PREVENTING SOLIDS FLOW PROBLEMS IN FEEDERS, BINS, HOPPERS AND STOCKPILES

Jerry R Johanson, JR Johanson Inc 2975 Hawk Hill Lane, San Luis Obispo, CA 95405

ABSTRACT
This presentation shows how to use basic properties and the indices derived from them to solve flow problems in bins, hoppers, stockpiles and feeders and how to use these valuable tools to select and size equipment for trouble free plant operation. Practical guidelines and suggestions are provided for avoiding solids handling problems in bins and stockpiles.

Flow Properties effecting feeders, bins, hoppers and stockpile design and selection
Any quantitative discussion of bin and feeder selection must relate the flow properties of the ore concentrate or mineral being handled and processed. These basic properties are listed in table 1 along with the factors that affect each (1.2.3). Table 1. Basic Bulk Solids Properties That Affect bins and feeder selection and sizing

Name

Symbol

Unit

Factors usually increasing magnitude Increased solids contact pressure, increased moisture content, increased time at rest, and reduced particle size Increased solid contact pressure, time at rest, particle size and decreased moisture Decreased solids contact pressure, increased moisture, increased surface roughness, increased time at rest Decreased unconfined yield strength Increased unconfined yield strength Sin()= Sin()/Cos( - ) For coheasionless solids, ===angle of repose Increased moisture, decreased
1

Unconfined yield strength

fc

Force per unit area

Bulk specific weight

Weight per unit volume

Kinematic surface friction angle Angle of internal friction Effective angle of internal friction

Degrees Degrees Degrees

Steady state rough plate angle of slide Permeability (incipient

Degrees

fluidization velocity)

Velocity

solids contact pressure and increased particle size

Each of these properties is a function of the level of consolidation pressure and consequently the behavior of the material in a bin or feeder is a function of the size of the bin or feeder. Recognizing this allows one to simplify the flow properties to a series of indices where the indices basis is related to the size of the bin and feeder. For a conical bin, this size is characterized by the hopper outlet diameter d through which the material must flow on the feeder of related size and the bin top diameter D. In a practical sense the questions of hopper and feeder selection are summarized by: How large must the outlet be to insure that the material does not arch in the hopper? What is the maximum sustained flow rate that one can expect from the hopper outlet? How steep must the hopper be to provide cleanout? What size of flow channel must one provide in a flat bottom bin or stockpile to cause the sides to cave in at a reasonable angle of repose? What density does one use in calculating the gravimetric capacity of a given bin or pile? What density can one expect at the feeder for calculating the required feeder material crosssection to accommodate the required gravimetric rate? And will the material; stick onto feeder pans and chutes thus requiring special design considerations. These seven questions are answered directly by the indices illustrated in figure 1. Each of the indices is calculated from the basic flow properties of the solid handled as a function of the indices basis as shown in table 2. Figure 2 shows the basic properties of the corn meal used in the photographs of basic flow patterns.

Figure 2. Corn meal consolidation pressure vs , , Strength, Density and Permeability

45

40

0.4

Friction Angles (deg.), strength (psf), Density (lb/cu ft)

35

30

0.3 Permeability (ft/sec)

25

20

0.2

15

10

0.1

0 0 25 50 75 Consolidation Pressure, psf DELTA Strength Surface friction 304-2B SS Density gamma 100 125

0 150

Permeability K

Density Parameters 36.17 0.787852 0.031804

Permeability Parameters 37.8 0.252949 4.870417

=(1+/)

=(/)

Figure 1 Physical Meaning of Indices

ARCHING INDEX is the (AI) recommended outlet diameter to ensure arch collapse in a conical bin. RATHOLING INDEX is the (RI) recommended circular flow channel diameter to ensure rathole failure and cleanout in a funnelflow bin. HOPPER INDEX ( HI) is the recommended conical hopper halfangle to ensure flow at the walls. FLOW RATE INDEX ( FRI ) is the maximum solids flow rate expected after deaeration of a powder in the bin. DENSITY INDICES ( FDI and BDI) are the densities in the feeder and bin respecti vely. CHUTE INDEX ( CI) is the recommended chute slope angle at impact points. SPRINGBACK INDEX ( SBI ) is the percentage
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TABLE 2 Johanson Indices as They Relate to Basic Flow Properties d = Hopper outlet diameter indices basis D = Bin diameter indices basis
Name Arching Index Ratholing Index Symbol AI RI Units Linear Linear Relation to Basic Bulk Properties AI = 2.2 fc / where fc and are measured at a solids contact pressure equal to 3 d/2. RI = 3.5 fc / where fc and are measured at a solids contact pressure equal to D.

