Characteristics of Bulk Materials

By
K. P. Shah
Email: kpshah123[at]gmail.com (Please replace [at] with @)
Committed to improve the Quality of Life

For more articles on mechanical maintenance, visit www.practicalmaintenance.net

The information contained in this article represents a significant collection of technical

information about characteristics of bulk materials. This information will help to achieve
increased reliability at a decreased cost of bulk material handling plants. Assemblage of this
information will provide a single point of reference that might otherwise be time consuming to
obtain. Most of the information given in this article is from Bureau of Indian Standards' (BIS)
specification number IS 8005 and ANSI / CEMA 550. For more information, please refer
them. All information contained in this article has been assembled with great care. However,
the information is given for guidance purposes only. The ultimate responsibility for its use
and any subsequent liability rests with the end user. Please view the disclaimer uploaded on
http://www.practicalmaintenance.net.

(Edition: May 2017)

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 Characteristics of Bulk Materials
Basic classification of material is made on the basis of forms. They are gases, liquids, semi
liquids and solids. Solids are further classified into two main groups: Unit load and Bulk
Material. The successful design of a conveyor belt for bulk material handling begins with an
accurate appraisal of the characteristics of the material to be transported. The behavior of
bulk materials greatly depends on the moisture content and particle size distribution of the
material. Wide variations in material behavior and bulk density with moisture and particle
size can lead to unexpected tonnage or capacity issues, excessive spillage or material
buildup, and equipment or system malfunction and failure. In view of this, information about
characteristics of bulk materials is given in this article.

Unit Load and Bulk Material

Unit loads are formed solids of various sizes, shapes and weights. Some of these are
counted by number of pieces like machine parts and fabricated items. Tared goods like
containers, bags, packaged items etc. and materials which are handled en-masse like forest
products (logs), structural, etc. are other examples of unit loads. Unit loads have been
classified by Bureau of Indian Standards' (BIS) specification number IS 8005.

Bulk materials are those which are powdery, granular or lumpy in nature and are stored in
heaps. Example of bulk materials are: minerals (ores, coal, etc.), earthly materials (gravel,
sand, clay, etc.), processed materials (cement, salt, chemicals, etc.) and agricultural
products (grain, sugar, flour, etc.).

Characteristics of Bulk Materials

Major characteristics of bulk materials, so far as their handling is concerned, are: lump size,
bulk weight (density), moisture content, flowability (mobility of its particles), angles of repose,
abrasiveness, corrosivity, etc.

Lump Size

Lump size of a material is determined by the distribution of particle sizes. As shown in above
figure, the largest diagonal size ‘a’ of a particle in mm is called the particle size. The
materials may be distinguished as sized (classified) or unsized (non-classified) as follows:

Sized (classified) are the materials for which the ratio between the size of the largest
lump/particle, amax and smallest lump, amin is less than or equal to 2.5.

Unsized (non-classified) are the materials for which ratio amax / amin is greater than 2.5.

Average lump size of a sized material = (maximum particle size + minimum particle size) / 2

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Hence, average lump size of sized bulk material = (amax + amin) / 2

Sized materials are adequately defined by the values amax and amin. Unsized materials,
however, require, in most cases, a complete sieve analysis in which the ratio of the lump
size shall not exceed 2.5.

Bulk Density

Bulk weight or bulk density of a lumpy material is the weight of the material per unit volume
in bulk. Because of empty spaces between the particles in bulk materials, bulk density is
always less than density of a particle of the same material.

Repose Angle

As shown in above figure, when bulk material is dropped on the horizontal surface (ground),
it forms a conical heap with certain inclination (angle) with the horizontal surface. The angle
of repose (θ) of a material is the natural angle formed by gravity discharge of the material
and measured from a horizontal base.

Repose angle dependent on flowability of the material. The higher value of repose angle
signifies less flowability of the material. The repose angle for liquid is zero.

The repose angle of a material is an important parameter because it decides the shape and
volume of material in stockpiles and storages. It may be noted that the repose angle of a
material is susceptible to variation in moisture content.

Surcharge Angle

However, if the material is dropped on the horizontal surface which is in vibrating condition
or is having internal agitation, the material tends to settle/spread and will have lesser
inclination with the horizontal surface. This reduced inclination is known as surcharge angle.

