Bulk Materials Handling Handbook

Bulk Materials Handling Handbook

JACOB FRUCIITBAUM

~ SPRINGER SCIENCE+BUSINESS MEDIA, LLC

Copyright © 1988 by Springer Science+Business Media New York

Originally published by Van Nostrand Reinhold Inc Company Inc. in 1988

Library of Congress Catalog Card Number: 87-20715 ISBN 978-1-4757-4697-6

All rights reserved. No part of this work covered by the copyright hereon may be reproduced or used in any form or by any means-graphic, elec­tronic, or mechanical, including photocopying, recording, taping, or infor­mation storage and retrieval systems-without written pennission of the publisher.

16 IS 14 13 12 II 10 9 8 7 6 5 4 3 2

Library of Congress Cataloging-in-Publication Data Fruchtbaum, Jacob, 1894~

Bulk materials handling handbook / Jacob Fruchtbaum. p. cm.

Includes index.

1. Bulk solids handling-Handbooks, manuals, etc. I. Title. TSISO.S.B8F78 1988 621.S'6-dcI9 87-20715

CIP

ISBN 978-1-4757-4697-6 ISBN 978-1-4757-4695-2 (eBook)DOI 10.1007/978-1-4757-4695-2

Contents

llIustrations Tables Preface

Section 1: Introduction

1.1 Standardization in the Industry, 1 1.2 Computation Standards, 1 1.3 Properties of Materials, 1 1.4 Handling Special Materials, 2 1.5 Properties of Chains Referred to in This

Book, 2 1.6 References, 4

xiii xix

xxiii

1

1.7 Abbreviations, Letter Symbols; SI and Other Equivalents, 4

Section 2: Belt Conveyors

2.1 General, 15 2.2 Information Reqnired for Designing or

Estimating Belt Conveyors, 15 2.3 Angle of Incline, 16 2.4 Belt Conveyor Elements, 17

2.4.1 Belt Characteristics, 17 2.4.2 Rating of Multiple-Ply Belts, 17 2.4.3 Reduced-Ply Belting, 17 2.4.4 Steel Cable Belting, 17 2.4.5 Troughing Empty Belts and Load

Support, 18 2.4.6 Lagging of Pulley, 18 2.4.7 Belt Splices, 18

2.5 Selection of Belt; Size and Spacing of Idlers, 19

2.6 Drive, 22 2.7 Greasing ofIdlers, 23 2.8 Belt Trippers, 23 2.9 Plow Versus Tripper, 25 2.10 Magnetic Pulley, 25 2.11 Skirtboards, 29

15

v

2.12 Training of Belt on Conveyor, 29 2.12.1 Belt-Training Idlers, 30 2.12.2 Training of the Belt Should Be Done

by One Person, 30 2.12.3 CEMA Data, 30

2.13 Weighing Material in Motion, 30 2.13.1 Location of Scale, 31 2.13.2 Weigh Larries, 32

2.14 Shuttle Belt Conveyor, 34 2.15 Pinion-Swivel Arrangement for Foot of Belt

Conveyor, 34 2.16 Troughing and Return Idlers, 34 2.17 Snspended Idlers, 38

2.17.1 Catenary Type, 38 2.17.2 Garland Type, 38

2.18 Belt Cleaners, 39 2.19 Transfer of Material from Belt to Belt, 41 2.20 Takeups and Backstops, 41

2.20.1 Takeups,41 2.20.2 Backstops, 43

2.21 Cover, 43 2.22 Safety Protection at Pulleys, 43 2.23 Tension for Various Layouts, 43 2.24 Recommended Belt Speeds and Belt Widths, 48 2.25 Design of a Belt Conveyor, 48

2.25.1 Data, 50 2.25.2 Belt Tension Method (Using the

CEMA Formulas for Belt Tension), 50 2.25.3 Belt Flexure, 51 2.25.4 Slack Slide Tension (T2)' 55 2.25.5 Pulleys, 56 2.25.6 Graphic Solntion, 57 2.25.7 Jeffrey Formula, 60 2.25.8 Comparison of Methods, 61 2.25.9 Friction Factors, 61 2.25.10 Conveyor Bill of Material, 61 2.25.11 Conveyor Drive Bill of Materials, 61 2.25.12 Alternative Drive Bill of Material, 61

2.26 Belt Conveyor Calculation, 62 2.26.1 Data, 62 2.26.2 Horsepower Calculation, 62 2.26.3 Belt Selection, 63

vi CONTt:NTS

2.26.4 Head Pulley Selection, 63 2.26.5 Tail Pulley Selection, 63 2.26.6 Design of Drive, 63

2.27 Minimum Pulley Diameters for Belts, 63 2.28 Bend, Snub, Takeup, and Tail Pulleys, 63 2.29 Enclosures for Belt Conveyors, 64 2.30 Idler Selection, 64 2.31 Conveyor Belt Troubles, 66 2.32 Selected Nomenclature for Section 2, 66 2.33 Specification for Inclined 30" Belt

Conveyor, 72 2.34 Specification for 24" Shuttle Belt Conveyor, 73 2.35 Specification for 30" Reversible Belt

Conveyor, 73 2.36 Specification for 24" Belt Conveyor, 74

Section 3: Bucket Elevators

3.1 General, 77 3.1.1 Centrifugal-Discharge Bucket

Elevator, 77 3.1.2 Continuous Bucket Elevator, 77 3.1. 3 Positive-Discharge Bucket

Elevator, 77

77

3.1.4 Combination Elevator-Conveyor, 77 3.1.5 Full-Volume or Bulk-Flo Elevator-

3.1.6 3.1.7 3.1.8 3.1.9

Conveyor Unit, 78 Pivoted-Bucket Carrier, 79 Internal-Discharge Elevator, 79 Bucket Elevator on Incline,. 79 Centrifugal vs Continuous-Bucket Elevators, 79

3.1.10 Preliminary Selection of Type, 79 3.2 Casing, 79

3.2.1 Drives, 79 3.2.2 Inspection Doors, 82

3.3 Elevator Pits, 82 3.4 Boot Section, 83 3.5 Head Section, 84 3.6 Platforms and Ladders, 84 3.7 Buckets, 85 3.8 Chain, 87

3.8.1 Service Factor, 89 3.8.2 Recommended Speeds, 89 3.8.3 Chain versus Belt, 89

3.9 Traction Wheels and Sprockets, 89 3.10 Takeups, 90 3.11 Horsepower, 92

3.11.1 Tension on Chain or Belt, 93 3.11.2 Horsepower Allowance, 93

3.12 Standard Designs, 100 3.13 Belts, 100

3.14 Centrifugal-Discharge Bucket Elevators (Vertically Spaced), 100 3.14.1 General, 100 3.14.2 Buckets, 101 3.14.3 Inclined Elevators, 102 3.14.4 Centrifugal-Discharge Elevator

Buckets, 102 3.14.5 Design of Centrifugal-Discharge

Elevator Handling Sand, 103 3.14.6 Design of Centrifugal-Discharge

Elevator Handling Salt, 108 3.14.7 Specification for Vertical Centrifugal­

Discharge Elevator, 109 3.15 Continuous-Bucket Elevators, 110

3.15.1 General, 110 3.15.2 Speed, 110 3.15.3 Buckets, 111 3.15.4 Belts, 111 3.15.5 Types of Continuous Buckets, 111 3.15.6 Design of Continuous-Bucket

Elevator, 111 3.16 Super-Capacity Continuous Bucket

Elevator, 119 3.16.1 General,119 3.16.2 Materials Handled, 119 3.16.3 Guide Angles, 121 3.16.4 Takeups, 121 3.16.5 Specification for Super-Capacity

