C O N S I D E R AT I O N S T O WA R D S A N E F F E C T I V E B I N D E S I G N

C H E T S PA R K S
ADAO RA JO HNSO N
M AT T H E W M I L A N O W S K I
A N A S A L R A B B AT
MI CHAEL MC CLU RG

OBJECTIVES
Understand the Problems of
Bulk Solid Flow

Create Matlab
Programs That Aid In
Calculations

Understand the
Components of
Effective Bin Design

Perform
Calculations
Related to Bin
Design

http://bulksolidsflow.com.au/

http://eng.tel-tek.no/Powder-Technology/Silo-design-and-powder-mechanics/Silo-design-based-on-powder-mechanics-overv
http://www.fil.ion.ucl.ac.uk/spm/software/spm8/

KEY POINTS TO CONSIDER WHEN

DESIGNING BINS
S t or a g e c a p a c i ty :
A l w a ys ke ep in m in d th e a m o u n t
o f m a t e r ia l th a t y o u a re g o i n g t o
s t o re b ec a u s e t h a t w ill e ff e c t
h o w m a n y b in s y o u w il l n e e d t o
design.
T h e l o ca t io n o f th e b in w i l l a l s o
e ff e ct t h e d es ig n .
D i s c ha r g e Fr eq u en c y & r a t e :
H o w m u c h t im e w ill t h e s o l i d
re m a in w it h o u t c o n t a c t ?
A ro u n d w h a t r a n g e w il l t h e
in s t a n t a n eo u s d is c h a rg e r a t e b e ?
Does the rate depend on weight
o r o n t h e v o lu m e?
W h a t i s t h e req u ired f e e d
a cc u r a c y?

http://jenike.com/files/2012/10/BlueSiloCollapsing-41.jpg
http://
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf

KEY POINTS TO CONSIDER WHEN

DESIGNING BINS
Te m p e r a t u re a n d P r e s s u r e :
Wi l l t h e m a t e r i a l b e a t a l o w o r h i g h t e m p e r a t u re t h a n i t s
s u r ro u n d i n g s ?
I s t h e m a t e r i a l b e i n g f e d i n t o a p o s i t i v e o r n e g a t i v e p re s s u re
e n v i ro n m e n t ?
Fa b r i c a t i o n M a t e r i a l s :
Is the s olid abr asive or c orros ive?
Wi l l t h e r e b e n e e d f o r c o r r o s i o n - re s i s t a n t a l l o y s ?
A r e u l t r a h i g h - m o l e c u l a r- w e i g h t p l a s t i c l i n e r s t o l e r a b l e ?
I s t h e a p p l i c a t i o n s u b j e c t t o a n y re g u l a t o r y c o m p l i a n c e
re q u i re m e n t s ?
Saf ety a nd environmental co nsider ations :
A r e t h e re a n y s a f e t y e n v i ro n m e n t a l i s s u e s l i ke m a t e r i a l
explosive ability or maximum dust composer limits?
B u l k s o l i d u n i f o r m i t y:
W h a t i s t h e re q u i r e d m a t e r i a l u n i f o r m i t y ( e g : s i z e , s h a p e ,
m o i s t u re c o n t e n t )
H o w w i l l p a r t i c l e s e g r e g a t i o n a ff e c t p ro d u c t i o n a n d t h e fi n a l
pro duct ?

http://www.proagro.com.ua/eng/research/grain/4064511.html
http://
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf

UNDERSTAND BULK-SOLIDS FLOW

PROBLEMS
A r c h i n g o r B r i d g i n g : T h i s i s w h e n a n o - fl o w c o n d i t i o n o c c u r s
i n w h i c h a m a t e r i a l f o rm s a s t a b l e b r i d g e / d o m e a c ro s s t h e
outlet of a bin.
R a t h o l i n g : A n o t h e r n o - fl o w c o n d i t i o n i n w h i c h m a t e r i a l f o rm s
a s t a b l e o p e n c h a n n e l w i t h i n t h e b i n re s u l t i n g i n e rr a t i c fl o w
t o t h e d o w n s t re a m p ro c e s s .
F l o o d i n g o r fl u s h i n g : a c o n d i t i o n i n w h i c h a n a e r a t e d b u l k
s o l i d b e h a v e s l i ke a fl u i d a n d fl o w s u n c o n t ro l l a b l y t h ro u g h a n
o u t l e t o r f e e d e r.