During belt conveying, the material is lying on moving belt. Since the belt sags down
between two idlers and rises up when passing on an idler, material particles on the belt is
made to move up and down along the belt as it travels forward. This creates presence of
vertically fluctuating inertial forces in the body of the bulk material. The belt also opens out
slightly between two idlers and closes when passing on the idler. Thus material particles are

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also oscillating horizontally. This phenomenon results in internal agitation to the material on
belt and therefore the material’s external faces assume inclination at surcharge angle. The
angle of surcharge of a material is the angle to the horizontal which the surface of the
material assumes while the material is at rest on a moving conveyor belt. Thus belt’s ability
to accommodate material is governed by surcharge angle instead of repose angle. In
general, the surcharge angle is 5 to 15 degrees less as compared to repose angle. However,
in some materials it may be as much as 20 degrees less.

Abrasivity

The property of particles of bulk materials to wear away the surface they come in contact
with when in motion is called abrasivity. The abrasiveness of the material affects the wear of
belt and other components of conveyor / material handling equipment (like hoppers, chutes,
skirtboards, buckets, chain links, etc.) coming in contact with the material. At loading point,
the incoming material’s velocity is different than the belt velocity. Material takes some time to
acquire belt velocity resulting in momentary sliding of the material on belt and causes belt
wear. Due to this, for lesser wear, the conveyor handling more abrasive material should
have lesser belt speed whereas less abrasive material can be conveyed at higher speed.
The agitated condition of material on a belt also causes wear on the belt surface
continuously from loading point to discharge point.

Conveyor Capacity

Belt conveyor is required to convey certain quantity of material per hour. As shown in the
figure given below, the material is accommodated on the belt forming certain cross-section
of the material [S = S1 (Upper Section) + S2 (Lower Section)]. This cross-section multiplied
by belt velocity provides volume of material being transported in unit time. Thus belt
conveyor’s ability to transport material is volumetric in nature.

The transported volume is converted into tonees (1 metric tonee = 1000 kg) by multiplying it
with the ‘Bulk Density’ of the material, in the condition as it is on the belt.

Classification and Codification of Bulk Materials

Information on classification and codification of bulk materials as per IS 8730: 1997

(Reaffirmed 2002) and ANSI / CEMA 550 - 2003 - R2009 is given in this section.

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Codification System as per IS 8730

Classification and codification of bulk materials (being handled by continuous material

handling equipment) based on lump size, flowability, abrasiveness, bulk density and various
other characteristics have been specified by the Bureau of Indian standards (BIS)
specification number IS 8730. Following figure shows the alphanumeric codification system
as per this specification (IS 8730: 1997, Reaffirmed 2002).

In this material code, if any of the above characteristics is not known, corresponding number
or alphabet is dropped from the material code.

The following table shows the descriptions and limits of the different classes of material
characteristics.

Classification of Bulk Materials as per IS 8730

Material Description of characteristics with Limits of Characteristics Class
Characteristics Typical Examples
1. Lump size Dusty material (cement) ‘‘amax’’ upto 0.05 mm A
Powdered material (fine sand) ‘‘amax’’ upto 0.05 to 0.50 mm B
Granular material (grain) ‘‘amax’’ upto 0.5 to 10 mm C
Small sized lumpy (crushed, iron ore) ‘‘amax’’ upto 10 to 60 mm D
Medium sized lumpy (chipped wood) ‘‘amax’’ upto 60 to 200 mm E
Large lump materials ‘‘amax’’ upto 200 to 500 mm F
Especially large lump size (boulder) ‘‘amax’’ over 500 mm G
2. Flowability Very free flowing (cement, dry sand) Angle of repose: 0°- 20° 1
Free flowing (whole grains) Angle of repose: 20°- 30° 2
Average flowing (anthracite coal, clay) Angle of repose: 30°- 35° 3
Average flowing (bituminous coal, ores, Angle of repose: 35°- 40° 4
stone)
Sluggish (wood chips, bagasse, Angle of repose: > 40° 5
tempered foundry sand)
3. Abrasiveness Non-abrasive (grains) - 6
Abrasive (alumina) - 7
Very abrasive (ore, slag) - 8
Very sharp (metal scraps) Cuts belting of conveyors. 9
4. Bulk density Light (saw, dust, peat, coke) Up to 0.6 t/m3 H
Medium (wheat, coal, slag) 0.6 to 1.6 t/m3 I
Heavy (iron ore) 1.6 to 2.0 t/m3 J
Very heavy 2.0 to 4.0 t/m3 K
5. Miscellaneous Please refer the following table. Note: Sometimes more than L to Z
characteristics one of these characteristics
may apply.