Elevator, 121 3.16.6 Design of Super-Capacity

Elevator, 122 3.17 Positive-Discharge Bucket Elevator, 123

3.17.1 General, 123 3.17 . 2 Perfect-Discharge Bucket Elevator

Handling Run-of-Mine Bituminous Coal (ROM), 124

3.17.3 Specification for Positive-Discharge Bucket Elevator-Conveyor, 125

3.18 Gravity-Discharge Elevator-Conveyor, 127 3.18.1 General, 127 3.18.2 Design of Gravity-Discharge Elevator­

Conveyor, 127 3.18.3 Specification for Gravity-Discharge

Elevator-Conveyor, 129 3.19 Full-Volume or en Masse Elevator-Conveyor

Unit, 130 3.20 Pivoted Bucket Carrier, 133

3.20.1 General, 133 3.20.2 Strap Chains, 136 3.20.3 Travel Paths, 136 3.20.4 Peck Carrier Capacity and Weight,

136 3.20.5 Cast-Tooth Equalizing Gears, 136

3.21 Selected Abbreviations and Letter Symbols Used in Section 3, 136

Section 4: Screw Conveyors

4.1 General, 139 4.2 Advantages of Screw Conveyor, 139 4.3 Helicoid Versus Sectional Conveyors, 139 4.4 Types of Flights, 140 4.5 Pitch of Conveyor Screw, 140 4.6 Short Feeder Sections, 142 4.7 Supporting Hangers, 142 4.8 Troughs, 142 4.9 Nomenclature, 146 4.10 Handling Food Products, 146

139

4.11 Shafts, Couplings, and Coupling Bolts, 146 4.12 Long Screw Conveyor Design, 146 4.13 Intermediate Hanger Bearings, 148 4.14 End Bearings, 151 4.15 Live Bottom Screw Coverings in Refuse

Bins, 151 4.16 Inclined Screw Conveyors, 151 4.17 Screw Conveyors over 20 Feet Long, 155 4.18 Screw Elevator, 155 4.19 Jacketed Screws, 156 4.20 Overflow Protection, 156 4.21 Screw Conveyor Drive, 158 4.22 Reclaiming Screw Conveyors Handling

Coal, 158 4.23 Carbon-Chip Refuse Screw Conveyors, 159 4.24 Design of a Screw Conveyor Handling

Sulfur, 159 4.24.1 Jeffrey Screw Conveyor, Catalog No.

951, 160 4.24.2 Stephens-Adamson Catalog

No. 66, 161 4.24.3 Link-Belt Catalog 1000, 161 4.24.4 CEMA Formula, 161 4.24.5 Comparison of Results, 162 4.24.6 Final Design, 162 4.24.7 Specifications, 162 4.24.8 Bill of Material, 164 4.24.9 Drive Equipment, 164

4.25 Design of a Screw Conveyor Handling Petroleum Coke, 164 4.25.1 Data, 164 4.25.2 Size of the Conveyor, 165 4.25.3 Horsepower, 165 4.25.4 Drive, 166 4.25.5 End Thrust, 166

CONTENTS vii

4.26 Screw Conveyor Handling Petroleum Coke, Screw Free of Hangers, 166 4.26.1 Data, 166 4.26.2 Size of the Conveyor, 167 4.26.3 Horsepower, 167 4.26.4 Deflection, 167 4.26.5 Components, 168 4.26.6 Finishes, 168

4.27 Lump Size Limitations, 168 4.28 Safety, 170

Section 5: Apron and Mold Conveyors

5.1 General, 171 5.2 No-Leak Types, 171 5.3 Heavy Ores and Large Lumps, 171 5.4 Data on Apron Conveyors, 174 5.5 Selection of Apron, 174 5.6 Design of Apron Conveyor, 174

5.6.1 General Data, 174 5.6.2 Capacity, 174 5.6.3 Horsepower, 175 5.6.4 Size of Head Shaft, 177 5.6.5 Drive Layout, 179 5.6.6 Inclined Conveyor, 180

5.7 Leakproof Conveyors, 181 5.8 Handling Heavy Material, 182

171

5.9 Apron Conveyor with Horizontal and Inclined Sections, 182

5.10 Design of Apron Conveyor with Horizontal and Inclined Sections, 183 5.10.1 Data, 183 5.10.2 Capacity, 184 5.10.3 Loads, 184 5.10.4 Motor Selection, 184 5.10.5 Head Shaft, 184 5.10.6 Layout of Drive, 184

5.11 Hinged-Steel Belt Conveyors, 184 5.12 Flat-Plate Conveyors, 185 5.13 Open-Top Deep-Bucket Carrier, 185 5.14 Cooling and Mold Conveyors, 186 5.15 Coal-Handling System, 187 5.16 Specification for 24-Inch Steel-Apron

Conveyor, 189

Section 6: flight and Drag Conveyors

6.1 General, 193 6.2 Uses, 193

193

viii CONTENTS

6.3 Single-Strand Flight Conveyors, 193 6.4 Double-Strand Flight Conveyor with Roller­

Suspended Flights, 193 6.5 Drag Conveyors, 194 6.6 Selection of a Scraper Flight

Conveyor, 197 6.6.1 Data, 197 6.6.2 Size Selection of Flights, 197

6.7 Design of a Double-Strand Scraper Conveyor, 197 6.7.1 General Data, 197 6.7.2 Considerations; 197 6.7.3 Capacity, 198 6.7.4 Horsepower, 200

6.8 Design of a Drag Conveyor, 201 6.8.1 Data, 201 6.8.2 Size of Trough, 201 6.8.3 Head Shaft, 201 6.8.4 Horsepower, 202 6.8.5 Design of Drive, 202 6.8.6 Bill of Material, 202

6.9 Scraper Flight Conveyors in a Cannery, 203 6.10 Loading Bales of Scrap into Railroad Cars

Directly from Baling Machine, 203 6.11 Drag and Scraper Flight Conveyors in a Pulp,

Paper, and Saw Mill, 203 6.12 Standard Method of Handling Logs by Chain

(Scraper) Conveyors, 206 6.13 Cable Drag Scraper (Power Hoe), 206 6.14 Design of Cylinder Conveyor, 207

6.14.1 Data, 207 6.14.2 Rolling Friction (rf) of Chain, 207 6.14.3 Load on Run A, 207 6.14.4 Load on Run B, 207 6.14.5 Load on Run C, 208 6.14.6 Load on Run D, 208 6.14.7 Total Pull at Head Shaft, 208 6.14.8 Rechecking Conveyor Chain

Strength, 208 6.14.9 Horsepower, 208 6. 14.10 Size of Head Shaft, 208

6.15 Specification for Chain Drag Conveyor, 208

Section 7: Feeders and Vibrating Conveyors 211

7.1 General-Feeders, 211 7.2 Reciprocating Feeders, 211

7.2.1 Space for Reciprocating Feeder, 211 7.2.2 Capacity of Reciprocating Feeder, 212

7.3 Belt Feeders, 215 7.3.1 Material Handled, 215 7.3.2 Belt Feeders Under Dump

Hoppers, 215

7.4 Apron Feeders, 215 7.4.1 Handling Considerations, 215 7.4.2 Open-Top Deep-Bucket Carrier, 215

7.5 Design of Apron Feeder, 217 7.5.1 Horsepower, 217 7.5.2 Size of Head Shaft, 217 7.5.3 Capacity,217 7.5.4 Details, 218

7.6 Bill of Material, 218 7.7 Design of No-Leak Type Apron Feeder, 219

7.7.1 Data, 219 7.7.2 Actual Capacity, 219 7.7.3 Horsepower at Head Shaft, 219

7.8 Selection of Type, 221 7.9 Rotary Table Feeder, 221 7.10 Screw Feeders, 222 7.11 Mechanical Vibrating Feeders, 222 7.12 Vibrating Feeders-Electromagnetic and

Electromechanical, 225 7.12.1 General,225 7.12.2 Design Options, 225 7.12.3 Bulk Materials, 225 7.12.4 Typical Designs, 225 7.12.5 Capacity Calculations, 225