Arching

F l o w r a t e l i m i t a t i o n : I n s u ffi c i e n t fl o w r a t e , t y p i c a l l y c a u s e d
b y c o u n t e r- fl o w i n g a i r s l o w i n g t h e g r a v i t y d i s c h a rg e o f fi n e
p o w d e r.
Pa r t i c l e s e g r e g a t i o n :
s e g re g a t i o n m a y p re v e n t a c h e m i c a l
re a c t i o n , c a u s e o u t o f s p e c p ro d u c t , o r re q u i re c o s t l y re w o r k .
Capacity:
c a p a c i t y.

As low as only 10-20% of the bins rated storage

http://
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf

Ratholing

MEASURE THE FLOW PROPERTIES OF

THE BULK SOLID
T h e p u r p o s e o f m e a s u r i n g t h e fl o w p ro p e r t i e s i s m a i n l y i n o rd e r t o
c o n t ro l h o w t h e fl u i d w o u l d b e h a v e i n a b i n .

T h e t a b l e s h o w s t h e m o s t i m p o r t a n t b u l k - s o l i d h a n d l i n g p ro p e r t i e s .
Va r i a b l e s t h a t a ff e c t s o l i d p a r a m e t e r s :

Mo ist ure co nt ent

Pa rt icle size, shape, and hardness
Pressure
Temperat ure
St orage t ime at rest
Wall surface
Chemical a ddit ives

http://
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf

CALCULATE THE APPROXIMATE SIZE

OF THE BIN

T h e a b o v e e q u a t i o n i s u s e d t o fi n d t h e h e i g h t o f t h e c y l i n d e r s e c t i o n
n e e d e d t o s t o re t h e d e s i re d c a p a c i t y. T h i s d e s i g n p ro c e s s i s i t e r a t i ve .
H: Height
m: the mass in Kg.
A : t h e c ro s s - s e c t i o n a l a re a o f t h e c y l i n d e r.
a v g : Av e r a g e b u l k d e n s i t y i n ( k g / m ^ 3 )
Due to the volume lost at the top of the cylinder which is due to the bulk
s o l i d s a n g l e o f re p o s e a n d a l o n g w i t h t h e v o l u m e o f m a t e r i a l i n t h e
h o p p e r s e c t i o n , a re a s o n a b l e s u ffi c i e n t e s t i m a t e f o r t h e h e i g ht c a n b e
f o u n d b y ke e p i n g t h e h e i g h t o f t h e b i n b e t w e e n o n e a n d f o u r t i m e s t h e
d i a m e t e r o r w i d t h s i n c e v a l u e s o u t o f t h a t r a n g e a re m o s t o ft e n
uneconomical.

http://
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf

TYPE OF FLOW PATTERNSFUNNEL FLOW

Bulk solids flow much
differently than liquids in
tanks. A liquid would flow in a
first-in/first-out sequence, but
many bins have flows in a
funnel-flow pattern.
Funnel-flow is defined as when
some of the material flows in
the center of the hopper while
the rest remains stationary
along the walls. Funnel-flow is
the most economical choice if
the bulk solid is
nondegradable, coarse, freeflowing, and if the segregation
during discharge is not an
http://
issue.
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf

Funnel Flow
Discharge

TYPE OF FLOW PATTERNSMASS FLOW

Mass Flow
Discharge

Many problems can

occur when there is
funnel-fl ow. Some
problems include
ratholes, arches, caking,
equipment failure, etc
Mass-fl ow occurs when
all the material moves
when any is discharged.
Mass-fl ow bins work well
with powders, cohesive
materials, materials that
degrade with time, and
whenever sifting
segregation must be
minimized.
9

http://
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf

DESIGNING FOR MASS FLOW

The converging hopper section must be steep enough, the
wall surface friction low enough, and the outlet large
enough to allow a fl ow without stagnant regions.
This will also help prevent arching.
In order to determine the wall friction angle, various wall
surfaces are powder tested. These tests are conducted
using a direct shear tester along the lines of ASTM D-6128.

S a n d w i l l re q u i re a s t e e p h o p p e r
a n g l e i n o rd e r t o a c h i e v e m a s s fl o w
because it is a highly frictional bulk
solid.
S m o o t h c a t a l y s t b e d s w i l l a ch i e v e
m a s s fl o w a t a re l a t i v e l y s h a l l o w
hopper angle because it is a lowfriction bulk solid.

http://
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin
%20Design.pdf
http://www.dietmar-schulze.com/storage.html

