Things to consider:

-moisture of GCT Product

-capacity of GCT for screw conveyor

-quantity/amount of product

-length and dimension from gct to screw conveyor going to elevator (RMT16)

-specific power consumption

-health and safety of tinder (silica content)

-power saving consumption

Maximum Allowable Silica Content

How much silica dust is too much?

It only takes a very small amount of the very fine respirable silica dust to create a health
hazard. Recognizing that very small, respirable silica particles are hazardous, OSHA
regulation 29 CFR 1926.55(a) requires construction employers to keep worker exposures at
or below a Permissible Exposure Level (PEL) of 50 µg/m3. The American Conference of
Governmental Industrial Hygienists has a lower non-regulatory Threshold Limit Value of 25
µg/m3. More information about the hazard and links to examples of exposures with and
without controls compared to the OSHA PEL

Source: https://www.silica-safe.org/ask-a-question/faq (OSHA)

The following steps are required for proper screw conveyor selection:

1. Calculate required capacity in cubic feet per hour (ft3/hr).

2. Select the recommended trough loading percentage from the Bulk Material Table
for the specific bulk material to be conveyed.

3. Select the screw conveyor diameter that corresponds with the recommended
trough loading and is less than the capacity at maximum RPM from the Capacity
Table.

4. Calculate actual conveyor speed by dividing the required capacity by the capacity
at 1-RPM from the Capacity Table.
Designing Inclined Screw Conveyors for Industrial Applications

Screw conveyors are one of the most reliable and cost-effective methods for conveying
bulk materials. Due to their versatility, screw conveyors can convey a wide variety of
bulk materials ranging from dry, free-flowing portland cement to wet, sluggish
dewatered biosolids.

Screw conveyors can be designed to operate in almost any position, from horizontal to
vertical. Inclined screw conveyors are used to convey and elevate bulk materials from
one level to another. Depending upon the bulk material and the objective, proper design
and construction of an inclined screw conveyor will provide many years of uninterrupted
service and productivity. The purpose of this article is to help the reader understand the
basics of inclined screw conveyor design for various applications.

History of Screw Conveyors

Archimedes designed the screw conveyor in the third century B.C. The first screw was
used for removing water from ships and for irrigating farmland. The original device
consisted of spiral flights fixed to the inner wall of a hollow cylinder driven by a center
shaft. As the assembly rotated, water was conveyed and lifted from one location to
another. The spiral design is based on the theory of the inclined plane. The screw
conveyor has evolved in modern times and is now used in almost every major industry.
Today, thousands of processing plants throughout the U.S. and the world are using
screw conveyors to convey bulk materials from A to Z (Adipic Acid to Zinc Concentrate).
Typical Applications for Inclined Screw Conveyors
Inclined screw conveyors solve the basic need for conveying bulk materials a specific
distance while elevating it. Because of equipment stack up, inclined screw conveyors
are needed to create the optimum plant layout and reduce the number of pieces of
equipment in the process flow. Typical applications for inclined screw conveyors include
receiving bulk materials from a screener and transferring it to a bucket elevator or as
part of a bulk bag discharge system. There are thousands of successful applications for
inclined screw conveyors currently in use today.

Classification of Bulk Materials

Bulk materials are classified by particle size, flowability, and other physical properties.
The Conveyor Equipment Manufacturers Association (CEMA) provides material
classification codes for the most commonly conveyed bulk materials. This information is
available in CEMA Book No. 350. The material classification code for each material
describes the density, particle size, flowability, abrasiveness, and other important
factors. Proper design of inclined screw conveyors is dependent upon the physical
properties of the bulk material to be conveyed.

Basic Theory and Design

Screw conveyors are volumetric conveying devices. With each revolution of the screw,
a fixed volume of material is discharged. The purpose of a screw conveyor is to transfer
product from one point to the next. Screw conveyors are always control fed at the inlet
by another conveyor or metering device. Rotary valves, screw feeders, belt conveyors,
grinders, or even other screw conveyors typically are connected to the inlet of a screw
conveyor.

The flowrate or capacity of a screw conveyor is measured in cu ft/hr. If the capacity is

given in lb/hr, tn/hr, or bu/hr, it must be converted to cu ft/hr. Unlike “flood fed” screw
feeders, screw conveyors are control fed at the inlet and therefore, the cross-sectional
trough loading is less than 100 percent. CEMA has developed standards for trough
loading based on the material classification codes. The percentage of trough loading
allowed is determined by the bulk material characteristics and if applicable, the
obstruction of internal hanger bearings. When necessary due to excessive screw pipe
deflection, hanger bearings are located inside the conveyor and are used to support the
screw.

