skirtplate friction coefficient
L s  = total length of skirtplates (m)

5.1.3 Belt Load Resistance

i.  Hopper Section

 
Fbh  = (Q + ρgBLy)µb               (42)
 
ii.  Extended Section

Fbe = ρgB(L s  ­ L)yµb               (43)

Where µb  = Idler friction.

5.1.4 Empty Belt Resistance

Fb  = Wb  L b  µb               (44)

Where:
Wb  = belt weight per unit length
L b  = total length of belt

5.1.5 Force to Accelerate Material onto Belt

FA = Qm v              (45)

Where:
Qm = mass­flow rate
v = belt speed

It is assumed that

Qm = ρByv              (46)

Usually the force Fa is negligible.

5.1.6 initial and Flow Loads and Powers

The  foregoing  loads  and  resistances  are  determined  for  the  initial  and  flow  conditions  using  the  appropriate
values of the variables involved.
The power is computed from

P = (Σ Resistances). v/η              (47)

Where η = efficiency and v = belt speed.

The condition for non­slip between the belt and bulk solid under steady motion can be determined as follows:

µ3 (Qf + w) > (Ff + Fsp )              (48)

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Where:
µ3 =coefficient of friction between belt and bulk solid
Qf =flow surcharge at hopper outlet
W = weight of bulk material between skirtplates in hopper section of conveyor
Ff =force to shear material at hopper outlet
Fsp  = skirtplate resistance.

5.2 Example

5.2.1 Problem Description

As  an  extension  of  the  example  of  section  4.6.1,  consider  the  bin  being  used  in  conjunction  with  a  belt
conveyor. referring to Figure 36 the relevant details are

i.  Bin
Opening Dimension B = 1.5 m
Height H = 8.0 m
Width D = 5.0 m
Surcharge H S = 1.5 m
Height of Hopper H h = 2.16 m
Half angle α = 39°
Length of bin L = 5 m
Cylinder   = Mild steel
Hopper lining   = Stainless steel

ii.  Bulk Solid
Type   = coal
Effective angle of internal    
friction δ = 50°
Angle of friction between    
coal and steel ø = 30°
Angle of friction between  
 
coal and stainless steel = 18°
Bulk density   = ρ = 0.95 t/m³

iii.  Conveyor
Belt velocity v = 0.5 m/s
Conveyor length L c = 20.0 m

Length of skirtplate L s = 20.0 m
Average skirtplate height y = 0.8 m
Belt width Bb = 2.0 m

5.2.2 Solution

i.  Hopper Surcharges

 
From Section 4.6

Qi = 242.2

Qf = 35.9 kN

ii.  Force to Shear Material at Hopper Outlet

Fi = Qi sinδ = 242.2 sin 55 = 185.6 kN

Ff = Qf sinδ = 35.9 sin 55 = 27.5 kN

iii.  Skirtplate Resistance ­ Hopper Section

Equation (40)

Assume µ2 = tan 20° for polished mild steel
                    = 0.364

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