10

DESIGNING FOR MASS FLOW

To prevent arching you must measure the cohesive
strength of the material you want to transport.
First the flow function of the
material, the is measured in a
laboratory test according to
ASTM D-6128 with a direct
shear tester. Just like in the
wall friction test, consolidating
forces are applied to a
material.
In the test cell, the force
required to shear the material
is measured.
Minimum outlet sizes needed
to avoid arching can be
calculated once the flow
11
function is determined.

http://
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf

This equation can be used to approximate the maximum discharge

rate from a converging hopper. This can only be used if the bulk
material is coarse and free-flowing. In order for a material to be
considered coarse, the particles must have a diameter of at least 3
mm (1/8 in). An example of this scenario is on the next slide. In the
above equation, the variables are defined as:

M: mass flow rate (kg/s)

: bulk density (kg/m3)
A: outlet area (m2)
g: acceleration (m/s2)
B: outlet size (m)
: mass-flow hopper angle measured from vertical
(deg.)
m: outlet parameter dependent on type of hopper
For conical: m = 1 for a circular outlet
For wedge-shaped: m = 0 for a slot-shaped outlet 12

http://
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf

TYPES OF BULK SOLIDS

Mass
flowing
bulk solids

Does not
follow mass
flow
equations
This equation only works for coarse and free-flowing material because
it neglects the materials resistance to airflow. For example, the
equation would not correctly estimate the flow rate for a fine powder.
The fine powder would have particles with diameters much less than 3
mm and would be greatly affected by airflow. Thus, the equation would
give an answer that is much greater than the true value for the mass 13
http://
flow rate.
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf
ttp://upload.wikimedia.org/wikipedia/commons/9/98/Rhodium_powder_pressed_melted.jpg

FUNCTION THAT CALCULATES

MASS FLOW RATE
function [ M ] = DischargeRate( rho,A,g,B,theta,m )
% DischargeRate: Approximates the maximum discharge rate from a
converging
% hopper.
% For this function to be accurate, one must assume that the bulk
material
% is both coarse and free-flowing, such as plastic pellets.
% Input:
%
rho = bulk density (kg/m^3)
%
A = outlet area (m^3)
%
g = acceleration (m/s^2)
%
B = outlet size (m)
%
theta = mass flow hopper angle measured from vertical (deg.)
%
m = 1 for a circular outlet and m = 0 for a slot shaped outlet
% Output:
%
M = mass flowrate (kg/s)
M=rho*A*sqrt((B*g)/(2*(1+m)*tan(theta*pi/180)));
end
14

RESULTS
The first answer is for a circular outlet. The second answer is for a
slot-shaped outlet with the same parameters.

>> DischargeRate(10,1,9.81,1,60,1)
ans =
11.8994
>> DischargeRate(10,1,9.81,1,60,0)
ans =
16.8283

http://www.inti.gob.ar/cirsoc/pdf/silos/SolidsNotes10HopperDesign.pdf

15

FLOW RATE VS HOPPER ANGLE

Comparison of Outlets

180

Circular
Slot-shaped

160

mass flowrate (kg/s)

140
120
100
80
60
40
20
0

10

20
30
40
50
60
70
80
mass flow hopper angle measured from vertical (deg.)

90
16

THE PREVIOUS PLOT COMPARES THE TWO SHAPES OF OUTLETS AND ALSO THE MASS
FLOW WITH RESPECT TO A CHANGING HOPPER ANGLE. AS THE PLOT SHOWS, THE
SLOT-SHAPED OUTLET HAS A LARGER MASS FLOW FOR ALL VALUES OF THE HOPPER
ANGLE THAN THE CIRCULAR OUTLET. THE PART OF THE GRAPH BETWEEN 20 AND 70
IS WHERE A REALISTIC HOPPER ANGLE WOULD EXIST. IN THIS REGION, AN
INCREASING LEADS TO A DECREASE IN MASS FLOW. ESSENTIALLY AS THE SLOPE OF
THE BIN DECREASES, LESS MASS EXITS THE BOTTOM OF THE BIN PER UNIT TIME. THE
C O D E T H AT C R E AT E D T H E P L O T I S G I V E N B E L O W :

% Creates a graph that shows the comparison of circular and slot-shaped

% outlets. The mass flow rates are plotted versus the mass flow hopper
% angle measured from vertical.
% rho = bulk density (kg/m^3)
rho=10;
% A = outlet area (m^3)
A=1;
% B = outlet size (m)
B=1;
% g = acceleration (m/s^2)
g=9.81;
% The values for theta are from 1 degree to 90 degrees.
theta=(1:1:90);
% Mc = mass flow rate for a circular outlet (kg/s)
Mc=rho*A*sqrt((B*g)./(2*(1+1)*tan(theta*pi/180)));
% Ms = mass flow rate for a slot-shaped outlet (kg/s)
Ms=rho*A*sqrt((B*g)./(2*(1+0)*tan(theta*pi/180)));
plot(theta,Mc,'-b',theta,Ms,'--r')
title('Comparison of Outlets')
xlabel('mass flow hopper angle measured from vertical (deg.)' )
ylabel('mass flowrate (kg/s)')
legend('Circular','Slot-shaped')