7.13 Bar Scraper Feeders, 229 7.14 Weigh Feeders, 229 7.15 Sizing Apron Feeder under Track Hopper, 231

7.15.1 Data, 231 7.15.2 Design, 231

7.16 Rotary Feed Valves, 231 7.17 Car Loading Devices, 232 7.18 General-Vibrating (Oscillating)

Conveyors, 232 7.19 Light-Duty Oscillating Conveyors (Up to 25

Tons per Hour), 232 7.20 Medium- and Heavy-Duty Oscillating

Conveyors, 235 7.21 Natural Frequency, 236 7.22 Supports, 236 7.23 Isolating Conveyor, 236 7.24 Maintenance, 236 7.25 Vibrating Drum Packers (Vibrating

Tables), 236 7.25.1 General, 236 7.25.2 Partial Specification, 236

Section 8: Wire Mesh Conveyors

8.1 General, 237 8.2 Heat-Resisting Alloy Belts, 237 8.3 Types of Wire Belts, 237 8.4 ANSI Chain Numbers, 237

237

Section 9: Drives 243

9.1 Speed Reducers. 243 9.2 Shaft Couplings, 243 9.3 Drives, 243 9.4 Torque Limiters, 246 9.5 Drive Selection, 246 9.6 Selection of Shafts Subject to Torsion and

Bending, 247 9.7 Drive Guards, 251 9.8 Selection of Type of V-Belt, 251 9.9 Chain for Drives, 253 9.10 Sprockets for Roller Chain Drives, 253

Section 10: Crushers and Screens 255

10.1 Introduction to Crushers, 255 10.2 Selection of Crushers, 255 10.3 Hammermills (Swing Hammermills), 255

10.3.1 High-Speed Hammermills, 257 10.3.2 Slow-Speed Hammermills, 257

10.4 Introduction to Roll Crushers, 257 10.5 Single-Roll Crushers, 257 10.6 Double-Roll Crushers, 258

10.6.1 Maximum Feed Size, 258 10.6.2 Maximum Feed Summary, 258

10.7 Bradford Breakers, 259 10.8 Jaw and Gyratory Crushers, 259 10.9 Raymond Mill, 261

10.9.1 CO2 System, 262 10.9.2 Flue Gas, 263 10.9.3 Other Raymond Machines, 264

10.10 Computation of Horsepower Required for Gyratory Crushers, 264 10.10. 1 General, 264 10.10.2 Design Formula, 264 10.10.3 Design Example, 264 10.10.4 Impact Testing, 266 10.10.5 Product Analysis of A-C Gyratory

Crusher, 266 10.10.6 Examples of Use of Figure 10.8, 268

10.11 Gundlach Crushers (Rexnord), 268 10.12 Introduction to Screens, 269 10.13 Fine Materials, 269 10.14 Vibrating Screens, 269 10 .15 Tyler Screens, 269 10.16 Exolon Screens, 269 10.17 Allis-Chalmers Vibrating Screens, 271 10.18 Simplicity Vibrating Screens, 273 10.19 Rotex Screens, 273 10.20 Magnetic Separators, 274 10.21 Size of Screen, 274 10.22 Specification for Sifter Screen, 274

CONTENTS ix

10.23 Typical Industrial Screen Requisition, 275 10.24 Blinding and Plugging, 275 10.25 Water Screens, 276

10.25.1 General, 276 10.25.2 Protection ofIntake, 276 10.25.3 Flow Through Water Screen, 276 10.25.4 Loss of Head, 276 10.25.5 Spray of Nozzles, 278 10.25.6 Accumulated Sand, 278

10.26 Screen in Laboratories, 278

Section 11: Skip Hoists 279

ILl General, 279 11.2 Types, 279 11.3 Loading Methods, 279 11.4 Manual Loading-Direct Type, 280 11.5 Manual Loading-Indirect Type, 280 11. 6 Full Bucket Control System, 280 11.7 Balanced Skip Hoist, 281 11.8 Materials Handled, 281 11. 9 Selection of a Skip Hoist, 281 11.10 Specification of a Vertical-Lift Drum

Conveyor, 281

Section 12: Hoists and Cranes

12.1 General, 283 12.2 Hoists, 283

12.2.1 Hoist Sheaves and Cables, 283 12.2.2 Hoists on Traveling Bridges, 284 12.2.3 Hoists-Electrical, 284

12.3 Swinging Jib Cranes, 284 12.4 Gantry Cranes, 284 12.5 Crane Classification, 284 12.6 Conventional Overhead Cranes: Two

Types, 286 12.6.1 Dimensions, 287 12.6.2 Diagram Notes, 287

283

12.6.3 Bridge, Trolley, and Hoist Speeds for Table 12.2, 299

12.6.4 Notes for Tables 12.3 and 12.4, 299 12.7 Auxiliary Hooks, 299 12.8 Speed of Travel, 299 12.9 Selection of Crane Rail, 299 12.10 Explosion-Proof Areas, 299 12.11 Specifications, 299 12.12 Monorail Systems, 300 12.13 Overhead Trolley Conveyors, 300

12.13.1 Uses, 303 12.13.2 Chain and Trolley, 303

x CONTENTS

12.13.3 Power and Free Trolley Conveyors, 304

12.13.4 Floor Conveyors, 304 12.13.5 Design Data for Overhead Trolley

Conveyors, 304 12.14 Number of Cranes, 304 12.15 Aerial Cableways, 305 12.16 35/l5-Ton Radwaste Handling Crane, 306

Section 13: Gates, Chutes, and Spouts; Bins and Hoppers 307

13.1 Introduction to Gates, Chutes, and Spouts, 307 13 .1.1 Types of Gates, 307 13.1.2 Linings, 307

13.2 Feeding More Than One Location, 307 13.3 Flexible Spouts, 314 13.4 Introduction to Bins and Hoppers, 315 13.5 Types of Bins and siios, 316 13.6 Track or Truck Hoppers, 320 13.7 Weigh (Scale) Hoppers, 320 13.8 Hopper Spouts, 320 13.9 Storing Hot or Cold Covered Material, 320 13.10 Bin Accessories, 324

Section 14: Handling Special Materials

14.1 General, 327 14.2 Ashes, 327 14.3 Bauxite Ore, 328 14.4 Carborundum, 329 14.5 Carbon Chip Refuse, 329 14.6 Cement, 329 14.7 Charcoal, 333 14.8 Chrome Ore, 333 14.9 Coal, 334 14.10 Coke, 339 14.11 Crushed Ice, 340 14.12 Crushed Stone (Limestone-Dolomite), 340 14.13 Explosive Materials, 342 14.14 Feed, Flour, and Grain, 351 14.15 Foundry Sand-Green Sand Molding, 353 14.16 Graphite, 354 14.17 Gypsum, 354 14.18 Lead and Zinc Ores, 357 14.19 Lime, 357

14.19.1 Apron Conveyor Design, 358 14.19.2 Horsepower at Head Shaft, 358

14.20 Logs, 359 14.21 Metallurgical Coke, 359 14.22 Pencil Pitch, 360

327

14.23 Perlite and Expanded Perlite, 360 14.24 Petroleum Coke, 360 14.25 Plastic (Fine) Material, 362 14.26 Rice, 362 14.27 Salt (Mineral-Halite), 362 14.28 Sand and Gravel, 365 14.29 Shale, Kaolin (Clay), 366 14.30 Soapstone, Talc, Asbestos, and Mica, 366 14.31 Soda Ash, 367 14.32 Steel or Cast-Iron Chips, 367 14.33 Sulfur, 369 14.34 Wood: Chips, Flour, and Sawdust, 370 14.35 Zirconium, 375

Section 15: Overhead and Portable Car Shakers

15.1 General, 377 15.2 Noise, 377 15.3 Heating Cars, 377 15.4 Hewitt-Robins Shakers, 377 15.5 Allis-Chalmers Car Shakers, 379 15.6 Portable Vibrators, 379 15.7 Large-Scale Car Unloaders, 379

