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A General Approach for Introducing Materials Handling Topics in a Mechanical

Engineering Degree Course

Article · January 2005

DOI: 10.1115/IMECE2005-82004

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 Proceedings of IMECE2005
2005 ASME International Mechanical Engineering Congress and Exposition
November 5-11, 2005, Orlando, Florida USA

IMECE2005-82004

A GENERAL APPROACH FOR INTRODUCING MATERIALS HANDLING TOPICS IN A

MECHANICAL ENGINEERING DEGREE COURSE

W. John Dartnall
Faculty of Engineering, University of Technology, Sydney,
No. 1 Broadway, Sydney, NSW, Australia, 2007.
Email: [email protected]

where designers work from basic mechanics and the common

ABSTRACT empirical design procedures often outlined by manufacturers.
This paper outlines the development of the teaching
materials for an introductory lecture/chapter in a single INTRODUCTION
semester final-year materials handling course for Since the industrial revolution, people have made
undergraduate and postgraduate mechanical engineers. increasing use of mechanical methods of handling materials.
The study of materials handling equipment and processes This has been to such an extent that in the western world
primarily involves the application of mechanical engineering almost everything, including food, raw minerals, building
design principles emanating from the mechanics of machine materials and finished products, has probably been
elements, structures, thermo-fluids and particle mechanics. mechanically handled many times before it reaches the
consumer.
The detail topics of our course are from two main areas: The materials handling industry is not only economically
significant, but it is fundamental to the productivity of
• Bulk materials handling by screw, bucket and belt manufacturing and distribution systems (for example, US
conveyors as well as pneumatic and hydraulic conveyors. companies invest over $90 billion annually in materials
• Unit (discrete) materials handling of artifacts and handling technology and systems). The materials handling
manufactured (packaged) products. industry is very broad, covering almost all industries,
including mining, mineral processing, agricultural production,
For undergraduate and early postgraduate students, we food processing, power production, chemical processing,
utilize this course to provide an opportunity for students to manufacturing, packaging, pharmaceutical production and
amalgamate and integrate their engineering knowledge and many others.
experiences, and solve complex, real world problems of the Our subject covers the main systems and methods of
materials handling industries. mechanical handling of materials, both bulk solids handling
Although the students are mostly fresh from their and unit (discrete) handling of products and goods.
engineering sciences and hence have skills at applying basic Topics include: screw, belt and bucket conveyors and
principles, many have little or no practical experience in the elevators; pneumatic and hydraulic conveying of bulk solids;
materials handling industries. For this reason we start by storage systems; feeding, sampling and weighing of materials
discussing the significance of the industry and expose them to and systems for handling artifacts, factory products and
that fact that these industries have historically expanded from packaged goods.
simple (manual) handling to large scale mechanical handling We spend most of our semester course on the bulk (or
of goods and bulk solids. solids) handling topics (retaining one or two lectures for unit
The particle mechanics aspect of the bulk handling handling) as we believe that the bulk handling topics are more
component of the course is relatively unfamiliar to the relevant to our Australian graduates. We concentrate on bulk
students. For this reason, after giving our brief history and materials handling in this chapter whilst unit materials
socio-economic perspective of the materials handling industry, handling is treated later in our course.
we emphasize general principles related to the handling of The teaching approach in this introductory lecture/chapter
particulate solids. We differentiate between design approaches is to introduce bulk materials handling machines with block
diagrams representing screw, bucket belt and other conveyors.

1 Copyright © 2005 by ASME

 The main elements of the block diagrams (Figure 5),
(motors, mechanical transmissions, bearings, conveying
systems, hoppers, chutes, control elements, etc.) are labeled
and the design and operation issues surrounding these
elements are expanded.
The friction losses of mechanical machine elements will
be well understood by students, but the internal and external
friction of the particulate materials will need introduction.
This frictional energy loss is sometimes high. Thus a machine
such as a screw conveyor may have unusually high friction
loss due to the fact that all carrying surfaces rub against the
bulk solids, whereas a belt conveyor, which carries the
material on a belt supported by rollers, will usually offer a
considerably reduced percentage friction loss.
The students are expected to be familiar with the general
machine element design, engineering design processes,
structural analysis, fluid mechanics and engineering
thermodynamics.