17

 T h e m a i n f a c t o r s f o r f u n n e l fl o w
a re m a k i n g t h e h o p p e r s l o p e
s t e e p e n o u g h t o b e s e l f- c l e a n i n g ,
a n d s i z i n g t h e h o p p e r o u t l e t l a rg e
e n o u g h t o o v e rc o m e a rc h i n g a n d
ratholing.
Fo r t h e b i n t o c a p a b l e o f s e l fcleaning, the hopper slope must
b e 1 5- 20 d e g re e s s t e e p e r t h a n
the wall friction angle, assuming
t h a t a r a t h o l e h a s n o t f o rm e d .
Knowledge of the materials
c o h e s i v e s t re n g t h a n d i n t e rn a l
f r i c t i o n i s n e e d e d i n o rd e r t o
d e t e rm i n e t h e m i n i m u m
d i m e n s i o n s t o o v e rc o m e r a t h o l i n g
a n d a rc h i n g .
Fo r f u n n e l fl o w , t h e d e s i g n o f t h e
m a s s - fl o w b i n s i s i n d e p e n d e n t o f
scale, but the overall size
m a t t e r s . T h u s , l a rg e f u n n e l fl o w
bins have a higher ratholing
http://
t e n d e n c y , w h i l e m a s s fl o w b i n s
research.che.tamu.edu/groups/Seminario/numerical-topics/Bin%20Design.pdf

Flow Channel

DESIGNING FOR FUNNEL FLOW

Non-flowing
region

18

EXPERIMENTAL FLOW
CALCULATIONS:

U n f o r t u n a t e l y , s o m e fl u i d s h a v e p ro p e r t i e s t h a t c a n m a ke fl o w c a l c u l a t i o n s
d i ffi c u l t .
In these cases, collecting experimental data and interpolating can be the next best
thing.
Fo r e x a m p l e , t h i s d a t a w a s g e n e r a t e d t o s i m u l a t e s t o r i n g a v e r y v i s c o u s , s h e a rt h i c ke n i n g , n o n N e w t o n i a n fl u i d .
T h i s l i q u i d r a p i d l y t h i c ke n s a n d b e c o m e s m o re a d h e s i v e w h e n e x p o s e d t o a h i g h
p re s s u re g r a d i e n t .
W h i l e t h e e x a c t c a l c u l a t i o n s a re b e y o n d t h e s c o p e o f t h i s p ro j e c t , t h e d a t a s h o w s
t h a t a t a n y a n g l e l e s s t h a n 3 0 d e g re e s f ro m v e r t i c a l , fl o w r a t e d ro p s r a p i d l y a s t h e
fl u i d h a rd e n s i n t o a g o o e y s o l i d .
T h e q u e s t i o n i s , h o w d o w e m o d e l t h i s fl o w a n d fi n d a t h e o re t i c a l m a x i m u m r a t e ?

Angle
From
Vertical

Flow
(in^3/s)

Angle
From
Vertical

Flow
(in^3/s)

4.1

30

86.2

10

4.7

35

60.3

15

6.1

40

76.4

20

8.2

45

66.1

25

27.3

50

54.1

19

EXPERIMENTAL FLOW CONT.

We u s e s p l i n e s t o i n t e r p o l a t e t h e d a t a a n d p ro v i d e a m o d e l fi t . O u r
matlab code was:
O u r g r a p h p ro v i d e s e s t i m a t e d fl o w v a l u e s
a t a n y a n g l e f ro m 5 t o 5 0 f ro m v e r t i c a l .
I t s h o w s o u r t h e o re t i c a l m a x i m u m fl o w i s
a ro u n d 9 0 i n ^ 3 /s a t a p p rox 3 2 d e g re e s
f ro m v e r t i c a l .
AN=[5 10 15 20 25 30 35 40 45 50];F=[4.1 4.7 6.1
8.2 27.3 86.2 80.3 76.4 66.1 54.1];
EF=spline(AN,F,linspace(5,50,250));
ANE=linspace(5,50,250);
plot(ANE,EF);hold on;plot(AN,F,'*k');
xlabel('Angle from vertical'),ylabel('flow rate
(in^3/s)'),title('Experimental flow calculations')
legend('Experimental fit','Table values')