Flow Rate Index

FRI

Weight per unit time

FRI =( 2 B+(B**2 4 A C)**0.5) /(2 A) Where: A = 4 Tan K / (g d3 / 4) B = 1 - / BDI C = - K d2 / 4 where K and are measured at a solids contact pressure of d / 2, is the conical hopper angle measured from the vertical, and g is the gravitational constant dependent on units of .

Feed Density Index Bin Density Index Hopper Index Chute Index

FDI

Weight per unit volume Weight per unit volume Degrees

FDI = measured at a solids contact pressure equal to d/2. BDI = measured at a solids contact pressured equal to D. HI = 42-= where = is measured at a solids contact pressure equal to d/2, or if = is larger at a higher pressure, then use = at a pressure of D. CI = ASC + 10 where ASC is the angle of slide on a flat surface after the powder sample has been pressed against a surface at a solids contact pressure of 4700 N/m2 (100 psf), then released before the surface is tilted to determine ASC.

BDI

HI

CI

Degrees

Note that HI and CI are both specific to the surface the material is sliding on and consequently are not constant for any given bulk solid but have a dual dependency on solids and surface material and surface conditioning.

The indices thus defined for a conical hopper provide the answers to each question. The minimum outlet for prevent arching [3] at the conical hopper outlet is AI. The minimum flow channel diagonal to prevent ratholing [8] and thus cause the sides of the channel to cave in at a reasonable angle of repose is RI. The maximum flow rate that one can expect from the outlet is FRI. The density at the feeder is FDI. The density in the bin is BDI. The 5

hopper angle measured from the vertical to insure flow at the walls is HI. Sticking on chutes and feeders is very likely whenever CI exceeds 70 degrees. Vibrating feeders should not be used with CI larger then 80 degrees. So far these indices have been related only to conical hoppers. As various hopper shapes are discussed these indices will be related to the particular hopper shape usually by a simple multiplier. In this way the effectiveness of various shapes can be expressed relative to the common conical hopper.

Stockpile hopper selection

Stockpiles are essentially flat-bottom bins. The basic flow patterns in flat bottom bins are photographed in a model using corn meal, a relatively cohesive material for the model size. The indices for the meal in the model are given in table 3 as calculated from the basic properties given for the meal in figure 2. The table also shows the indices for a fine wet coal in a large bin (example 2 and in a pile worked with tractors (example3). The ratios of AI/d and RI/D for the various materials and conditions provided a measure of relative cohesiveness. The meal in the model is much like the coal in the large bin and consequently the flow patterns photographed in the model will closely resemble those observed with the coal. The flow rate divided by the density and the area of the outlet giving the velocity through the outlet is somewhat higher in the large bin. The compressibility as given by the BDI/FDI ration is much larger for the large coal bin.

Table 3 Indices
Indices name or ratio Example 1 Corn meal D=0.833 ft d=0.0125 ft 0.025 2 0.75 0.9 37.5 101 37.8 40.8 1.078 Example 2 Fine wet coal D=40 ft D=3 ft 5.34 1.78 26.0 0.67 41,600 150 40.0 61.0 1.496 Example 3 Fine wet coal D= 30 ft d= 30 ft 13.4 0.46 ----------59.0 ---

Arching AI (ft) AI / d Ratholing RI (ft) RI / D Flow rate FRI (lb/ min) FRI / (FDI x Pi x d**2 /4) (ft/min) Feeder density FDI (lb/cu ft) Bin density BDI (lb/cu ft) Compressibility ratio BDI/FDI Hopper HI (degrees) Chute CI (degrees)

30* 16** --22* 90** --*On Plexiglas **on aged carbon steel

The corn meal of example1 was used in the photographs of the 10-inch diameter model. Example 2 is for a large 40-foot diameter bin with a 3-foot diameter or square outlet. This also applies to a bottom tunnel reclaim pile 40 feet tall that was initially formed by having the feeder running at least intermittently during the filling until the pile height reached 10 feet. Example 3 is for the top of a hopper under a pile worked with tractors that compact the solids to 1700 psf. It is also for the top of a hopper under a bottom tunnel reclaim pile that was fill initially from a flat surface at the top of the hopper to a height of 30 feet without running the feeder.