Section 16: Heating, Cooling, and Ventilating Furnace Buildings

16.1 General-Heating and Cooling, 381 16.2 Types, 381 16.3 Cooling of Lime, 381

16.3.1 Data, 381 16.3.2 Cooling Air Requirements, 383

16.4 Requisition for Coke Dryer, 383 16.5 Design of Coke Dryer, 383

16.5.1 Data,.383 16.5.2 Internal Heat Required, 384 16.5.3 Required Air, 384 16.5.4 Thermal Efficiency, 384 16.5.5 Inlet Air, 384 16.5.6 Exhaust Air, 385 16.5.7 Furnace Heat Required, 385

16.6 Operation of the Roto-Louvre, 385 16.7 Heating Material in Bins, 385

16.7.1 General,385 16.7.2 Volumes and Areas, 387 16.7.3 Properties, 387 16.7.4 Heat Transfer Equations, 388 16.7.5 Sample Computations for

Section 1, 389 16.7.6 Details of Bin Design, 390

377

381

16.7.7 Nomenclature for Paragraph 16.7,392

16.S General-Ventilation, 392 16.9 Check of Building Ventilation, 393

16.9.1 Object, 393 16.9.2 Data, 393 16.9.3 Ventilation Arrangement, 393 16.9.4 Heat Content of the Discharged

Air, 393 16.9.5 Evaluation of the Pressure Differential

for Air Flow, 395 16.10 Calculation of the Flow Rate, 398

16.10.1 Case 1: NW Wind at 6 mph, 39S 16.10.2 Other Cases, 401

16.11 Computer Program for Calculations of Ventilation, 401

16.12 Design of Cupola Exit Gas Scrubber, 401 16.12.1 Data, 407 16.12.2 Physical Constants, 407 16.12.3 Cupola Exit Gases, 407 16.12.4 Air Required, 407 16.12.5 Temperature of Cupola Exit Gas, 40S 16.12.6 Size of Scrubber Shell, 40S 16.12.7 Water Requirements, 409

Section 17: Package Handling Conveyors

17.1 General, 411 17.2 Roller Conveyors, 411 17.3 Basic Conveyor Bearing Load Rating, 411 17.4 Spacing of Rollers, 412 17.5 Weight of Rollers, 412 17.6 Curves, 413 17.7 Transfers, 413 17.S Bearings,414 17 . 9 Gravity Rollers (Nonpowered), 414

17.9.1 General, 414 17.9.2 Grade, 414 17.9.3 Curves, 415

17.10 Package Belt Conveyors, 415 17.10.1 General, 415 17.10.2 Roller Type, 415 17.10.3 Slider Type, 415

411

17.10.4 Inclined Package Belt Conveyor, 415 17.10.5 Package Configuration, 415 17.10.6 Transfers, 415 17.10.7 Frames, 416

17.11 Belt- and Chain-Driven Roller Conveyors, 416 17.11.1 General, 416 17.11.2 Cross-Sections, Chain Arrangements,

and Ball Transfer Beds, 417 17 .11.3 Pressure Rollers for Belt-Driven

Conveyors, 417

CONTENTS xi

17.11.4 Design of Chain-Driven Live Roller (Roller-to-Roller Chain Drive) Conveyor, 417

17.12 Roller and Shaft Deflection, 419 17.13 Airport Baggage Conveyors, 421 17 .14 Bag Filling, 421 17.15 Handling of Pallets, 421 17.16 Chain Pull, 421

17.16.1 Level or Inclined Slat, Apron, or Sliding Conveyors, 421

17.16.2 Vertical Chain or Suspended Tray Conveyors, 421

17.16.3 Allowable Chain Pull-Max Unit Load, 421

17.17 Drives, 421 17.1S Specification for Vertical Lift Drum

Conveyor, 424 17.1S.1 Work to Be Perfonned by Others, 426 17.1S.2 Equipment to Be Provided by

Contractor, 426 17 .19 Comparison with Belt Conveyors, 427

Section 18: Pneumatic Conveying 429

IS. 1 General, 429 IS.2 Design of System, 429

IS.2.1 General Data, 429 IS.2.2 Buffalo Forge Company's Fan

Engineering Method, 429 18.2.3 Analysis of Results, 434

IS.3 High-Pressure Systems, 434 IS.3.1 General, 434 IS.3.2 Friction, 435 18.3.3 Efficiency, 435

18.4 Airslide, 435 IS.5 Adaptation, 437 18.6 Comparison of Methods, 438

18.6.1 Advantages of Dense Phase over Dilute Phase, 438

18.6.2 Limitations of Dense Phase, 438

Section 19: Dust Collection 439

19.1 General, 439 19.2 Sound Testing and Occupational Noise

Exposure, 442 19.3 Details of Dust Collection Inlets, 442 19.4 Design of Problem on Figure 19.2,447

19.4.1 Data for Design, 447 19.4.2 Capture Velocities, 447 19.4.3 Cfm Required, 453 19.4.4 Design Procedure, 453

xii CONTENTS

19.4.5 Balancing System Without Use of Blast Gates, 456

19.5 Dust Collectors and Selection, 457 19.5.1 Fabric Filter Collectors, 457 19.5.2 Intermittent-Duty Fabric

Collectors, 457 19;5.3 Multiple-Section, Continuous-Duty,

Automatic Fabric Collectors, 459 19.5.4 Reverse-Pulse, Continuous-Duty

Fabric Collectors, 460 19.5.5 Removal of Dust, 460

Section 20: Layout of a Material Handling Plant 461

20.1 General, 461 20.2 Unloading Material, 461 20.3 Dryers and Coolers, 461 20.4 Screening, 462 20.5 Storage, 462 20.6 Entering Process, 462 20.7 Duplicating Equipment, 462 20.8 Bypassing Equipment, 462

20.9 Sampling Material, 462 20.10 Interconnection of Equipment, 462 20.11 Controls, 464

20.11.1 General, 464 20.11.2 Types of Control, 464 20.11.3 Emergency Stops, 464 20.11.4 Availability of Controls, 464

20.12 Layout of a Plant, 464 20.12.1 Explanation of Diagrams, 464 20.12.2 Material Flow, 464

20.13 Electrical Control for a Material-Handling System, 467 20.13.1 General, 467 20.13.2 Reliability, 467 20.13.3 Ease of Maintenance, 470 20.13.4 Competitive Low Cost, 470 20.13.5 Operating Instructions for Conveyors,

Crushers, and Storage-Bin Systems, 470

20.13.6 Equipment List, 470

Index 473

Illustrations

Section 2: Belt Conveyors

Figure 2.1 Cross-section of belt conveyors, 16 Figure 2.2 Lagging of a pulley, 18 Figure 2.3 Vulcanized joint, 18 Figure 2.4 Mechanical joints, 18 Figure 2.5 Arrangement of a cable-propelled belt

tripper, 26 Figure 2.6 A movable belt plow, 27 Figure 2.7 Standard-type arrangement of a magnetic

pulley, 28 Figure 2.8 Magnetic pulleys, 28 Figure 2.9 Skirtboard details for a 24-in. belt, 29 Figure 2.10 Troughed idlers, 31 Figure 2.11 Location of the scale, 31 Figure 2.12 Shimming of idlers, 31 Figure 2.13 Weigh larry, 33 Figure 2.14 Shuttle belt conveyor diagram, 34 Figure 2.15 Shuttle belt conveyor, 35 Figure 2.16 Outdoor ore storage system using a

traveling wing tripper and shuttle belt, 36 Figure 2.17 Details of a 30-in. belt-conveyor

pinion, 37 Figure 2.18 Catenary-type suspended idler, 38 Figure 2.19 Belt cleaner, 39 Figure 2.20 Arrangement of a belt scraper, 40 Figure 2.21 Transfer from belt to belt, 41 Figure 2.22 Takeups, 42 Figure 2.23 Nip guard, 42 Figure 2.24 Head pulley drive-horizontal or