20

RATHOLE CALCULATIONS
Ra t h o l e s c a n c a u s e s e r i o u s p ro b l e m s w i t h fl o w. To b e t t e r u n d e r s t a n d t h e
i s s u e s t h e y c a u s e , t h i s f u n c t i o n c a l c u l a t e s t h e f r a c t i o n o f u s a b l e fl o w
a re a l e ft b y a r a t h o l e , a n d t h e f r a c t i o n o f t h e t o t a l v o l u m e o f t h e b i n t h e
r a t h o l e t a ke s u p .
I t m a ke s t h e a s s u m p t i o n t h a t y o u a re u s i n g a n e c o n o m i c a l l y d e s i g n e d
( H = ( 1 : 4 ) * m a x d i a m e t e r ) c y l i n d r i c a l h o p p e r w i t h a c e n t e re d c y l i n d r i c a l
r a t h o l e a n d a c i rc u l a r o u t l e t .
Ad d i t i o n a l l y , i t a s s u m e s t h e m a t e r i a l i s n o t s i g n i fi c a n t l y l a rg e a n d h a s
n e g l i g a b l e t e n d e n c y t o c l u m p t o g e t h e r.
T h e f u n c t i o n i s a s f o l lfunction
o w s : [FA,FV]= Rathole(DI,DO,Hbin,DR,BA);

%Inputs:
%DI is the input diameter, or the diameter of the cylindrical bin
%DO is the output diameter, or the diameter of the circular outlet
%Hbin is the height of the cylindrical bin area
%DR is the diameter of the rathole
%BA is the bin angle in degrees.
%Outputs
%FA is the usable fractional area of the outlet for flow
%FV is the fraction of the total volume of the bin the rathole takes up
%In function
%AI,AO,RA are the input, output, and rathole area
%HC and HT are the height of the conical bottom section and the total area
%Vtotal and VR are the total volume of the bin and the rathole volume
21

RATHOLE FUNCTION CONTINUED:

if Hbin<DI | Hbin>4*DI, error('Bin height should be 1 to 4 times bin diameter to be economical.')
end
if DR > DO | DO > DI, error('Diameters should be: DI>DO>DR')
end
%Our article stated that H should be DI*(1-4); this step checks that condition and other logical
conditions
A I = p i . * D I . ^ 2 . / 4 ; AO = p i . * D O. ^ 2 . / 4 ; RA = p i . * ( D R. ^ 2 ) . / 4 ;
%This step calculates the input, output, and rathole area.
U A = AO - RA ;
%This step computes the usable area by subtracting rathole area from output area.
FA = U A . / A O ;
%The fractional area is computed by dividing the usable area by the output area.
HC=(DI-DO)./2.*tand(BA);HT=HC+Hbin;
% T h e h e i g h t o f t h e b o t t o m s e c t i o n i s c o m p u t e d b y t h e s l o p e o f t h e b i n a n d t h e d i ff e r e n c e o f t h e
% i n p u t a n d o u t p u t d i a m e t e r s , a s s u m i n g t h e b o t t o m s e c t i o n i s a p p rox i m a t e l y a f r u s t r u m o f a c o n e .
V t o t a l = p i . * H C . / 3 . * ( D I . ^ 2 + D O. * D I + D O. ^ 2 ) + A I . * H b i n ;
%The volume total is a combination of the formula for the volume of a
%cylinder for the top combined with the volume of the bottom frustrum.
V R = H T. * R A ;
%The volume of the rathole is calculated by multiplying the bins total height by the ratholes area.
FV=VR./Vtotal;
%The fractional volume of the rathole is calculted by dividing the rathole volume by the total volume.

22

EXAMPLE RATHOLE CALCULATIONS

Assuming a bin with a 10 foot diameter inlet, a cylindrical bin height of
2 5 ft b e f o re t h e c o n i c a l s e c t i o n ,
a b i n a n g l e o f 6 0 d e g re e s f ro m h o r i z o n t a l , a n d a v a r y i n g o u t p u t d i a m e t e r ,
t h i s g r a p h s h o w s t h e e ff e c t o f r a t h o l e s o n f r a c t i o n a l o u t p u t a re a .
As you can see, even small
ratholes cause immediate
d ro p s i n t h e u s a b l e fl o w a re a ,
even when the output diameter
i s v e r y l a rg e ( 1 / 2 i n l e t d i a m e t e r )
While it is not shown, the
fraction of the total volume
t a ke n u p b y t h e s e r a t h o l e s
is very low; the maximum was
just over 20% for a rathole
t h a t w a s 5 ft a c ro s s , o r h a l f
the diameter of the input.
Fo r o u t l e t s t h a t a re s m a l l
fractions of the inlet diameter,
less than 5% of the total volume
will cause near complete loss
o f u s a b l e fl o w a re a
23