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 Miscellaneous Characteristics of Bulk Materials as per IS 8730
Miscellaneous Characteristics Class
Aerates and develops fluid (or dual operating) characteristics L
Contains explosive (or external) dust M
Sticky N
Contaminable affecting use or saleability P
Degradable, affecting use or saleability Q
Gives off harmful fumes or dust R
Highly corrosive S
Mildly corrosive T
Hygroscopic U
Oils or chemicals present. May affect rubber products. W
Packs under pressure X
Very light and fluffy (or very high flowability and dusty). May be wind swept Y
Elevated temperature Z

BIS specification number IS 8730:1997 lists 486 different bulk materials with their bulk
densities, flowability properties and codes.

Material characteristics and codes as per IS 8730:1997 for some common materials are
given in the following table.

Material Characteristics and Codes as per IS 8730:1997

Material Average Bulk Angle of Recommended Material
Density, kg/m3 Repose, Maximum Inclination, Code
Degrees Degrees*
Alumina 800-1040 22 10-12 B27M
Ashes, fly 640-720 42 20-25 A58
Bagasse 112-160 - - E56Y
Bauxite, mine run 1280-1440 31 17 B38
Cement, Portland 1500 39 20-23 A27M
Cement, Clinker 1200-1520 30-40 18-20 D38
Clay, dry, lumpy 960-1200 35 18-20 D37
Coal, anthracite, sized 960 27 16 C27
Coal, bituminous, mined, 960 35 16 D36QT
classified
Coke, petroleum calcined 560-720 - 20 D37Y
Copper ore 1920-2400 - 18-20 D28
Earth as excavated dry 1120-1280 35 20 B37
Iron ore 1600-3200 35 18-20 D37
Iron ore, crushed 2160-2400 - 20-22 C27
Iron ore, pellets 2500-2880 20 12 D28 & D28Z
Lignite, air dried 720-880 - - D26
Lignite, raw, heavy 900-960 38 22 D37T
Limestone 1360-1440 30-45 - -
Limestone, crushed 1360-1440 38 20 A26M
Limestone, dust 1360-1520 38-45 18 A57M
Phosphate acid, fertilizer 1440 26 13 B26TQ
Phosphate, triple, super, 800-880 45 30 B56T
ground fertilizer
Phosphate rock, broken, 1200-1360 25-30 12-15 D27
dry
Phosphate rock, 960 40-42 25 B37
pulverized
Rock, crushed 2000-2320 - - D27
Salt, common dry, coarse 720-800 30-45 18-22 C27TU
Salt, common dry, fine 1120-1280 25 11 D27TUW

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Sand, bank, dry 1440-1760 35 16-18 C37
Sand, foundry, prepared 1440 39 22 D38
Sand, foundry, shakeout 1440 39 22 D38
Sand, silica, dry 1440-1600 30-35 10-15 B28
Sulphur, crushed 880-960 30-45 16 C36MS
Sulphur, powdered 880-960 30-45 21 B36MW
Urea, prills 700 23-27 13 C26SU
* The angle of inclination is for conventional belt conveyors which allow free rollback of material.

Material Classification and Code System as per ANSI / CEMA 550 - 2003 - R2009

CEMA is the Conveyor Equipment Manufacturers Association (6724 Lone Oak Boulevard,
Naples, Florida, USA 34109 239-514-3441 www.cemanet.org) and is an industry group
dedicated to the advancement of the conveyor industry.

CEMA material code consists of actual bulk density, loose and code designations for size,
flowability, abrasiveness and miscellaneous properties or hazards as per the following table.

Material Classification and Code System as per ANSI / CEMA - 550 - 2003 - R2009
Major Class Material Characteristic Included Code
Designation
Density Bulk Density, Loose Actual
Lbs/Cu Ft
Size Very Fine - No. 200 Sieve (.0029") And Under A200
Very Fine - No. 100 Sieve (.0059") And Under A100
Very Fine - No. 40 Sieve (.016") And Under A40
Fine - No. 6 Sieve (.132") And Under B6
Granular - 1/2” And Under C 1∕2
Granular - 3" And Under D3
Granular - 7" And Under D7
Lumpy - 16" And Under D16
Lumpy - Over 16" To Be Specified, DX
X=Actual Maximum Size
Irregular - Stringy, Fibrous, Cylindrical, Slabs, Etc. E
Flowability Very Free Flowing - Flow Function >10 1
Free Flowing - Flow Function >4 But <10 2
Average Flowing - Flow Function >2 But <4 3
Sluggish - Flow Function < 2 4
Abrasiveness Mildly Abrasive - Index 1 - 17 5
Moderately Abrasive - Index 18 - 67 6
Extremely Abrasive - Index 68 - 416 7
Miscellaneous Builds Up and Hardens F
Properties or Hazards Generates Static Electricity G
(More than one may apply) Decomposes - Deteriorates in Storage H
Flammability J
Becomes Plastic or Tends to Soften K
Very Dusty L
Aerates and Becomes Fluid M
Contains Explosive Dust N
Stickiness-Adhesion O
Contaminable, Affecting Use P
Degradable, Affecting Use Q
Gives Off Harmful or Toxic Gas or Fumes R
Highly Corrosive S
Mildly Corrosive T
Hygroscopic U
Interlocks, Mats or Agglomerates V

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 Oils Present (May Affect Rubber) W
Packs under Pressure X
Very Light and Fluffy - May be Wind Swept Y
Elevated Temperature Z
Angle of Repose Loose -
Maximum Angle of Conveyor -
Inclination

More information on flowability and abrasiveness is given below.