elevating, 43 Figure 2.25 Head pulley drive-lowering without

regeneration, 44 Figure 2.26 Head pulley drive-lowering with

regeneration, 44 Figure 2.27 Tail pulley drive-horizontal or

elevating, 45 Figure 2.28 Tail pulley drive-lowering without

regeneration, 45 Figure 2.29 Tail pulley drive-lowering with

regeneration, 46 Figure 2.30 Drive on return run-horizontal or

elevating, 46

xiii

Figure 2.31 Drive on return run-lowering without regeneration, 47

Figure 2.32 Drive on return run-lowering with regeneration, 47

Figure 2.33 Design diagram of a belt conveyor, 50 Figure 2.34 Horsepower required to drive an empty

conveyor, 58 Figure 2.35 Horsepower required to elevate

material, 59 Figure 2.36 Horsepower required to convey material

horizontally, 59 Figure 2.37 Diagram of a belt conveyor alternative

drive, 62 Figure 2.38 Jeffrey design belt conveyor, drive

diagram, 64 Figure 2.39 An 8-ft tubular steel gallery supporting a

belt conveyor, 65

Section 3: Bucket Elevators

Figure 3.1 A typical elevator, 78 Figure 3.2 Arrangement of intermediate dust-tight

casing section, 81 Figure 3.3 Detail of a typical inspection door, 82 Figure 3.4 Venting-type inspection door, 83 Figure 3.5 Head section with the head takeup drive

supported on the casing, 84 Figure 3.6 Dust-tight construction of the head section

and hood arrangement, 85 Figure 3.7 Head shaft dust seal, 86 Figure 3.8 Elevator platform, 86 Figure 3.9 Alternating buckets, 87 Figure 3.10 Detail of a split sprocket, 90 Figure 3.11 Details of a centrifugal-discharge

elevator, 90 Figure 3.12 Arrangement of a gravity takeup inside a

20-in. wide casing, 91 Figure 3.13 Arrangement of an elevator boot for a

gravity takeup, 92 Figure 3.14 Headshaft equipped with a backstop, 93 Figure 3.15 Centrifugal-discharge chain

elevator, 100

xlv ILLUSTRA TIONS

Figure 3.16 Detail at a sprocket, 109 Figure 3.17 A standard loading leg bucket

elevator, 112 Figure 3.18 Tail shaft loads, 117 Figure 3.19 Head shaft loads, 118 Figure 3.20 Head shaft layout for a super-capacity

elevator, 123 Figure 3.21 Bucket attachments, 124 Figure 3.22 Two buckets on a single strand of

chain, 124 Figure 3.23 Inclined perfect-discharge elevator, 125 Figure 3.24 Perfect-discharge bucket on a double

strand of chain, 126 -Figure 3.25 Gravity-discharge elevator, 127 Figure 3.26 Gravity-discharge conveyor-elevator,

129 Figure 3.27 Full-volume elevator, 131 Figure 3.28 Cross-section of en masse elevators, 132 Figure 3.29 Detail of a Peck carrier, 133 Figure 3.30 Strap chains for pivoted-bucket

carriers, 134 Figure 3.31 Typical arrangements of pivoted-bucket

carriers, 135 Figure 3.32 Cast-tooth equalizing gears, 136

Section 4: Screw Conveyors

Figure 4.1 A typical screw conveyor, 140 Figure 4.2 Types of conveyor screws, 141 Figure 4.3 Types of screw conveyor pitch, i41 Figure 4.4 Hangers and troughs, 144 Figure 4.5 One possible design of a slide gate at the

side inlet of a 9-in. screw conveyor, 145 Figure 4.6 Hip-top cover, 144 Figure 4.7 Breaking up a long run of a 14-in.

conveyor, 149 Figure 4.8 A screw conveyor feeding into an inclined

screw conveyor, 150 Figure 4.9 Detail of pedestal-type end bearings for

16H616 helicoid spiral conveyor, 152 Figure 4.10 Cross conveyor, 153 Figure 4.11 Inclined screw conveyors, 153 Figure 4.12 Inclined screw conveyor capacity

chart, 154 Figure 4.13 Support at a coupling, 156 Figure 4.14 Overflow chute, 156 Figure 4.15 Protection against overflow, 157 Figure 4.16 A reclaiming scew conveyor, 158 Figure 4.17 Carbon chip screw conveyor, 159 Figure 4.18 Sulfur screw conveyor, 160 Figure 4.19 An inclined screw conveyor handling

sulfur, 163

Figure 4.20 A chart for the values of factor Fa> 165 Figure 4.21 Elevation of a screw conveyor, 167 Figure 4.22 Drive machinery, 168

Section 5: Apron and Mold Conveyors

Figure 5.1 Heavy-duty no-leak apron, 172 Figure 5.2 Section A-A (from fig. 5.1) through the

heavy apron, 173 Figure 5.3 Assembly of chain-suporting rollers and

pans on a standard no-leak apron, 173 Figure 5.4 A 30-in. apron conveyor, 174 Figure 5.5 Diagram of the designed conveyor, 179 Figure 5.6 Diagram of the head shaft of the designed

conveyor, 179 Figure 5.7 Schematic of an apron conveyor

drive, 180 Figure 5.8 Bearing detail, 181 Figure 5.9 A 30-in. wide apron handling ferro­

alloys, 182 Figure 5.10 Cross-section of an apron at the loading

bin, 183 Figure 5.11 Loading sketch, 183 Figure 5.12 Diagram of the designed conveyor, 184 Figure 5.13 Apron conveyor drive diagram, 185 Figure 5.14 Mayfran's hinged-steel belt conveyor,

185 Figure 5.15 Stearns baggage conveyor, 186 Figure 5.16 An open-top carrier, 187 Figure 5.17 An apron cooling conveyor handling

carbide cakes, 188 Figure 5.18 A mold conveyor handling aluminum

alloy ingots from a furnace, 189 Figure 5.19 Section A-A (from fig. 5.18) through the

mold conveyor, 189 Figure 5.20 A 30-in. wide apron conveyor handling

material for cooling or cleaning, 190 Figure 5.21 Details of a 42-in. wide shuttle cast-steel

apron conveyor, 190 Figure 5.22 Coal-handling system, 191

Section 6: flight and Drag Conveyors

Figure 6.1 Popular types of flight conveyors, 194 Figure 6.2 A single-strand flight conveyor with shoe­

suspended flights, 195 Figure 6.3 A double-strand flight conveyor with

roller-suspended flights, 195 Figure 6.4 A bar scraper feeder carrying coal from

the hopper to the elevator drag conveyor in a boiler plant, 196

Figure 6.5 A drag conveyor handling ashes just below the floor in a boiler plant, 196

Figure 6.6 A double-strand scraper conveyor, 198 Figure 6.7 A section through the pit of a scraper

conveyor, 199 Figure 6.8 Scraper conveyors, 199 Figure 6.9 Trough details, 201 Figure 6.10 Details of steel chain for double-strand

flight conveyor with roller-suspended flights, 202 Figure 6.11 Drive diagram of drag conveyor, 203 Figure 6.12 A steel bales conveyor, 204 Figure 6.13 A log conveyor, 205 Figure 6.14 Arrangement of a cylinder conveyor

chain drive, 206

Section 7: Feeders and Vibrating Conveyors

Figure 7.1 Typical arrangement of a track hopper and reciprocating feeder handling bulk material, 212

Figure 7.2 Arrangement for a reciprocating feeder, 213

Figure 7.3 Belt feeder under a dump hopper, 214 Figure 7.4 Chrome ore apron feeders, 216 Figure 7.5 Diagram of an apron feeder, 217 Figure 7.6 Head shaft diagram, 217 Figure 7.7 Apron feeder drive diagram, 218 Figure 7.8 Typical cross-section of a 24-in. no-leak

apron feeder with a double strand of RS-953 chain, 220

Figure 7.9 Diagram of no-leak apron feeder, 221 Figure 7.10 No-leak apron feeder drive diagram, 221 Figure 7.11 Cross-section of a rotary table

feeder, 222 Figure 7.12 Plan view of a rotary table feeder, 223 Figure 7.13 A reclaim screw feeder with 9-in. screw

feeders, 223 Figure 7.14 A short screw feeder, 224 Figure 7.15 Details of a vibrating feeder, 226 Figure 7.16 Electromagnetic and electromechanical

vibrating feeders, 227 Figure 7.17 Minimum gate openings, 228 Figure 7.18 Limestone feeder gate opening, 228 Figure 7.19 Sand and gravel feeder gate

opening, 229 Figure 7.20 Arrangement of a shallow track hopper

with bar feeder, 230 Figure 7.21 Cross-section of a bar feeder through a

shallow track hopper, 230

ILLUSTRA TlONS xv

Figure 7.22 Cross-section and plan of track 'hopper, 231

Figure 7.23 Oscillating conveyors, 233 Figure 7.24 Link-Belt vibrating conveyor, 235