The relationship between the indices and the flow patterns in bins is evident in the photographs of the model flat bottom bin.

Photo 1 shows flow from a small outlet 1.5 by 1.5 inches square. An arch initially developed over the outlet. This was expected since the AI for the corn meal in the 10-inch diameter bin with a 1.5-inch circular outlet is 0.25 feet or 3 inches. When this arch is broken by prodding from the bottom, a stable rathole forms as is expected with an RI of .75 feet Since the flow channel that develops is essentially equal to the side of the outlet or about 1.5 inches (0.125 feet). Since the ratio of RI /flow diameter is 6, the rathole is very stable. Photo2 shows the result of flow from a 4inch square outlet. No arch forms as would be expected since AI = 3 inches. However there is still a stable rathole of about 4 inches in diameter (the side of the outlet). With a free flowing material the flow channel will expand to the diagonal of the outlet, however since AI/d is almost 1 (indicating a very cohesive condition) the material arched at the corners of the square causing a circular flow channel diameter of dimension equal to the side of the square. This rathole is still very stable since the flow channel is about half of the RI.

Photo 3 shows the results with a 1.5 by 4 inch outlet. There is only a slight hesitation to flow. Any arch is easily broken with a slight tapping. Once broken the flow continues as long as there is no major collapse of material onto the exposed outlet. There is no arch even though the width of the slot is less than AI. This is because of the material

is required to converge in one dimension only above the long slot. For a one dimensional convergence channel, the critical arching dimension is AI/2. Note that at the ends of the slot, there is a tendency to arch and thus neck down the flow channel to about 3 inches in diameter. For a slot to be considered one dimensional as far an arching is concerned, the length must be 2.5 to 3 times the width or greater. Photo 4 shows the result when the slot length is increased to 7 inches. There is still a tendency to close in the ends of the slot, however the diameter of the flow channel is increased to about 6 inches. This channel diameter is very close to the RI and as a result, the rathole is much less stable. This is evident by the expansion of the channel almost to the bin walls.

Photo 5 shows the flow when the slot length equals the diameter of the bin. The rathole collapses completely to the bin walls. The material flows freely from the flat bottom bin. The reclaim angle is about 60 degrees from the horizontal at the center of the slot. The support from the bin walls tends to make the angle slightly steeper at the ends of the slot. This is likely caused from the arching tendency at the slot ends. The general conclusions emerging from these photos are: 1. Arching occurs whenever AI is less than the side of a square or the diameter of a circular outlet. 2. Arching over a one dimensional convergence long slot does not occur when the slot width exceeds AI/2. 3. The flow channel in a flat bottom bin forms equal to the diagonal of the outlet provided arching is eliminated at the ends of the slot. 4. A rathole above an outlet is stable whenever the diagonal of the outlet is less than RI. 5. Extending the outlet to the full diameter of the bin eliminates any ratholing. Indices basis for stockpiles Applying these general principals to stockpiles begs the question, what is the rathole indices basis D for a stockpile where there is no defining diameter. D for a pile is the height of the pile above the flow channel. For example consider photo 6 with a.15 by10 inch slot under a 7-inch tall pile. The height at the center is 7 inches where as the height at the ends of the slot is only 3 inches. The RI are respectively 6.5 inches and 3.3 inches. Since the slot length and hence the flow channel diameter is 6 inches we expect the ends of the slot to be unstable and the rathole caves in. Notice that the reduced head at the ends of the slot has eliminated the arching tendency at the ends of the slot. The d for determining AI when initially filling the pile on the flat bottom without running the feeder is given by half the pile height. This is a very unusual case however and in most cases the d is given by the outlet width at the flat bottom of the hopper outlet diameter in the case of a hopper. When tractors are working the pile the indices basis must be modifies to account for the compaction given by the tractor wheels or tracks and the material. At the level or the flat bottom d is equal to half the pressure from the tractor divided by the bulk density of the material. At the bottom of the hopper d is the hopper outlet diameter. Stockpile layout

Using the above general principles, suggests the following pile outlet parameters: For a single outlet under a conical pile as shown in figure 3 the length of the slot l must be greater than RI and the width greater than AI/2 for a long slot. The dashed line circles indicate the region of influence of the flow above each slot.