NOMENCLATURE:
CEMA: Conveyor Equipment Manufacturer’s Association
γ = bulk density of material (kg/m3)
q = load per unit length of conveyor (kg/m)
A = cross-sectional area of load on conveyor (m2)
m& = mass flow of material (kg s-1)
v = bulk mean flow velocity of material (m s-1 )
Q = volume material flow (m3 s-1 ) Figure 1: Elevator with endless chain (1581)
g = acceleration due to gravity (m s-2 ) Figure 2 illustrates an endless chain used to haul hand-
L = conveyor length (m) trucks up an incline such as on a ship-loading ramp.
H = height through which material is elevated (m) Nowadays a few men operating ship-loaders will load
N = rotational speed (rev/min) thousands of tons in a few hours.
ω = rotational speed (rad s-1 ) The mechanized materials handling industry has moved
PH = theoretical power to elevate the material (kW) apace with human progress. It includes the movement and
Paccel = power accelerating material loading conveyor (kW) storage of goods and materials. For this reason, the materials
handling industry is primarily about its requirement for space
Pempty _ conv = power overcoming empty conveyor losses (kW) for its handling and storage equipment, the consumption of
Pconv _ load = additional power for load on conveyor (kW) energy for moving the materials and finally, but not least, its
requirement for its own space and materials of construction.
Pdig = conveyor load digging power (kW)
f1 = mathematical function
f2 = mathematical function
k1, k2 … = factors for friction, inertial and deflection losses per
unit length of conveyor (kg/m or as appropriate)

BRIEF HISTORICAL AND SOCIO-ECONOMIC

CONTEXT
Human chains were used from ancient times to move
materials, for example the moving of rocks and earth to
construct a mound on which to build the palace of king
Sennacherib. The first illustration (Figure 1) is of an elevator
with endless chain, illustrated in AD 1561. Although a similar
principle had been used in ancient Egypt in the form of a chain
of pots for moving water, it seems to never have occurred to
anyone to use it for moving earth during many centuries.
In the 1800’s, gangs of humans loaded coal on to ships or
railway trucks moving about 3 to 4 tons per day per carrier.
Later, wheel barrows were used and then narrow gauge lines Figure 2: Endless chain used to haul hand-trucks up an
with hand trucks; productivity increased to about 10 tons per incline such as on a ship loading ramp (approx. 1900)
day per carrier.

2 Copyright © 2005 by ASME

 Table 1: A portion of a large table of materials and
SOME EXAMPLES OF MODERN BULK SOLID properties relevant to belt conveyor calculations.
MATERIALS HANDLING SYSTEMS AND THEIR

Characteristics

Bulk Density
CONTEXT

Conv. Slope
Surcharge

Max. Rec.
Most of the manufactured solids handling equipment is

(degrees)

(degrees)
Angle of
Material
supplied by manufacturers in the form of modular, fabricated