Certain parameters are required for sizing a screw conveyor. The capacity calculation
for screw conveyors takes into account the outside diameter of the screw, the outside
diameter of the center pipe, the pitch of the screw, and the trough loading. The
calculation determines the capacity that will be conveyed with each revolution of screw
rotation. Most CEMA-approved screw conveyor manufacturers have the capacity
calculation and the CEMA guidelines as part of their screw conveyor design software.

Inclined Screw Conveyors

Inclined screw conveyors typically operate from slightly above the horizontal position to
45 degrees from the horizontal position. Above 45 degrees an inclined screw conveyor
is considered a vertical screw conveyor and must be designed in accordance with the
CEMA guidelines for vertical screw conveyors. As the degree of incline increases,
conveying efficiency is reduced and horsepower requirements increase due to the
effects of gravity and bulk material fall back. Conveying efficiency is affected by angle of
incline, characteristics of the specific bulk material, type of screw conveyor trough, and
screw pitch. CEMA recommends designing screw conveyors using the lowest possible
degree of incline for maximum efficiency.

Designing Inclined Screw Conveyors

When designing an inclined screw conveyor, it is important to understand how the
construction features affect the flowrate or conveying capacity. Selecting the proper
trough type and screw pitch will greatly increase the conveying efficiency.

Two types of troughs are typically used with inclined screw conveyors: U-trough and
tubular housing. The U-trough design is simple, economical, and provides access for
maintenance. U-troughs are used in most horizontal screw conveyor applications and
inclined applications up to about 20 degrees. As the degree of incline increases, U-
troughs become inefficient because bulk materials will fall back over the top of the
screw flights in the open area of the U-trough. Tubular housings are used in most
inclined screw conveyor applications above 20 degrees. Conveying efficiency is greatly
improved because bulk materials are contained within the tubular housing and fall back
is reduced.

Proper selection of screw pitch is also very important for successful inclined screw
conveyor operation. Screw pitch is the measurement from the tip of one flight to the tip
of the next. Full pitch screws have a measured pitch equal to the outside diameter of the
screw. CEMA has developed standard pitches for screw conveyors: full pitch, short (2/3)
pitch, and half (1/2) pitch. Full pitch screws are typically used in horizontal screw
conveyors because there is no loss in conveying efficiency. As a screw conveyor is
inclined, a full pitch screw will lose efficiency due to the angle of the flight.

Pitch Efficiency
The pitch efficiency chart shows the relative conveying efficiency at different degrees of
incline and pitch configurations. As the degree of incline increases, reduced pitch
screws (1/2 and 2/3) are more efficient than full pitch screws. As pitch decreases, the
perpendicularity of the flight to the pipe improves, thereby improving the carrying angle
on the incline. The combination of reduced pitch screws (1/2 and 2/3) and tubular
housings provide the highest conveying efficiency.

Design and Construction Features to Consider for Inclined Screw Conveyors:

• Incline Up to 10 Degrees – Loss in conveying efficiency is minimal on inclines up to

10 degrees. A screw conveyor with U-trough and full pitch screw is sufficient for most
applications. Loss in efficiency can be overcome by increasing the speed of the screw
conveyor, increasing the diameter of the screw conveyor or reducing the pitch of the
screw.

• Incline Between 10 and 20 Degrees – Loss in conveying efficiency is typically

between 10 and 40 percent on inclines up to 20 degrees. A screw conveyor with U-
trough and 2/3-pitch screw is sufficient for most applications. Loss in efficiency can also
be overcome by increasing the speed or the diameter of the screw conveyor. Additional
horsepower is required to overcome gravity and bulk material fall back.

• Incline Between 20 and 30 Degrees – Loss in conveying efficiency is typically

between 10 and 70 percent on inclines up to 30 degrees. A screw conveyor with tubular
housing and reduced pitch screw (1/2 or 2/3) is recommended for most applications.
Loss in efficiency can also be overcome by increasing the speed or the diameter of the
screw conveyor. Additional horsepower is required to overcome gravity and bulk
material fall back.
• Incline Between 30 and 45 Degrees – Loss in conveying efficiency is typically
between 30 and 90 percent on inclines up to 45 degrees. A screw conveyor with tubular
housing and reduced pitch screw (1/2 or 2/3) and larger diameter is recommended for
most applications. Increasing the speed of the screw conveyor is also required.
Additional horsepower is required to overcome gravity and bulk material fall back.