Plan View FLOW CHANNEL FROM SLOT OUTLET

L>RI W>AI/2, if L>3W

L

EDGE OF PILE

FIGURE3 BASIC SINGLE OUTLET PERAMETERS

The elongated pile in figure 4 is serviced by a series of single slots each designed to break its associated rathole.

Plan View
AS CLOSE AS FEASABLE

EDGE OF PILE

FUGURE 4 INDEPENDENT SINGLE SLOTS

The single slot design is not practical when RI is very large. Arranging multiple outlets as shown in figure 5 reduce the required slot length by causing adjoining flow patterns to intersect. This increases the effective diameter to about 2.14 times the slot length as illustrated in the figure. The multiple direction feeder arrangement allows room for feeder head and tale pulleys.

Plan View

DO=2.14 L > RI EXTENT OF COMBINED FLOW PATTERN

W>AI/2

FIGURE 5 LAYOUT FOR EXPANDED

10

W
L

Plan View
EDGE OF PILE

FIGURE 6 MULTIPLE ADJIONING FLOW PATTERNS

The multiple parallel slots shown in figure 6 extends this multiple intersecting flow patterns to a series of slots arranged to form a combined slot essentially the full length of the elongated pile. Any combined flow pattern must produce an effective length greater than RI or extent the flow to the bin walls or full pile extent. Flat bottom bins Any of the flow patterns discussed for stockpiles can be used effectively in flat bottom bins to produce a flow pattern that extends the full bin diameter. Photo 5 shows the results when a1.5-inch wide slot is extended across the entire diameter of the bin. The 60 degree angle of reclaim (measured from the horizontal) is much steeper than the angle of repose in a conical pile of about 42 degrees and is much steeper than a hopper angle would need to be for cleanout. A figure 5 arrangement when used in a flat bottom bin minimizes the dead regions. Hopper selection Hoppers under stockpiles and flat-bottom bins serve to reduce the size and consequently the cost of the feeders required and to prevent potential arching from initial pile loading or the use of tractors on the pile. This last consideration requires that the hopper inlet be sufficiently wide to break up the over compacted solids before they reach the outlet just above the feeder.

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Plan View
Corner Plate typical

W top > AI for tractor worked pile or for initial fill pile height before feeder is run

L > 2.5 W top

W top

>HI

>HI+10

MATERIAL PROFILE ON BELT

W bottom > AI / 2 for hopper conditions

tapered transition to belt

Side View End View

FIGURE 7 TYPICAL BELT FEEDER HOPPER

Figure 7 shows a rectangular hopper and belt feeder. The width of the hopper can be as small as AI/2 for the appropriate pile condition. The length however must be at least 2.5 times the width for the arch breaking to be effective. Consider the wet coal and tractor worked pile condition of table 3 example 3. W= 6.9 feet and L= 17.3 feet. W at the bottom is taken from example 2 at 2.7 feet. The end and sidewalls are HI and HI+10 degrees respectively or 16 and 26 in the coal example. The sharp corners will build up with solids unless corner plates are provided as indicated. A tapered transition to t belt feeder is essential as shown to reduce feeder power requirements and to eliminate bridging from cohesive material packed by the belt against the front end of the hopper. This type of hopper design tends to reduce headroom requirements but maximizes the feeder length feeder width and feeder power required. The belt feeder in the coal example would be about 20 feet long and 4 feet wide. Using the hopper concept in figure 8 can minimize feeder requirements.