(t/m )
3
products for feeding, conveying, elevating, storing and
measuring of materials. The manufacturers offer catalogues :
Ashes, coal, wet MA 0,75 25 25
containing engineering information and selection procedures. Ashes, fly MA 0,70 30 23
Examples of manufacturers’ catalogue information and solids Ashes, gas producer, wet MA 1,20 30 28
handling equipment are illustrated in Table 1 and Figure 3. Bagasse NA 0,13 30 30
Bark, wood, refuse NA 0,24 30 27
The performance of the equipment is usually significantly Barley NA 0,60 10 12
influenced by the nature and characteristics of the material Barytes, powdered MA 2,10 10 15
interacting with it. For this reason, manufacturers and national Bauxite, ground, dry VA 1,10 20 18
standards organizations have developed tables such as Table 1 Bauxite, mine run
Bauxite, crushed, 75mm
VA
VA
1,36
1,30
20
20
17
20
(for belt conveying) in which various properties and Beans NA 0,70 5 7
characteristics are listed such as abrasiveness, bulk density, :
surcharge angle, etc. Brewers grain, spent, wet NA 0,90 30 27
:
The three well-known examples in Figure 3 of bulk Quartz HA/S 1,36 10 15
materials transportation equipment operate on mechanical Rice NA 0,65 5 8
principles evident from the illustrations. In the bucket elevator, Rock, crushed HA/S 2,15 20 18
:
a chain or belt carries a series of evenly-spaced buckets that Vermiculite, expanded MA 0,25 20 23
dig into the material at the lower entry chute/hopper and carry Vermiculite, ore MA 1,20 20 20
it over the top sprocket, where it is discharged due to a Walnut shells, crushed NA 0,65 20 20
Wheat NA 0,77 10 12
combination of gravitational and centrifugal effects. In the Woodchips NA 0,32 30 27
screw conveyor, the material partially fills the voids between
flights and is transported due to the rotating screw effect. Characteristics Key:
HA/S - Highly abrasive/sharp
Overfilling inhibits transport due to rotation of the particulate MA - Mildly abrasive
material. The belt conveyor is primarily used for horizontal NA - Non-abrasive
transportation with relatively small inclination. VA - Very abrasive

Figure 3: Three common bulk solids handling machines: bucket elevator, screw conveyor and belt conveyor

3 Copyright © 2005 by ASME

 Figure 5 illustrates an example of a system comprising a loaded with any material. Additionally, the bulk solid will
combination of machines: a feeder, horizontal conveyor and exhibit friction both internally as it moves against itself and
an elevator. The feeder may control the rate of flow of the externally as it slides against machine members. When a
material and it discharges on to the horizontal conveyor which machine is operating 24 hours per day for the whole year
discharges into the feed chute of the elevator. The system (except for down-time) the friction energy can amount to a
designer often has to choose between varieties of operating considerable cost.
principles for each component of the system. For example, The machine designer needs to understand where energy
some of the operating principles employed for horizontal is lost and how to maximize the efficiency of these machines.
conveying are: belt-on-rollers, screw, pneumatic or hydraulic A simplified Conveyor Equipment Manufacturer’s
transport in pipes, drag and air fluidization. Association [16] (C.E.M.A) formula for power to drive a
Over the years, many inventions have occurred in the conveyor belt is:
materials handling industry. Some of these have led to
integrated manufactured products, such as the pneumatic grain Power (kW) =
drill (Figure 4), now commonly used by farmers for
continuously sowing crop seeds. This implement contains the ⎡ 9.81 ⎤ ⎡ HWm ⎤
⎢⎣1000 ⎥⎦ Lv ⎢⎣ kX + {kY (Wm + Wb ) + 0.015Wb} + L ⎥⎦
(1)
following bulk solids handling sub-systems: hopper, seed
metering rotary valve, fan, and pneumatic transfer tubes.
Where:

L = Horizontal distance between pulley centres (m )

H = Vertical distance between pulley centres (m)

v = Belt velocity (m/s)

Wm = Mass of material per metre run (kg)

Wb = Mass of belt per metre run (kg)

0.015 = Factor accounting for friction in return belt run

kX = Factor from belt slip and idler rotational resistance

= 0.00068(Wm + Wb) + 0.022(rotating mass of idlers
per metre) (kg/m)

kY = Resistance of belt to flexure as it moves over the

idlers. (kg/m)
Table 2: Selection of the kY factor based on belt length,
Figure 4: Pneumatic grain drill for sowing crop seeds [2]. lift and capacity