JANSSEN CALCULATIONS:

The Janssen equation, as seen in (CITE OTHER POWERPOINT HERE), calculates the
p re s s u re o n a b i n a s a f a c t o r o f b i n m a j o r d i a m e t e r , b i n h e i g h t , g r a v i t y , m a t e r i a l
d e n s i t y , J a n s s e n c o e ffi c i e n t , a n d b i n a n g l e f ro m v e r t i c a l .
* I N S E RT F I G U R E W I T H E Q U AT I O N H E R E *
B u t w h a t i f w e k n o w t h e m a x i m u m p re s s u re o u r b i n c a n s u p p o r t , b u t w a n t t o fi g u re
o u t t h e m i n i m u m d e v i a t i o n f ro m v e r t i c a l o u r b i n c a n s u p p o r t ?
We c a n u s e M a t l a b s f z e ro e s f u n c t i o n , t h e J a n s s e n e q u a t i o n , a n d o u r m a x i m u m
p re s s u re t o s o l v e f o r t h e m i n i m u m a n g l e f ro m v e r t i c a l .

ction AD = Amin(D,H,y,g,K,pmax);
his function calculates the minimum angle from the vertical a hopper must be using the Janssen equation.
he function calculates angle using US units.
We use .8 pmax in our calculations as a safety factor, so that fluctuations during use do not go over our maximum tolera
=Diameter, H=Height, y=density, g=gravitational acceleration
=Janssen coefficient,pmax=max pressure
D is the minimum bin angle from vertical in degrees.
=fzero(@(x) ((y.*g.*D./(4.*tand(x).*K)).*(1-exp(-4.*H.*tand(x).*K./D))-.8.*pmax),45);
his finds the zeroes of an anonymous Janssen function of angle, minus the (practical) pmax.
guesses an intermediate angle of 45 degrees to start.
D>70, error('Pmax is too low to be practical')
eif AD<0,error('Pmax is high enough angle is irrelevant.')
d
hese statements alert you if your Pmax is so low as to be impractical (bin angle nearly horizontal)
r too high to be practical (your bin can support being near completely vertical).
;
24

EXAMPLE JANSSEN
U s i n g o u r J a n s s e n e q u a t i o n f ro m b e f o re , w e c a n s h o w t h e m i n i m u m a n g l e
f ro m v e r t i c a l f o r s o m e ex a m p l e b i n s o f v a r y i n g d i a m e t e r a n d m a x p re s s u re .
O u r ex a m p l e b i n s h a v e a m a t e r i a l o f d e n s i t y 3 5 l b / f t ^ 3 , J a n s s e n
c o e ffi c i e n t o f . 4 , g r a v i t y o f 3 2 . 2 ft / s ^ 2 ,
a n d a c o n s t a n t h e i g h t o f fi f t y f e e t .
Code to generate graphs:
for i=1:325
P(i)=5000+(i-1)*200;
AD1(i)=Amin(14,50,35,32.2,.4,5000+(i-1)*200);
AD2(i)=Amin(12,50,35,32.2,.4,5000+(i-1)*200);
AD3(i)=Amin(10,50,35,32.2,.4,5000+(i-1)*200);
AD4(i)=Amin(8,50,35,32.2,.4,5000+(i-1)*200);
AD5(i)=Amin(6,50,35,32.2,.4,5000+(i-1)*200);
end
%A for loop is required because Matlabs fzero function,
which is used in Amin, does not support using arrays.
plot(P,AD1);hold on;
plot(P,AD2,'r')
plot(P,AD3,'g')
plot(P,AD4,'k')
plot(P,AD5,'c');
xlabel('Absolute Maximum Pressure (psi)')
ylabel('bin angle from vertical (degrees)')
title('Maximum pressure versus angle at various diameters')
legend('D= 14 ft','D= 12 ft','D= 10 ft','D= 8 ft','D= 6 ft')

25

DEVELOPING THE OVERALL BIN

GEOMETRY
A re c t a n g u l a r s t r a i g h t s i d e d s e c t i o n a t t h e t o p o f t h e
b i n i s p re f e rre d o v e r a c i rc u l a r c ro s s - s e c t i o n , b e c a u s e
i t i s e a s i e r t o c o n s t r u c t a n d h a s a l a rg e r c ro s s s e c t i o n a l a re a p e r u n i t h e i g h t .