Section 8: Wire Mesh Conveyors

Figure 8.1 Design calculation parameters, 239

Section 9: Drives

Figure 9.1 Typical drive details, 244 Figure 9.2 Typical screw conveyor drive, 246 Figure 9.3 Selection of shafts subject to torsion and

bending, 249 Figure 9.4 Chain drive guards, 250 Figure 9.5 Typical chain drives, 252

Section 10: Crushers and Screens

Figure 10.1 Basic hammer types, 256 Figure 10.2 Roll crushers, 257 Figure 10.3 Bradford breakers, 259 Figure 10.4 KVS primary gyratory crushers, 261 Figure 10.5 Section of a high-side Raymond

mill, 261 Figure 10.6 Raymond mill handling explosive

material, 262 Figure 10.7 Allis-Chalmers primary gyratory

crusher, 264 Figure 10.8 Primary crusher-product analysis, 267 Figure 10.9 Arrangement of a suspension-mounted

vibrating screen, 270 Figure 10.10 Arrangement of a fioor-mounted

vibrating screen, 271 Figure 10.11 Discharge chute for a two-surface

vibrating screen, 272 Figure 10.12 Rotex screen, 274 Figure 10.13 Vertical section through a screen well

based on using 24-in. pitch elevator chain, 276 Figure 10.14 Section at a wall, 278

Section 11: Skip Hoists

Figure 11.1 Manual loading, 280

xvi ILLUSTRATIONS

12: Hoists and Cranes

Figure 12.1 P&H Hevi-Lift hoists, 284 Figure 12.2 Jib crane, 286 Figure 12.3 Gantry cranes, 286 Figure 12.4 Underhung crane, 287 Figure 12.5 A pendant-operated crane, 287 Figure 12.6 A cab-operated crane, 288 Figure 12.7 Cab-controlled overhead cranes with two

trolleys, 288 Figure 12.8 A coil-handling overhead trolley for wire

cleaning and coating tanks, 303 Figure 12.9 Chains 458 and 678, 304 Figure 12.10 A 35/15-ton radwaste crane, 305

Section 13: Gates, Chutes, and Spouts; Bins and Hoppers

Figure 13.1 Typical gates, 308 Figure 13.2 Flop gate detail, 309 Figure 13.3 Swivel spout with viewing ports, 310 Figure 13.4 Distributor spout assembly, 311 Figure 13.5 Swivel spout details, 312 Figure 13.6 A bucket elevator feeding five bins, 313 Figure 13.7 Chutes under vibrating screens, 314 Figure 13.8 Types of flexible joints for chutes, 315 Figure 13.9 Details of a typical spreader, 316 Figure 13.10 Rectangular steel bins, 317 Figure 13.11 Precast silos, 318 Figure 13.12 A scale hopper, 319 Figure 13.13 Weigh hopper wiring details, 320 Figure 13.14 Hand-operated slide gates in concrete

bins, 321 Figure 13.15 Details of a hopper spout, 322 Figure 13.16 Detail of a typical hopper gate, 323 Figure 13 .17 A circular bin storing hot material, 324 Figure 13.18 Details at the top of a bin, 325

Section 14: Handling Special Materials

Figure 14.1 An expansion detail, 330 Figure 14.2 A swinging baffle plate, 330 Figure 14.3 Floating expansion-type larger hangers

for cement and lime products over 150°F, 330 Figure 14.4 Floating expansion-type small hangers

for cement and lime products over 150°F, 331 Figure 14.5 Carryover of cement at a head

sprocket, 331 Figure 14.6 A cement elevator head, 331 Figure 14.7 A drag-chain conveyor for gypsum, 332 Figure 14.8 Bearing space, 334

Figure 14.9 Plan of a coal-handling plant, 336 Figure 14.10 A typical coal-handling system, 337 Figure 14.11 An apron conveyor at a coal

hopper, 338 Figure 14.12 An inclined-screw coal feeder, 339 Figure 14.13 Flow diagram of a crushed stone

plant, 341 Figure 14.14 A cross-section of a 60-in. wide heavy-

duty rock apron feeder, 341 Figure 14.15 Diagonal spacing of rail, 342 Figure 14.16 Flare of a feeder at a dump hopper, 342 Figure 14.17 A heavy-duty rock feeder, 343 Figure 14.18 An elevator handling explosive

material, 344 Figure 14.19 A container-dumping guide, 345 Figure 14.20 Details of a container holder, 346 Figure 14.21 A vibrating conveyor for plastic, 349 Figure 14.22 Electrical control diagrams for figures

14.19, 14.20, and 14.21, 350 Figure 14.23 A lagged wing pulley, 352 Figure 14.24 A foundry sand hopper over a molding

machine, 353 Figure 14.25 Layout of two drag conveyors in the

flat bottom of a silo, 356 Figure 14.26 Details of a conveyor for lime

hydrate, 358 Figure 14.27 Arrangement of a screw feeder under

track (typical for fine granular material), 361 Figure 14.28 An open storage tank for brine, 364 Figure 14.29 Arrangement of a drive for a steel-chip

conveyor, 369 Figure 14.30 Sawdust hoppers, 371 Figure 14.31 A system for handling wood chips, 372 Figure 14.32 An apron feeder for handling a mixture

of steel scrap and wood chips, 373 Figure 14.33 A drag conveyor for unloading wood

chips, 374

Section 15: Overhead and Portable Car Shakers

Figure 15.1 Car shakers, 378 Figure 15.2 A-C car-shaker hoist with trolley, 379

Section 16: Heating, Cooling, and Ventilating Furnace Buildings

Figure 16.1 A dust collection system at a cooler, 382 Figure 16.2 Layout of a coke dryer, 385 Figure 16.3 The Roto-Louvre, 386 Figure 16.4 Operation of the Roto-Louvre, 386 Figure 16.5 Heat diagram, 387

Figure 16.6 Heat transfer, 388 Figure 16.7 Details of a bin design, 391 Figure 16.8 Plan and section of a furnace

building, 394 Figure 16.9 Investigation of wind pressures on a

building, 396 Figure 16.10 Values of k in percentage of P W' 397 Figure 16.11 A computer program for building

ventilation requirements, 402 Figure 16.12 Scrubber details, 406

Section 17: Package Handling Conveyors

Figure 17. 1 Setting of rollers on angle frame rails, 411

Figure 17.2 Curves, 414 Figure 17.3 Slope of packages, 416 Figure 17.4 Transfer, 416 Figure 17.5 Belt- and chain-drive cross-sections, 418 Figure 17.6 Types of chain arrangements, 418 Figure 17.7 Ball transfer bed (Mathews), 419 Figure 17.8 Gear reduction, 419 Figure 17.9 Labyrinth steel and felt front seal,

Mathews No. 632 bearing, 420 Figure 17.10 Deflection diagram, 420 Figure 17.11 Details of a powered roller

conveyor, 422 Figure 17.12 A combination power and gravity

conveyor for handling pallets, 423 Figure 17.13 Slat, apron, and sliding-chain

conveyor, 424 Figure 17.14 Suspended-tray conveyor, 424 Figure 17 .15 Efficiency of double worm-gear

reducers, 424 Figure 17. 16 SR chain data and attachments, 425

Section 18: Pneumatic Conveying

Figure 18.1 Vm diagram, 432 Figure 18.2 Duct friction for velocity head loss (N)