Length Lift kY kY kY kY
PRINCIPLES OF DESIGN OF BULK MATERIALS m m 500t/hr 1000t/hr 2000t/hr 3000t/hr
HANDLING SYSTEMS
100 20 0.035 0.030 0.026 0.022
For a designer, these systems, which provide flow,
storage, measurement and control of the particulate solids, are 200 20 0.032 0.026 0.022 0.020
basically systems of individual machines involving motors, 200 40 0.030 0.022 0.020 0.020
transmissions, friction, corrosion, wear, environmental, 400 20 0.030 0.022 0.020 0.020
structural strength, control, maintenance considerations, etc. 400 40 0.026 0.020 0.020 0.020
The material flow could be called “interrupted-continuous”. 800 40 0.022 0.020 0.020 0.020
This is because it often ceases when emerging from one 1000 40 0.020 0.020 0.020 0.020
materials handling machine into the feeding hopper of another.
At this point the kinetic energy (and some potential energy) in
the material is lost and further energy is often required to feed A number of other formulae have been used over the
the material to the next machine, as between the horizontal years and these are constantly being refined [3, 4, 13, 16].
conveyor in the centre and elevator on the right hand side of Software has been developed that assists with design
Figure 5. optimizations, taking costs into account [6, 9].
The material does not necessarily flow in the familiar way For each of these bulk materials handling machines there
that many liquids do. There is always friction in the machine are various approaches available for energy analysis. It is
elements and this is present even when the machine is not worth pointing out that the energy analysis serves a double

4 Copyright © 2005 by ASME

purpose. It enables us to look at the running cost of the
machines; it also (iteratively during design) forms a basis for The power to provide the digging effect will be:
us to design the machine and its elements for strength to
accommodate safety and reliability. Pdig = Fdig v = Fdigω R (W) (4)

FUNDAMENTALS OF ENERGY ANALYSIS FOR

THESE MATERIALS HANDLING DEVICES 3. Power to overcome machine friction (other than
We teach students to view the various empirical power prime mover transmission losses)
equations as being built up from some basic elements. These Machines are often tested under standard conditions with
equations are intended to assist understanding and not no material present such as an unloaded belt conveyor
necessarily intended for direct use: operating horizontally. A similar standard test is done with
screw conveyors, of standard pitch and mounted horizontally
1. Power to lift the material [1, 11, 12].
From an ideal point of view, none of these machines
needs any power unless it lifts the material, in which case the Pempty _ conv = Lvgf1 (k1 , k2 , k3 ...) (W) (5)
power consumed will be:
The parameters are like the kX, kY and Wb above and are
PH = m& gH (W) (2) available from various (manufacturers’) empirical tables.

2. Power to accelerate or decelerate the material 4. Power to overcome both internal and
Often the machines are required to dig or accelerate a feed conveyor/material interface friction due to the material
material. In this case, the component of power to accelerate flowing
the material to a velocity of v will be:
Pconv _ load = Lvgf 2 (k4 , k5 , k6 ...) (W) (6)
1 2
Paccel = m& v (W) (3a)
2 Again, parameters are like the kX and kY above and are
available from various manufacturers’ empirical tables.
When material exits a conveyor it often loses all its
kinetic energy and becomes stationary, in which case the Generally, equations (5) and (6) involve the following:
power lost is as in (3).
P = L × (v, N or Q ) × function (" k " factors ) (7)
1
Pdecel = m& v 2 (W) (3b)
2
Pdecel = (1 / 2) m& v 2
Vertical Elevator: Requires power to overcome material
elevation, as well as frictional, inertial and digging losses in Material exiting the
the material. Addionally, machine losses. Types: bucket, elevator (possibly passing
belt, aero, screw etc. to a chute and processing
Material entering the system P = L × (v, N .or.Q )× function.(" k" factors ) M machine or a storage bin)
(possibly from a storage bin):
Horizontal Conveyor: Requires power to overcome
Elevated
frictional as well as inertial entry and exit losses, in the
height, H
material. Addionally, machine losses. Types: belt, air
slide, pneumatic, hydraulic, drag, screw etc. PH = m& gH
Paccel = (1 / 2) m& v 2
M P = L × (v, N .or.Q )× function.(" k" factors )
Pdecel = (1 / 2 ) m& v 2 Material stationary in a
feed chute/hopper: Energy
lost when material stops and
Feeder: Controls volume flow further energy required to
rate of entering material. Types: overcome digging friction
screw, belt, apron, rotary, and accererate material.
vibratory and reciprocating. M
P = L × (v, N .or.Q )× function.(" k " factors ) Conveyed distance, L
P dig = F dig v