Plan View
Typical corner plate

W top > AI for tractor worked pile or for initial fill pile height before feeder is run

W top

W top

>HI
Side View

> HI+10
End View

Vertical outer skirts

W bottom > AI / 2 for hopper

FIGURE 8 TYPICAL APRON FEEDER HOPPER

This concept requires more headroom than in figure 7 because the hopper width at the top is equal; to the length and consequently must be equal to AI instead of AI/2 as in figure 7. When the feeder cost is a major factor as

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in the case of an apron feeder, the extra headroom required may easily pay for itself. In the coal example 3, W=13.8 feet. The length of the feeder is reduced to about 10 feet. The figure also shows a typical transition to an apron feeder to minimize the width of feeder required. The vertical skirts prevent spillage and allow the material to occupy the full feeder width. This reduces the feeder width to about 3 feet. The hopper angles are as is figure 7. The corner filler plates are very important in this case. It is important to note that in both figures 7 and 8, the assumption is that the cohesive arching of the material dominates the hopper design, as is the case with example 3 where the tractors destroy any rathole. Ratholing may still be a serious problem without tractors so these hoppers must be used to form long slots as indicated in the pile layouts of figures 3, 4, 5 and 6. One very effective way of forming long slots in given in figure 9.

Plan View

3 x AI / 2

AI

HI+15
Belt

Gate

Side View

HOPPER DETAIL

End View

Side View Figure 9. One-dimensional converging hoppers for long slot

End View

Figure 9 uses a series of one dimensional convergence hoppers [4,5] to deposit material directly on the conveyor belt. This can totally eliminate any feeders. The hopper angles are Hi + 15 degrees and consequently are flatter than any of the previous hoppers. The size of outlet required to prevent arching is AI, the same as for a long slot. This configuration was used successfully to retrofit a covered limestone pile that had severe ratholing problems. In this case there were already a series of short vibratory feeders feeding from square outlets onto a collecting belt.

Erratic flow from hoppers and feeders Erratic flow with cohesive solids
Sequential arching and ratholing may cause pulsating or erratic flow. As an arch forms and vibration or other flow aid devices are activated, the arch breaks and flow continues until the rathole collapses. The impact of the collapsing solids compacts material at the hopper outlet, causing it to arch. The cycle then repeats itself. This sequence occurs when material is cohesive and bins walls are not steep enough or the right shape to prevent ratholing. While the frequency and duration of non-flow conditions can often be controlled with the judicious use of flow aid devices, the wear and tear of the solids impact and flow aid agitation on bin walls may still cause hopper wall failure. Sever flow rate limitations may occur with cohesive solids that have strain rate sensitive strength properties. Viscous solids such as oil sand and wet clay require special tests to determine the strength as a function of the strain rate occurring in converging hoppers. In effect the AI is a function of the feed rate. The limiting rate is reached when the arching tendency associated with the rate is equal to the hopper outlet size.

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Erratic flow of powders With respect to erratic flow, fine, relatively non-cohesive, dry powders such as lime added to coal or flue dust from a mineral processing unit, introduce an entirely different problem. One time a powder may flow like a fluid through belt feeders, screw feeders, rotary air locks or even hopper bolt holes. At other times, a powder may come out of a hopper so slowly that the feeder, even though active, appears empty. This is explained in reference [1]. This limiting rate is given by the Flow Rate Index (FRI) for the powder (see Table 1). The FRI is directly proportional to the air permeability at the hopper outlet, and inversely proportional to the density change that the powder experiences in the hopper. Uncontrolled powder flow is usually associated with a source of air such as a rathole collapse, air introduced to purge feeder bearings, air injected to aid flow such as from air cannons or pulse jets and leakage past rotary valves. The type of feeder under the hopper also influences the limiting flow rate. Erratic powder flow controlled with feeders Consider the condition where a powder is quickly loaded into a bin so there is little time for the air to escape. Before the gate is opened, pressure at the gate is positive and the powder tries to escape from any available hole. When the gate is opened, air pressure forces the powder out of the hopper. This forced flow may overcome the feeders resistance and the powder flushes. If flow occurs at the hopper walls, the powder flow may cause sufficient expansion to eliminate the positive pressure and given sufficient time, will reach the vacuum-limiting rate. If the powder flows in a limited diameter, central flow channel as shown in photo 1, the fresh pressurized powder may reach the hopper outlet and flushing may continue for several minutes. In some cases, the bin may totally empty as powder sloughing in the top of the rathole continually refills the rathole with freshly fluidized powder. Flow at the hopper walls controls erratic flow The lack of flow along hopper walls is the most likely cause of powder flushing. Photo 7 shows four oscillating plates in the corners of a pyramid shaped 45-degree hopper [6]. The plates are pivoted about a pin near the top and activated with a slight cross movement near the bottom [6]. This activation keeps the rathole full of deaerated powder, moves the powder along the hopper walls, prevents aeration of the material and allows the hopper to be emptied without flushing [9].