Horsepower Requirements and Upset Conditions

The horsepower requirements for inclined screw conveyors increase with the degree of
incline. Additional horsepower is required to overcome gravity and bulk material fall
back. Screw conveyors located on inclines over 10 degrees must be designed to start
and operate under upset conditions. An upset condition is caused when normal flow in
an inclined screw conveyor is interrupted and the bulk material inside the conveyor slips
back to the lower end, partially filling up the conveyor. Additional horsepower is required
to restart and convey the bulk material because the conveyor will temporarily
experience 100 percent trough loading. Please consult a trusted screw conveyor
manufacturer for the proper design of inclined screw conveyors for upset conditions.

Conclusion
Inclined screw conveyors are used in thousands of applications and provide a simple
solution for conveying and elevating bulk materials. If you utilize inclined screw
conveyors in your plant, proper design is extremely important to the long-term success
of your operation. Testing of bulk materials may be required in order to determine the
correct design for your specific application. Most CEMA-approved screw conveyor
manufacturers have a lab for testing bulk materials at various degrees of incline and can
recommend the proper design and construction features. The test information for bulk
materials that have been successfully conveyed in inclined screw conveyors is typically
kept in a database for use on future projects.

Bill Mecke, P.E. is president and owner of KWS Manufacturing Company, Ltd, one of
the largest screw conveyor manufacturers in the U.S. He has more than 25 years of
experience in the bulk material handling business. For more information,
visit www.kwsmfg.com.
Source : https://www.powderbulksolids.com/article/Designing-Inclined-Screw-
Conveyors-for-Industrial-Applications-02-21-2017

Breathing in very small ("respirable") crystalline silica particles, causes multiple diseases, including
silicosis, an incurable lung disease that leads to disability and death. Respirable crystalline silica
also causes lung cancer, chronic obstructive pulmonary disease (COPD), and kidney disease.
Exposure to respirable crystalline silica is related to the development of autoimmune disorders and
cardiovascular impairment. These occupational diseases are life-altering and debilitating disorders
that annually affect thousands of workers across the United States.
Silicosis
Breathing crystalline silica dust can cause silicosis, which in severe cases can be disabling, or even
fatal. When silica dust enters the lungs, it causes the formation of scar tissue, which makes it difficult
for the lungs to take in oxygen. There is no cure for silicosis.
Silicosis typically occurs after 15–20 years of occupational exposure to respirable crystalline silica.
Symptoms may or may not be obvious; therefore, workers need to have a chest x-ray to determine if
there is lung damage. As the disease progresses, the worker may experience shortness of breath
upon exercising. In the later stages, the worker may experience fatigue, extreme shortness of
breath, chest pain, or respiratory failure.
Because silicosis affects the immune system, exposure to silica increases the risk of lung infections,
such as tuberculosis. In addition, smoking causes lung damage and adds to the damage caused by
breathing silica dust.
In rare instances, individuals exposed to very high concentrations of respirable crystalline silica can
develop typical silicosis symptoms as well as fever and weight loss within weeks instead of years. In
these cases, medical evaluation should be performed as soon as possible.

Lung Cancer
Exposure to respirable crystalline silica increases the risk of developing lung cancer. Lung cancer is
a disease where abnormal cells grow uncontrollably into tumors, interfering with lung function. The
abnormal cancer cells can also travel ("metastasize") and cause damage to other parts of the body.
Most cases are not curable.

Chronic Obstructive Pulmonary Disease (COPD)

Exposure to respirable crystalline silica increases the risk of other lung diseases, primarily COPD,
which includes emphysema and chronic bronchitis. The main symptom of COPD is shortness of
breath due to difficulty breathing air into the lungs. COPD is not usually reversible and may worsen
over time.

Kidney Disease
Studies of workers exposed to respirable crystalline silica have found that these workers are at
increased risk of developing kidney disease. For instance, kidney failure has been observed among
workers with high silica exposure, such as in abrasive blasters who also were suffering from
silicosis.
https://www.osha.gov/dsg/topics/silicacrystalline/health_effects_silica.html