Figure 5: Some essential items and principles of bulk solids handling: feeding, horizontal conveying, chute/hopper and
elevating.

5 Copyright © 2005 by ASME

EXAMPLES OF INTRODUCTORY ENERGY
Pdecel = (1 / 2 ) m& v 2
ANALYSIS PROBLEMS GIVEN TO STUDENTS
We illustrate the estimation of power consumption in Material exiting the
materials handling equipment with example problems that we elevator (possibly passing
treat in two different ways; to a chute and processing
Firstly, we propose and solve a problem using only the
basic principles of the previous section of this paper. M machine or a storage bin)

Then, we propose and solve some problems using the

manufacturer’s code procedures that are commonly used in Elevated
industry. height, H
The code procedures in engineering selection and design
are now being replaced by software packages, and, as with the PH = m& gH
code procedures, the student is at risk of overlooking the need
Material stationary in a
to understand underlying factors and principles.
feed chute/hopper: Energy
There is ongoing research into the flow of particulate
material, and this research requires sophisticated analysis. lost when material stops and
Later in our course we introduce the students to this approach, further energy required to
pointing out that a clear understanding of the underlying overcome digging friction
mechanical principles is essential in this research. The and accererate material.
outcomes of the research are useful in developing software
that can enable a more detailed understanding than the two
approaches that we show here.
Pdig = Fdig v
AN EXAMPLE APPLYING BASIC MECHANICAL
PRINCIPLES:
Our first example for students to consider requires the use Figure 6: Diagram illustrating energy requirements for
of basic energy principles to estimate the power consumption the bucket elevator
of a bucket elevator.

Bucket elevator problem to demonstrate basic principles Pdig + Paccel + Pelev =

Estimate the power required to lift wheat grain using a
bucket elevator (Figure 6), given the following data: 251.3 + 77.2 + 719.3 = 1,047.8 W (11)
H = 12 m ; N = 160 rpm ; Material flow = 22 tonne/hr
Mean chain sprocket diameter = 400 mm Net shaft power required to drive bucket elevator =
Digging force at mean bucket centerline radius of 300 mm, 100
(Although this force fluctuates, a mean value is taken) = 50 N 1047.8 × = 1233 W (12)
Mechanical (shaft) efficiency of bucket elevator = 85 % 85

Solution, using a fundamental approach EXAMPLES APPLYING SELECTION DESIGN CODES

Mass flow of material = m& = 22/3.6 = 6.11 kg/sec INVOLVING EMPIRICAL PROCEDURES:
The examples below illustrate the use of codes, such as
the CEMA codes, in selecting bulk solids handling equipment
Power required for digging the material from the hopper:
and estimating the power requirement. The code power
N formulae are constructed along the empirical lines of the
Pdig = Fdig v = Fdigω r = Fdig r 2π =
60 previous section.
160
50 × 0.3 × π × = 251.3 W (8) NOTE: In the examples below all references are to the
30 procedures, formulae and tables of the relevant CEMA codes.
These codes are published on the websites of several
Power required to accelerate the material: manufacturers [7, 10, 11].
2
1 2 1 6.11 ⎛ 160 ⎞
Paccel = m& v = m& ω r 2 = ⎜ 0.3 × π × ⎟ = 1. Screw conveyor example:
2 2 2 ⎝ 30 ⎠ We provide a screw conveyor problem as our first example
because it demonstrates rather important issues for students:
6.11
× 5.032 = 77.2 W (9) the influence of friction on system efficiency. Another
2 important issue is that the materials handling industry
frequently uses empirical procedures rather than
Power required to elevate the material: fundamentally derived procedures.
Pelev = m& gH = 6.11 × 9.81 × 12 = 719.3 W (10)