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Flushing when refilling the hopper When hoppers are refilled after being almost emptied a large air pressure often develops in the powder as the entrained air is compressed. A tight closing gate is essential and the material must be allowed to stand until it is deaerated. The FRI, FDI, indices basis d and the height of the bin provide a guide for the time t to deaerated. t =FDI x H x (pi/4) x d x d / FRI (1) If this time is too short for the operation, then activating the oscillating plates during filling can significantly shorten the deaeration time.

Sealing screw feeders [7] can eliminate flooding and flushing. The sealing screw (Photo 8) is equipped with a pressure plate at the end that forces powder to make a plug. When deaeration and powder compaction is needed, a vent pocket allows compressed air to escape. If only a seal is required, the vent usually can be eliminated even though it serves as a safety valve to maintain the end seal. This feeder can contain the positive pressure created in the initial bin fill. If a rotary valve is required to isolate a high-pressure system from the bin, it should be placed at the discharge end of a sealing screw so that air leakage can be vented at the discharge end of the screw and not be allowed to penetrate the hopper.

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Belt and vibrating feeders do not have the same holdback characteristics of a screw feeder even with well-designed leveling boxes. The retention time in leveling boxes is usually too short for effective deaeration to occur. Equation 1 provides some guide as to their effectiveness where H is the height of the box.

Using air permeation to control erratic powder flow Since the cause of limiting rates is the vacuum that forms in the material, the obvious solution is to introduce air at key points in the hopper and eliminate the vacuum. This is accomplished with an air permeation unit APU. Air permeation can increase powder flow rates as much as several hundred times beyond that allowed without air injection. The objective of an APU is to increase the allowable flow rate to or beyond that required to fill the feeder below the hopper, and thereby allow the feeder to control the feed rate. In the case of free-falling powders, its possible to adjust the APU setting to keep rates within certain limits. Air permeation systems may be required whenever the following occur: (1) The fine, dusty powder has sufficient bin residence time to lose most of its entrained air; (2) the required instantaneous process flow rate exceeds the measured Johanson Flow Rate Index; or (3) the air pressure at the hopper outlet is sufficiently large, relative to the air pressure within the bin, to retard the powder flow rate. An APU may also help to a limited extent with viscous rate limits, however the air pressure required is usually several psi. Consequently the air tends to blow holes in the cohesive material allowing the air to escape. This results in wildly surging flow rates that may effect down stream operation.

Eliminating hopper flow problems

Hopper designed using the indices to size the outlet and the wall slopes to achieve flow at the walls can eliminate most hopper flow problems. The major hopper hang-up problems, their causes, relation to the indices and likely solutions are summarized in table 4. Table 4. Eliminating Hopper flow problems Observations Nothing comes out of the hopper when the feeder is started right after initial hopper loading. Likely causes The solids are cohesive enough instantaneously to arch over the hopper outlet. Flow Properties AI is greater than the conical hopper outlet diameter. Likely Solutions The outlet size must be increased or made more effective. Increasing the size means a new, larger, and more expensive feeder. The existing feeder may be used by replacing the lower portion of the hopper with a one-dimensional convergence racetrack- shaped cross section Diamondback Hopper. This will increase the outlet's effective diameter by a factor of two. Vibration should not be used in this case as it will likely over compact the solid and make arching worse. Vibration or air cannons placed near the outlet can be effective in initiating solids flow provided the conical hopper outlet diameter is greater than 1.5 times the instantaneous AI. If this is not satisfied, then the hopper and/or feeder will need to be modified to make the effective outlet 1.5

Solids initially flow from the hopper but nothing comes from the hopper after the solids sit at rest for some time.