Flowability

As per following table.

Flowability
Very Free Free Flowing Average Flowing 3* Sluggish 4*
Flowing 1* 2*
Equivalent Flow Function Ranges FF
>10 >4 to <10 >2 to <4 <2
Angle of Surcharge (degrees)
5 10 15 20 25 30
Angle of Repose (degrees)
10-19 20-25 26-29 30-34 35-39 >40
Uniform size, Rounded, dry Regular Irregular, Typical Irregular,
very small polished granular granular or common stringy,
rounded particles of materials such lumpy materials such fibrous,
particles, medium as fertilizer, materials of as bituminous interlocking
either very wet weight such as sand and medium coal, stone, material such
or very dry, whole grain washed weight, such most ores, etc. as wood chips,
such as dry and beans gravel. as anthracite bagasse,
silica sand, coal, cotton tempered
cement, wet seed meal, foundry sand,
concrete, etc. clay etc. etc.
* Numerical rating refers to Material Code

Relative Abrasiveness of Particles

Abrasiveness is a combination of the physical characteristics of a material that enables it to

abrade particles from surfaces with which it comes into moving contact. It seems from
observations that the following 4 characteristics are those which would contribute to the
abrasive character of a material.

 Particle hardness
 Particle shape
 Bulk material density
 Particle size

Hence the following factors are assigned to each of the above characteristics to determine
the relative abrasiveness of particles.

Hardness:

Mohs No. 1 2 3 4 5 6 7 8 9 10
Factor 1 4 9 16 25 36 49 64 81 100

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Density:

Wt./Ft.3 0-60 61-120 121-180 181-240 241-300 301-460 461-520

Factor 1.0 1.1 1.2 1.3 1.4 1.5 1.6

Shape:

Shape Type Rounded Subround, Subangular Sharp Angular

Factor 1.0 1.5 2.0

Size:

Class Code for Size A B C D E

Factor 1.0 1.1 1.2 1.3 1.3

To determine the relative abrasiveness of a particle, determine the factors from observation
of the material. Multiply the factors together to determine the abrasive index number.

Compare this number to the abrasive index range in the table below to determine the CEMA
abrasive code number.

Characteristics Code Number Abrasive Index Range

Mildly Abrasive 5 1 thru 17
Moderately Abrasive 6 18 thru 67
Extremely Abrasive 7 68 thru 416

ANSI / CEMA Standard 550 (Classification and Definitions of Bulk Materials) classifies over
500 bulk materials.

Following table lists some common materials and their CEMA classifications

Material Loose CEMA Material Angle of Max. Allowable

Description Bulk Code Repose Angle of Conveyor
Density (degrees) Inclination
(lbf/ft3) (degrees)
Alumina 55-66 58B627MY 22 12
Bark, Wood, Refuse 10-20 15E45TVY 45 27
Bentonite, 100 mesh 50-60 55A10025MXY 42 20
Cement, Clinker 75-95 85D336 30-40 18-20
Coal, Powder River Basin 40- 55 50D35LV 38 15
Coal, Bituminous, Mined 45-55 50DX35 38 15
Coal, Lignite 37-45 41D335TN 38 15
Coke, Petroleum, Shot 45-63 50C36LTWZ 35-40 14
Coke, Petroleum, Sponge 45-63 50C36LTWZ 35-40 14
Copper, Ore 120-150 125DX36 30-44 20
Cullet, Fines 80-120 120C1/237 30-44 20
Earth, Wet, Containing Clay 100-110 105D1646OV 45 23
Gravel, Pebbles 90-100 95D327 30 12
Kaolin, Clay, 3 in. & Under 63 63D325 35 19
Lime, Hydrated 40 40B635LM 40 21
Limestone, Crushed 85-90 88DX36 38 18
Phosphate, Rock, Pulverized 60 60B636 40 25
Rice, Hulled 45-49 47C1/225P 19 8
Sand, Foundry, Prepared 65-75 70B647X 30-44 24

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