6 Copyright © 2005 by ASME

Example: 18 tonnes per hour of brewer’s grain (wet) is to be calculate the required horsepower to convey 853 ft3/hr for
moved to an elevation of 3 m. Allow sufficient floor space for 38 feet in a 12” conveyor.
effective performance of the screw conveyor. Using the known factors find that: (16)

Solution 1: using CEMA procedure [1, 4, 7, 10, 11]: L = 38´ C = 853 ft3/hr N = 67 RPM from step 2 above

Preliminary calculations and conversions to Imperial units. W = 58 lb/ ft3 from step 1A

Data for brewer’s grain: Fd = 55 see Table 1-12, for 12”

γ = 55-60 lb/ft3 , CEMA code: 58 C1 / 2 45T, Fm = 0.8
Fb = 2.0 see Table 1-13 for L
Try an inclination of 150 :
L
Ff = 1 see Table 1-14, standard 30%

H=3m Fp = 1 see Table 1-15 e = .88 see Table 1-17

150
(4.) Solve the following horsepower equations: (17)
Figure 7: Estimate length of conveyor
L = 3/sin(150) = 11.6 m, = 11.6/0.305 = 38 ft (~ 12 m) A. HPf = LNFd Fb = 38 × 67 × 55 × 2.0 = 0.280
CEMA Fig 7.1, derating due to 150 inclination ~ 80% 1000 1000
Flow ( m& ) = 18 tonne/hr = 18,000/3,600 = 5 kg/sec
= 5*60/0.455 = 659 lb/min. CLWF f Fm Fp 853 × 38 × 58 × 1 × 0.8 × 1
B. HPm = = = 1.50
Flow (Q) = 659/58 = 11.4 ft3/min = 659x60/58 = 682 ft3/hr 1,000,000 1,000,000
Allowing for derating due to inclination,
Flow (Q) = 682/0.8 = 853 ft3/hr (13)
Find the Fo factor from 1-16; by adding HPf and HPm and
(1.) Refer to material characteristic table 1-2 for Brewers matching this sum to the values on the chart.
grain, spent, wet and find: (14) ( HPf + HPm ) Fo 1.78 × 1.65
C. HPt = = = 3.34
e 0.88
A. γ: 55 – 60 lb/ft3 (use 58 lb/ft3 )

B. material code: C½ - 45T Total power to convey the material horizontally:

Refer to table 1-1, material classification code chart where: = 3.34x 0.746 = 2.5 kW (this is all frictional) (18)
C½ = Fine ½” and under
4 = Sluggish
5 = Mildly abrasive Solution 2: Theoretical power to lift the material:
T = Mildly corrosive