The solids are caking sufficiently to cause arching after time at rest.

Instantaneous AI is smaller than the conical hopper outlet. However, the AI, after sitting at

16

some time.

rest, is greater than the conical hopper outlet. There is likely a rathole in the hopper, and the walls are not steep enough to cause flow at them. The hopper is likely cone or pyramid shaped. HI is less than the steepest hopper angle measured from the vertical. RI is greater than the diagonal of the hopper outlet. Instantaneous AI is less than the conical outlet diameter, but instantaneous RI is large. This indicates that the solid is pressuresensitive.

times the instantaneous AI.

Flow from hopper occurs for several minutes then stops completely

Vibrators or air cannons may be effective if placed so as to open up the flow channel diameter enough to exceed RI. However, the impact of the falling rathole may cause an arch in the hopper, or in extreme cases, break the hopper from the bin. A safer solution is to replace the lower part of the hopper with one that causes flow at the walls up to a diameter of RI or greater. The simplest way to avoid buildup is to provide a vertical section between the hopper outlet and the feeder so that the buildup does not affect hopper flow. In cases where the buildup is too severe, it will be necessary to modify the feeder interface or feeder to provide flow along the entire outlet cross-section.

No flow occurs at the front of the feeder. This may be observed at the feeder or at the top of the bin.

This is caused by solids buildup against the front edge of the hopper. This indicates that either the feeder interface to the hopper is improper or that the feeder is not designed to draw from the entire outlet cross-section.

Eliminating feeder problems

Feeder problems often start with the selection of the feeder type and size. In general the feeder must be sized based not only of the feeder rated capacity but also on the arching and ratholing capability of the material being handled. If the opening to the feeder is less than AI for a square or slot opening less than 2.5 times the width, there will be arching problems at least some or the time. Using a small one dimensional convergence hopper [2, 3, 4] can reduce this requirement to AI/2. Using oscillating plates [6] in conjunction with the one dimensional convergence hopper can reduce the requirement to AI/4. Even meeting the arching requirement does not guarantee feeder performance if the hopper is not designed to produce at least intermittent flow at the hopper walls and thus eliminate ratholing. Collapsing the rathole with flow aid devices such as vibrators or air cannons will likely produce erratic flow that is independent of feeder operation. Making the feeder inlet long enough to eliminate ratholing (length =RI) may be feasible with belt feeders apron feeders and specially designed screw feeders provided the feeder interface is properly designed. This approach is almost imposable with vibratory feeders. Table 5 lists some of the common feeder problems and their solutions.

Table 5. Eliminating Feeder problems

Observations Any feeder type cannot start after the bin is initially filled without overloading it. Likely Causes The likely cause after all of the obvious impediments to feeder operation such as improper wiring, wrenches, hard hats, rocks, or other foreign material in the feeder are Flow Properties Large FDI and large HI increase the load problem. Likely solutions Running the feeder when the bin is initially filled and then maintaining a heel in the bin of at least three hopper outlet diameters above the hopper outlet eliminates the excessive initial loads. If the process makes this impossible, then the feeder could be suspended from the hopper on springs or high loads should be

17

material in the feeder are ruled out, is excessive solids pressure from the initial bin loading. These pressures can be 2.5 to 3.0 times the normal running pressures. Any feeder type suddenly feeds very inefficiently even though it remains active. The feed rate reacts to feeder speed but at a lesser amount. Any feeder type gradually loses feeding capacity over time. There is likely a blockage of the outlet either from foreign material or from chunks of solids likely dislodged from the hopper walls. Large time RI and a small H, possibly caused by temperature cycles over a time period, contribute to the problem. Large CI, large time AI and RI are indications of this problem.

hopper on springs or high loads should be designed for and a high starting torque feeder motor should be provided.

A grizzly at the top of the bin will keep out most foreign materials and will limit lump size into the bin. The best way to eliminate lumps formed inside of the bin is to design the hopper for flow at the walls.

This is an indication that there is solids buildup on the belt, screw shaft, vibrating pan or rotating vane pockets.