Rectangular Silo
http://krishnagrainsystems.co.in/Compartmental%20Silo.html

Circular Silo
26

DEVELOPING THE OVERALL BIN

GEOMETRY
H o w e v e r , fl a t w a l l s a re s u s c e p t i b l e t o
b e n d i n g u n l i ke a c y l i n d e r t h a t h a s
h o o p t e n s i o n t h a t c a n s u p p o r t g re a t e r
i n t e rn a l p re s s u re .
The stresses around the wall
balance the internal pressure
across the cross section.

Rectangular shaped bin that

succumbed to overloading.
http://www.efunda.com/formulae/solid_mechanics/mat_mechanics/pressure_ve
ssel.cfm
http://singcore.com/images/MetalCrunched2txt.jpg

Static equilibrium
between the total
hoop stress h and
pressure p.

27

DEVELOPING THE OVERALL BIN

GEOMETRY

Re c t a n g u l a r b i n s a l s o h a v e
c o rn e r s w h e re t h e m a t e r i a l m a y
build up.

http://www.emeraldinsight.com/content_images/fig/1820300201017.png

28

5 Considerations to Have
When Choosing a Hopper

29

HOW MUCH HEADROOM IS

AVAILABLE
Wedge and pyramidal shapes can be made less steep than
conical and transition shapes

10 Steps to an Effective Bin Design Article

30

OUTLET SIZE
Conical hoppers must have an outlet diameter of twice the outlet
width a wedge shaped hopper (provided that the outlet length is 3
times the width) in order to avoid developing cohesive or interlocking
arches during transport. Cones generally require larger feeders

31
http://www.scielo.br/scielo.php?pid=S0100-69162013000300003&script=sci_a

DISCHARGE RATE
Slot outlets generally have a larger cross-sectional area than
circular outlets so they provide larger flowrates

A depiction of various flowrates of

material through a silo
http://www.friedrich-electronic.com/applications/blending/free-flowing-products/

32

SHARP VS ROUND CORNERS

Conical and transition hoppers don't have corners which allows material
build-up. Pyramidal Hoppers cause funnel flow problems because of
their in-flowing valleys which are less steep than the adjacent side
walls.

http://www.chemicalprocessing.com/articles/2002/94/

33

CAPITAL COST:
CONSERVING YOUR CASH
Depending on the shape of your silo, costs will vary many areas. For
instance, wedge shapes require less headroom and thus less material
and money. However, feeders and gate valves for wedge shapes may
be more expensive.

http://24.media.tumblr.com/a51c48a643929194ce44d0594291aaa0/tumblr_mqua3ubkKx1r
jcfxro1_500.gif

34

SELECTING THE OUTLET FEEDER

3 Common Types of Bulk Solids

Feeders

35

SCREW FEEDERS
Use these with hoppers that have elongated outlets. These feeders are
totally enclosed, making them perfect for use with dusty material.
There are few moving parts to manage. The key to an effective screw
feeder design is a tapered cut and an increase in capacity in the
direction of feed.

10 Steps to an Effective Bin Design Article

36

BELT FEEDERS
Belt feeders are good for elongated hopper outlets and great for
handing cohesive and bulk solids that require a high discharge rate.
Theyre not good for handling dusty materials because of the lack
of containment. They can also be equipped to perform gravimetric
operations (weighing the material it transports). The key to a
proper belt feeder is an increasing capacity in the direction feed

10 Steps to an Effective Bin Design Article

37

ROTARY VALVES
These are used with hoppers that have square or circular outlets.
These cannot handle highly cohesive solids, because bridges are
likely to form. Interfaces are used with both these and belt feeders
to ensure that solids are withdrawn uniformly across the entire
hopper outlet. Without this interface, a preferential flow channel
may develop on the side on the side of the hopper outlet, which
results in non-uniform discharge.

Shown above is a rotary valve feeder to the left and a blueprint of

its in workings to the right
http://www.mikropul.com/index.php/products/details/rotary_airlocks

38

OUTLET GATE OR SHUT-OFF VALVE

FUNCTIONAL COMPONENTS

The outlet gate is not needed to regulate fl ow rate, but

instead it should be used for maintenance only. Outlet
gates or valves should be either fully open or fully closed.