C. Intermediate bearing selection: L or S

PH = m& gH = 5 × 9.8 × 3 = 147 W = 0.15 kW (19)
Refer to table 1-11 Bearing Selection, Find:
L = Bronze S = Nylatron, Nylon, Teflon, Hi-density, An approximate total power obtainable from the CEMA
Polyethylene, Graphite Bronze, Oil-impreg. Bronze, and procedure for both conveying and elevating the material
oil-impreg. requires the addition of (18) and (19), giving:
Total power to elevate material 2.65 kW (20)
D. Material Factor: Fm = 0.8
Machine efficiency = (0.15/2.65) x 100 = 5.6 % (21)
E. Trough Loading: 30%A (horizontal standard pitch,)
Refer to Table 1-6 capacity table and find 30%A which Check this problem by the methods of companies such as
shows the various capacities per RPM of the standard size [9, 11, 12], all of whom use the CEMA procedure.
screw conveyors and the maximum RPM’s for those sizes.
2. Bucket Elevator example:
(2.) From Table 1-6, Capacity table under 30%A note that a The bucket elevator requires a smaller floor area than the
12” screw will convey 1,160 cubic feet per hour at 90 inclined screw conveyor, and we show it to be a more efficient
RPM maximum, therefore at 1 RPM a 12” screw will machine in our second example by applying it to the same
convey 12.9 cubic feet. For 853 ft3/hr capacity at 12.9 problem of elevating18 tonnes per hour of wet brewer’s grain
ft3/hr per RPM, the conveyor must therefore run at 67 by 3 m.
RPM (853 ÷ 12.9 = 66.1). (15)

(3.) With the above information and factors from Tables 1-12
through 1-17 refer to the horsepower formulas on H-22 and

7 Copyright © 2005 by ASME

Solution: using CEMA procedure [10, 11]:
kX = 0.00068(Wm + Wb) + 0.022(rotating mass of idlers
Data: per metre) (kg/m)
= 0.00068(46.3+60) + 0.022(30) = 0.732
Flow (Q) = 682 ft3/hr as calculated in (13)
kY = 0.035 from Table 1 (27)
Material: Brewers grain, spent, wet
Power (kW) as (1) =
Weight per cubic foot: 58 pounds
⎡ 9.81 ⎤ ⎡ HWm ⎤ (28)
Capacity:18 tonnes per hour or 682 cubic feet per hour ⎢⎣1000 ⎥⎦ Lv ⎢⎣kX + {kY (Wm + Wb ) + 0.015Wb} + L ⎥⎦

Lump size: small, < ¼ inch

⎡ 9.81 ⎤ ⎡ 3 × 46.3 ⎤
⎢⎣1000 ⎥⎦100 × 3⎢⎣0.732 + {0.035(106.3) + 0.015 × 60} + 100 ⎥⎦
Percentage of lumps: as above

Shaft centres: 10 feet = 19.8 kW (29)

Service: 8 hours per day (22)
Theoretical power to elevate material:
Referring to Table 1, note that the material is non-abrasive,
non-corrosive, but sluggish (angle of repose beyond 45 PH = m& gH = 139 x 9.8 x 3/1000 = 4.09 kW (30)
degrees). Type 100 is recommended. Turning to Table 2, it
is found that Type 100 will meet the capacity and lump Efficiency = (4.09/19.8) x 100 = 21 % (31)
size requirements. However, since the material is sluggish,
the Type 700 continuous elevator is selected as that best
DISCUSSION
suited to handle the material. Referring to the capacity In this introductory lecture we provide a general overview
table for Type 700 elevators, it is found that a No. 705 of the bulk materials handling industry. We consider the
elevator will adequately handle the capacity and lump size evolution of this economically and sociologically significant
of the material. (23) industry from the days when materials were manually handled
to current times when almost everything, including food, raw
Horsepower is then calculated as follows: minerals, building materials and finished products has been
mechanically handled many times by the time it reaches the
SHP = (0.136 + 0.036 x 10) x 58/50 = 0.472 x 58/50 consumer of the developed countries.
We describe some of the main elements of a mechanical
SHP = 0.548 (24) handling systems employed in the movement and storage of
particulate materials.
Assuming a drive efficiency of 85 %, actual required We generalize the principles involved in the construction
power is then calculated as follows: of power estimation formulae and demonstrate some of the
code procedures that are employed by the industry.
P = 0.548/0.85 = 0.65 hp = 0.65 x 0.746 = 0.48 kW (25) The total design of equipment and systems is to be
covered in the remaining modules of the course. The
Efficiency = (0.15/0.48) x 100 = 31 % (26) specialised areas include:

• Screw, bucket and belt conveyors (movers).