While better belt scrapers, vibration of the feeder and rotating vane blow-through may help; the problem is the interaction of the solid and the feeder surface as reflected by the high CI. Using stainless steel shafts vanes and pockets, or coating them with materials with a low CI will work in some cases. Other times there may be no solution except to eliminate the use of the offending feeder types (most often a vibrating feeder). If the pinch point occurs in a region where there is no solids flow into the screw from the hopper, eliminating the shroud at the pinch point and at all points down stream reduce the overload. If the pinch point occurs under the hopper, or if the screw is in a barrel, it is necessary to rework the screw to eliminate pinching to within a tolerance of half the percentage difference between FDI and BDI.

A screw feeder initially starts then soon stops with an overload.

The likely cause is a pinch point in the screw flights where the screw flight spacing in the direction of solids flow decreases significantly. This is usually a manufacturing tolerance problem but may be caused by the feeder running against a closed gate and thus bending the final flight. The most likely cause is an improperly designed belt interface that does not provide an increased capacity in the direction of feed. The next likely cause is belt sagging between pulleys.

Less than 5% difference between FDI and BDI indicate a moderately incompressible solid that is likely to have problems with typical screw conveyor tolerances.

A belt feeder initially starts then suddenly stops with an overload.

Large FDI and a small percentage difference between FDI and BDI contribute to the overload.

The belt interface must be designed so that the gap between the belt and the interface edge increases at least 3 of an inch per foot in the direction of solids movement. Belt sagging can be reduced by placing idlers as close together as possible, or by using a slide plate instead of idlers.

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REFERENCES [1] Troubleshooting Bins, Hoppers and Feeders Chemical Engineering Progress CEP April 2002 pp100-112 [2] Eliminating arching hang-ups in hoppers. Diamondback Technology News. Vol. 1, No.1, Summer 1997, pp. 1-3. Johnson, J. R. Making Solids Flow in Hoppers Using Passive Activation. bulk solids handling, Vol. 20, No. 1, January/March 2000, pp. 9-15. Johanson, J. R. Arch breaking Hopper for Bulk Solids. U. S. Patent 6,055,781. May 2, 2000. Johanson, J. R. Modular Mass-Flow Bin, European Patent 0477219, March 3, 1996. Johanson, J.R. Modular Mass-Flow Bin (a.k.a. Diamondback Hopper). Canadian Patent 2058942. May 16, 1995. Johanson, J. R. Modular Mass Flow Bin (a.k.a. Diamondback Hopper). Australian Patent 640933. January 17, 1994. Johanson, J.R. Modular Mass-Flow Bin (a.k.a. Diamondback Hopper). Canadian Patent 2058942. May 16, 1995. Johanson, J. R. Modular Mass Flow Bin (a.k.a. "Diamondback Hopper"). Australian Patent 640933. January 17, 1994. Johanson, J. R. Modular Mass Flow Bin (a.k.a. Diamond-back Hopper).U.S. Patent 4,958,741. September 25, 1990. [5] Johanson, J. R. Combination Hopper (a.k.a Diamo-Cone). U. S. Patent 5,361,945. November 8, 1994. Johanson, J. R. Combination Hopper (a.k.a. Diamo-Cone). Canadian Patent 2,161,521. March 30, 1994. Johanson, J. R. Combination Hopper (a.k.a Diamo-Cone). U. S. Patent 5,361,945. November 8, 1994. Johanson, J. R. Combination Hopper (a.k.a. Diamo-Cone). Canadian Patent 2,161,521. March 30, 1994. [6] Johanson, J. R. Hoppers with Directionally Applied Relative Motion to Promote Solids Flow. U. S. Patent 6,086,307. July 11, 2000. Johanson, J. R. Compacting Screw Feeder. U. S. Patent 5052874. October 1, 1991.

[3]

[4]

[7]

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Johanson, J. R. Compacting Screw Feeder. Canadian Patent 2058942. May 16, 1995.

[8]

Understanding and eliminating costly rathole. Diamondback Technology News. Vol. 1, No. 2, Fall 1997, pp. 1-3. Preventing powder flooding and flushing. Diamondback Technology News. Vol. 2, No.1, Spring 1998, pp. 1-3.

[9]

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