ILLUSTRATIONS xvii

and roughness correction factors for ducts (Fcl,433

Figure 18.3 Correction factors for pipe roughness, 434

Figure 18.4 High-pressure system diagram, 435 Figure 18.5 Friction of air in straight ducts for

volumes of 10-2000 cfm, 436 Figure 18.6 Friction of air in straight ducts for

volumes of 1000-100,000 cfm, 437

Section 19: Dust Collection

Figure 19.1 A typical dust collector, 440 Figure 19.2 A system to collect graphite dust, 441 Figure 19.3 Bucket elevator ventilation, 442 Figure 19.4 Bin and hopper ventilation, 443 Figure 19.5 Conveyor belt ventilation, 444 Figure 19.6 A dust hood over a swivel spout, 445 Figure 19.7 A barrel hood, 446 Figure 19.8 A conveyor hood, 446 Figure 19.9 A chute loading hood, 446 Figure 19.10 A bagger hood, 447 Figure 19. 11 Duct design data, 447 Figure 19.12 Ductwork design data, 448 Figure 19.13 Screens, 449 Figure 19.14 Hood entry loss, 450 Figure 19.15 Detail of a discharge gate and dust

hood, 451 Figure 19.16 Dust hood at a discharge hopper, 452 Figure 19.17 Stackhead designs, 453

Section 20: Layout of a Material Handling Plant

Figure 20.1 A typical flow diagram, 463 Figure 20.2 Electrical identification diagram, 465 Figure 20.3 Diagram of plant material flow, 466 Figure 20.4 Flow diagram of bin system no. 1, main

control panel, 468 Figure 20.5 Electrical block diagram, 469 Figure 20.6 Automatic filling schematic for bin

system 1 only, 469

Tables

Section 1: Introduction

Table 1.1 Material Classification Code, 3 Table 1.2 Material Characteristics, 5 Table 1.3 Chain Details, 7 Table 1.4 Chain Numbers Used Throughout the

Book, 8 Table 1.5 Chain Correction Factors for Cast and

Combination Chains, 10 Table 1.6 Chain Correction Factors for SS Class

Chains, 10 Table 1.7 Service Factors, 11 Table 1.8 Abbreviations for Terms Used in This

Book, 11 Table 1.9 Abbreviations for Trade Associations,

Professional Societies, and Manufacturers Mentioned in Text, 12

Table 1.10 Letter Symbols for Units, 13 Table 1.11 SI and Other Eqnivalents, 13

Section 2: Belt Conveyors

Table 2.1 Tension Rating of Multiple-Ply Belts, 18 Table 2.2 Maximum Plies for Troughing of Empty

MP (Multiple-Ply) Type Belts, 19 Table 2.3 Troughability of Reduced-Ply Type

Belts, 20 Table 2.4 Minimum Plies for Load Support, 20°

Idlers, MP (Multiple-Ply) Belts, 20 Table 2.5 Minimum Plies for Load Support, 35-45°

Idlers, MP (Multiple-Ply) Belts, 20 Table 2.6 Goodyear Tire & Rubber Company's

Minimum-Ply Recommendations, 21 Table 2.7 Capacity of Belt Conveyors, 23 Table 2.8 Surcharge Capacity, 23 Table 2.9 Spacing and Types of Idlers, 24 Table 2.10 Recommended Takeup Travel in Percent

of Center Distance, 41 Table 2.11 Maximum Recommended Belt Speed as

Determined by Material Handled and Belt Width, 48

xix

Table 2.12 Recommended Maximum Belt Speeds and Widths Based on Material Handled, 49

Table 2.13 Estimated Average Belt Weight, Multiple- and Reduced-Ply Belts (lb/ft), 49

Table 2.14 Weight per Linear Foot of Belt and Revolving Idler Parts (lb), 49

Table 2.15 Factor Ky Values, 51 Table 2.16 Corrected Factor Ky Values When Other

Than Tabular Carrying Idler Spacings Are Used, 53

Table 2.17 Belt Tension to Rotate Pulleys, 54 Table 2.18 Skirtboard Friction Factor, Cs, 54 Table 2.19 Recommended Belt Sag Percentages for

Various Full Load Conditions, 55 Table 2,20 Wrap Factor, Cw , 55 Table 2.21 Wrap Limits, 56 Table 2.22 Minimum Pulley Diameters for Multiple­

Ply Type Belts (in.), 56 Table 2.23 Minimum Pulley Diameters (in.), 57 Table 2.24 Minimum Pulley Diameters for Reduced­

Ply Type Belts (in.), 57 Table 2.25 Minimum Pulley Diameters for Steel-

Cable Belts (in.), 57 Table 2.26 Friction Factors, 60 Table 2.27 KJ Lump Adjustment Factor, 66 Table 2.28 K2 Environmental and Maintenance

Factors, 66 Table 2.29 K3 Service Factor, 66 Table 2.30 K4 Belt Speed Correction Factor, 66 Table 2.31 Load Ratings for CEMA A Idlers

(lb), 66 Table 2.32 Load Ratings for CEMA B Idlers

(lb), 66 Table 2.33 Load Ratings for CEMA C Idlers

(lb),66 Table 2.34 Load Ratings for CEMA D Idlers

(lb), 67 Table 2.35 Load Ratings for CEMA E Idlers

(lb),67 Table 2.36 Causes and Corrections of Conveyor Belt

Troubles, 68

xx TABLES

Section 3: Bucket Elevators

Table 3.1 Preliminary Selection of Elevator Type, 80 Table 3.2 Properties of SBS Class Chains, 88 Table 3.3 Properties of Class C Combination

Chain, 88 Table 3.4 Centrifugal-Discharge Bucket Elevator

Selection/Specifications, Type I-Chain, 94 Table 3.5 Centrifugal-Discharge Bucket Elevator

Selection/Specifications, Type I-Belt, 96 Table 3.6 Continuous-Bucket Elevator Selection/

Specifications, Type 7-Chain, 98 Table 3.7 AA Buckets, 101 Table 3.8 Budd Cast Nylon Style AA Buckets, 102 Table 3.9A Dura Buckets, Style SS, Plastic, 103 Table 3.9B Dura Buckets, Style LP, Plastic, 104 Table 3.10 AA-RB Buckets, 105 Table 3.11 SCC Polymer Buckets, 105 Table 3.12 AC Buckets, 106 Table 3.13 B Buckets, 106 Table 3.14 C Buckets, 107 Table 3.15 Type MF Buckets, 113 Table 3.16 Type HF Buckets, 114 Table 3.17 Type LF Buckets, 114 Table 3.18 Type HFO Buckets, 115 Table 3.19 Type D Buckets, 115 Table 3.20 Type D Budd Cast Nylon Buckets, 116 Table 3.21 SC Buckets, 120 Table 3.22 Gravity-Discharge Conveyor-Elevator

Capacity and Horsepower, 128 Table 3.23 Peck Carrier Capacity and Weight, 135

Section 4: Screw Conveyors

Table 4.1 Deflections of Screw Conveyor Pipe, 143 Table 4.2 Properties of Pipe, 143 Table 4.3 Design Torque on Coupling Shafts, 147 Table 4.4 Allowable Torque on Bolts in Bearing, 147 Table 4.5 Allowable Torque of Coupling Bolts in

Shear, 148 Table 4.6 Torque Capacities of Conveyor Pipe

Couplings and Coupling Bolts with Conveyor Pipe Having Internal Collars (Also Without Collars), 148

Table 4.7 Capacity of Screw Conveyors, 155 Table 4.8 Hanger Bearing Factor, Fb , 162 Table 4.9 Conveyor Diameter Factor, Fd , 162 Table 4.10 Flight Factor, FI , 162 Table 4.11 Paddle Factor, Fp, 162 Table 4.12 Continuous-Weld Finishes, 168 Table 4.13 Maximum Lump Size, 169