3. Belt conveyor example:
The belt conveyor is often used for conveying materials • Hydraulic transport of bulk solids.
considerably larger distances than the screw or bucket • Pneumatic transport of bulk solids.
machines, with possible vertical undulation.
• Bins, chutes and hoppers.
Example: 500 tonnes/hour of bituminous coal, 50 mesh • Measuring and weighing of bulk solids.
and under, to be transported at a velocity of 3 ms-1 100 m • Design tools for the materials handling industry:
and elevated 3 m. The belt used has a mass/unit length of mathematical modelling, finite element modelling,
60 kg/m. Rotating mass equivalent of idlers = 30 kg/m. discrete element modelling and custom software.
Solution: using CEMA procedure as in (1) above [1, 6]: • System design for materials handling. This is treated by
having several real case study projects spread throughout
Wb = 60 kg/m the course. The complexity of the materials handling
systems progressively increases with the students’
m& = 500 tonnes/hr = 500/3.6 kgs-1 = 139 kgs-1 familiarity with the subject.
• Introduction to unit handling principles.
& /v = 139/3 = 46.3 kg/m
Wm = q = m

8 Copyright © 2005 by ASME

CONCLUSIONS
Our introductory lecture/chapter provides the students [5] http://www.cemanet.org/
with an overview of the materials handling industry, its
[6] http://overlandconveyor.com/
economic and sociological context and an introduction to the
type of equipment and systems that are commonly used in the [7] http://www.conveyoreng.com/
bulk handling of materials. We feel that this is important for
many Australian mechanical engineers, who are all likely to [8] http://www.goodmanconveyor.com/
spend at least part of their working career in dealing with [9] http://www.helixtech.com.au/
materials handling systems. The systems that our graduates
will encounter are most likely to involve particulate materials [10] http://www.martinsprocket.com/SecH_TOC.htm
from the mining and food industries. [11] http://www.screw-conveyors.com/
Having set the above scene, we show in a summary way
how a few general mechanical principles underlie the various [12] Lodewijks, Ir. G., 1995; “The Two-Dimensional Dynamic
empirical codes of practice used in the selection of equipment Behavior of Conveyor Belts”, Beltcon conference.*
and the design of materials handling systems. [13] Müller, K. P., 1991; “Do Belt Conveyor Standards
We point out that the few general principles are, in effect, Replace Fundamental Principles ?” Beltcon conference.*
preliminary to more advanced analyses that result from
research efforts that are constructing a science about the [14] Nordell, L. K., 1997; “Particle Flow Modeling: Transfer
movement and storage of particulate solids. These advanced Chutes & Other Applications”, Beltcon conference.*
analyses are likely to become available to practicing engineers [15] Roberts A. W., 2001; “Design Considerations and
in the form of design software. We also point out to the Performance Evaluation of Screw Conveyors”. Beltcon
students that the trend towards sophisticated design software is conference.*
similar to the trend to finite element modelling software used
in mechanics, electrical engineering and thermo-fluids that [16] Staples, P., 1981; “Conveyor Design and Design
they have already experienced in their undergraduate courses. Standards, (Belt Conveyors - Design, Operation and
Optimization)”. Beltcon conference.*
[17] * Beltcon conferences are on the following website:
REFERENCES http://www.saimh.co.za/beltcon/belt_main_index1.html
[1] ANSI/CEMA 350-1988, 1988; “Screw Conveyors”,
Conveyor Equipment Manufacturers Association.
[2] Bell, Brian, 1996; “Farm machinery”, Farming press
books and Videos, Miller Freeman Professional Ltd, UK
[3] CEMA, 1997; “Belt Conveyors for Bulk Materials 5th
Ed”, Conveyor Equipment Manufacturers Association.
[4] Colijn, Von H., 1985; “Mechanical Conveyors for Bulk
Solids (Studies in Mechanical Engineering 4)”, Elsevier
Science Publishers, Amsterdam.

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