This is a slide gate valve

operated pneumatically for
rapid action. These gates can
also be operated hydraulically
for power or electronically for
precision and timing.

http://www.dclinc.com/product-profile/14/19
/
http://www.pneuvay.com.au/images/pneuvay-vortex-abrasive-duty-gate.jpg

39

NUMBER OF OUTLETS
FUNCTIONAL COMPONENTS

Multiple outlets are attractive for production fl exibility, but

they can have severe consequences structurally and from
a fl ow perspective. A single outlet will be enough to fi nish
the desired task of the bin.

CLICK

A single outlet bin will allow for a more structurally sound design,
but it will only permit for production of one material.
http://www.metalfabinc.com/images_pages/bin_acti
v.gif

40

BIN VENT OR DUST COLLECTOR

FUNCTIONAL COMPONENTS

Depending on t he met hod used, an air-s olid separa to r m ay be

needed . Dust part icles are highly explosive in a clos ed area and
need to be remo ved from t he prod uct .

Aftermath of a dust explosion.

High concentrations of dust in a
closed area causes rapid
combustion.

http://media.syracuse.com/news/photo/2010/04/2010-0
4-12-gw-silo004jpg-16f57a8db1f3b6e9_medium.jpg

41

CONSERVATION VENT
FUNCTIONAL COMPONENTS

Needed for thin-walled steel hoppers. These vents help

relieve excess pressure and prevent vacuum conditions
which will cause damage to the structure of the bin.
Cross-section of a conservation vent.

42

http://www.protectoseal.com/vaporFlame/vfVacuumReli

LEVEL DETECTORS
FUNCTIONAL COMPONENTS

Two diff erent types of level

detectors:
Point level detection:
Attached to the side wall or roof of
the bin
Measure solids by direct contact
using capacitance sensors or
pressure diaphragms

Continuous level detection:

Attached to the roof of the bin
Continuous level detector (radar)
Emits radar or ultrasonic signals to
measure the surface of the
material
http://img.directindustry.com/images_di/photo-g/tdr-guided-wave-radar-level-sensors-16712-4346365.jpg 43

MAINTENANCE
FUNCTIONAL COMPONENTS

Acce ss door s

Manways

Poke Holes

Ladders, railways, and platforms: minor details for easy maintenance

These accessories help make the bin accessible for maintenance
and cleaning. These items need to be strategically placed in order
to not hinder the flow rate of the material.
44

METALS

M AT E R I A L O F C O N S T R U C T I O N

Metal silos are made from car bon steel, sta inless steel, or
aluminum. Listed below are some a dva nta ges meta l silos ha ve over
concrete silos:
Flexible fabrication - ca n be constructed in the shop or the fi eld
Sanitary construction metals can be used for food products or
pharmaceuticals
Wide variety of materials ma ny diff erent meta ls exist to crea te
the silo
Construction fl exibility can be constructed in most
environments (freezing precludes concrete construction)

45

CONCRETE

M AT E R I A L O F C O N S T R U C T I O N

Most commonly used for silos with dia meters greater than 9 meters
because it allows for grea ter sta bility when processing larger
volumes of materials. Listed below a re the a dva ntages of a
concrete silo over a meta l silo:
Corrosion resistance require less ma intenance
Resistance to abrasion withstand impact loads better
Withstand internal pressures resist localized buckling
No need for paint corrosion of metal silos will require periodic
repainting
Lower cost for large diameters meta l silos require thicker walls
for large diameters

46

CONCLUSION
This bin design process has been used for the last half century,
and has been able to eff ectively handle bulk solids in
everything from chemical powders to biomass. It is important
to design the bin to meet the needs of the material being
produced or stored in order to maintain effi ciency, but more
importantly safety.
In the future scientists could
develop computer programs
that automatically design bins
based on parameters that you
input yourself such as the type
of bulk solid, the state the
solid is in, and the amount of
solid present.

http://mycomsats.com/blogs/software-engineering-universities-in-pakistan/

47

BIN DESIGN CAN BE EASY SO LONG

AS YOU REMEMBER THESE STEPS
1. Define Storage Requirements
2. Understand Your Bulk Solids Flow
3. Measure Your Materials Flow
Properties
4. Calculate the Size of Your Bin
5. Determine Flow Patterns
6. Design the Hopper's Geometry
7. Develop the Overall Bin Geometry
8. Select the Outlet Feeder
9. Select Other Necessary
Components
10.Choose the Construction Material

48
http://www.cgtrader.com/3d-models/architectural-exterior/industrial/cement-silo-unibeton-79-m3
http://www.wired.com/insights/2013/02/tear-down-old-silo-walls-in-the-new-enterprise/