Section 5: Apron and Mold Conveyors

Table 5.1 Data for Aprons with Style AC Pans, 175 Table 5.2 Data for Aprons with Style AA Pans, 176 Table 5.3 Data for Aprons with Style AB Pans, 177 Table 5.4 Data for No-Leak Aprons with Style AB

Pans, 178 Table 5.5 Maximum Lump Sizes and Speeds, 178

Section 6: Flight and Drag Conveyors

Table 6.1 Flight Conveyor Capacities, 197 Table 6.2 Properties of SD and WD Drag

Chains, 200 Table 6.3 Wide-Chain Drag Conveyors, 200

Section 7: Feeders and Vibrating Conveyors

Table 7.1 Conveyability of Materials, 234

Section 8: Wire Mesh Conveyors

Table 8.1 Drag Chain Selection, 238 Table 8.2 Coefficient of Friction, 239 Table 8.3 Constant K, 240 Table 8.4 Roll Support, 240 Table 8.5 Metal Mesh Belt with Standard Roller

Chain and lournaled Rods, 240 Table 8.6 Metal Mesh Belt with SBS or RS Bushed

Roller Chain, 241 Table 8.7 Metal Mesh Belt with Standard Precision

Roller Chain, 241 Table 8.8 Metal Mesh Belt with Extended-Pitch

Roller Chain and Standard Rollers or Large Rollers, 242

Table 8.9 Metal Mesh Belt with Pintle Chain and Through Supporting Rods (Pins), 242

Section 9: Drives

Table 9.1 Recommended Minimum Sheave or Sprocket Diameters for Electric Motors (in.), 245

Table 9.2 Service Factors Listed by Application for Electric-Motor Drives, 245

Table 9.3 Mechanical Efficiencies of Speed­Reduction Mechanisms, 246

Table 9.4 Service Factors for V-Belt Drives, 247 Table 9.5 Stock Sprockets for Roller Chain, 248 Table 9.6 Roller Chain-Ultimate Strength, 251 Table 9.7 Multiple Strands, 251 Table 9.8 Chain Working Factor, 251 Table 9.9 Minimum Size of Driver (Small)

Sprockets, 251

Section 10: Crushers and Screens

Table 10.1 KVS Primary Gyratory Crushers Capacity Chart, 260

Table 10.2 Screen Analysis, KVS Gyratory Crusher-Closed Circuit, 261

Table 10.3 Screen Analysis, KVS Gyratory Crusher-Open Circuit, 261

Table 10.4 KVS Swing Jaw Crushers, 262 Table 10.5 Product Analysis for KVS Overhead

Eccentric and Swing Jaw Crushers, 263 Table 10.6A Primary A-C Gyratory Crushers

Performance Table, 265 Table 1O.6B Secondary A-C Gyratory Crushers­

Performance Table, 266 Table 10.7 Product Curve Selection, A-C Gyratory

Crusher, 266 Table 10.8 Cumulative Percentages as Read from

Figure 10.8, 266 Table 10.9A Gundlach Two-Stage Crusher Data, 268 Table 1O.9B Gundlach Single-Stage Crusher

Data, 268 Table 10.10 Recommendations for A-C Types of

Screens, 273 Table 10.11 Net Effective Screening Area (fe), 275 Table 10.12 Wire Cloth Standards for Square

Openings (Dry Screening Only), 277

Section 12: Hoists and Cranes

Table 12.1 P&H (Harnischfeger) Beta Hevi-Lift Hoists, 285

Table 12.2 Pendant-Operated Overhead Cranes, 289 Table 12.3 Design Data for Cab-Operated

Cranes, 292 Table 12.4 Cab-Operated Overhead Cranes, Two

Trolleys, 297 Table 12.5 Suggested Operating Speeds (fpm), 300 Table 12.6 Guide for Maximum Bridge and Trolley

Wheel Loadings (Ib) (P), 301

TABLES xxi

Section 16: Heating, Cooling, and Ventilating Furnace Buildings

Table 16.1 Tabulation of Calculations for Section 1, 390

Table 16.2 Tabulation of Final Results, 390 Table 16.3 Summary of Calculations of Air

Flow, 392 Table 16.4 Air Change: Pressure Coefficients on

Building Surface, 396 Table 16.5 Percent of Exit Gas Components by

Weight, 407

Section 17: Package Handling Conveyors

Table 17.1 Values for Equation 1, 412 Table 17.2 Values of C, 413 Table 17.3 Average Weight of Rollers (Ib), 413 Table 17.4 Package Conveyor Chains, 417 Table 17.5 Percent Rolling Friction, Steel Roller

Chain, Clean Track, 417 Table 17.6 Percent Sliding Friction, 417 Table 17.7 Section Properties of Common Hexagonal

Shafts, 419 Table 17.8 Section Properties of Common Round

Shafts, 420

Section 18: Pneumatic Conveying

Table 18.1 Average Velocities and Air Volumes Required for Conveying Materials at Low Pressures, 430

Table 18.2 Classification of Pneumatic Conveyor Systems, 438

Section 19: Dust Collection

Table 19.1 Permissible Noise Exposures, 442 Table 19.2 Hood Design Formulas, 454 Table 19.3 Recommended Air Flows, 455 Table 19.4 Hood Design Data, Range of Capture

Velocities, 455 Table 19.5 Cfm and Duct Data, 456 Table 19.6 Tabulation of Cfm and Pressures, 458

Preface

The handling of bulk materials is a continuously changing science. Since very few schools teach the han­dling of bulk materials, it is necessary for practicing en­gineers to develop their own training manuals. This book is an abbreviated version of a manual used for that pur­pose in our office, and developed over a period of more than 50 years. While some industrial firms follow their own practices, the trend in the past few years has been to adopt the standards of equipment manufacturers' as­sociations and similar organizations. The selection of material and the use of drawiugs instead of photographs is based on our experience.

It is hoped that users of this text will comment on items of their choosiug to make a next edition even more responsive to the needs of the profession. Skilled pro­fessionals active in other areas may find the book useful for information and data not usually encountered in their special fields but, in general, the handbook is not for them. It should be of help in training new engineers, and as a reference for engineering students, and those active in the bulk materials handling field.

In 1965, Stanley Snyder joined our staff. A short time later, he was assigned the task of coordinating all of our notes and bringing them up to date. When completely assembled, the result proved too voluminous for prac­tice, and had to be cut down.

During the last four years, various sections of the text were sent, for suggestions and comments, to individuals I respect for their knowledge in their special fields. In addition, some sections were tried out in practice. I felt that great weight should be given to the suggestions of those training younger people, of purchasing agents, plant operators, and maintenance personnel. All the in­formation gathered and suggestions received were con­sidered in preparing the present text. Every effort was made to arrive at an appropriate balance.

The project designs used as illustrations and exam­ples have, with few exceptions, been built and have op­erated well for many years. To illustrate a desired point, some projects are based on problems presented in man­ufacturers' catalogs, or slight modifications of actual

xxiii

completed projects. Much of the nomenclature has been brought up to date.

Publication of the material contained herein is not in­tended as a representation or warranty on the part of the author, publisher, editors, or any other person or firm named herein that it is suitable for any particular use, or free from infringement of any patent or patents.

The text is intended as a guide. When used for any specific project, a competent professional engineer should be retained to verify the assumptions, applica­bility, calculations, and accuracy of the particular de­sign.

Whenever standards are established by an industry, it is best to follow those standards. This text is intended to replace neither the catalogs supplied by manufactur­ers nor the texts published by manufacturers' associa­tions. They cover the field in much greater detail than is possible here.

For their help and encourangement, I feel especially indebted to G. Leslie Lardie, former chief engineer of the Electrometallurgical Division of Union Carbide; Ar­thur Toronski, former chief engineer and president of Speer Carbon Company; and Henry Crosby, former chief engineer of General Mills.

Special thanks are due the Conveyor Equipment Manufacturers Association, and the topflight engineers who work for some of its members.

My gratitude goes to Roger M. Stem, technical and copyeditor of the manuscript, and to Bernice Pettinato, managing editor, from whom I learned much about what happens to a book from the time the author submits the manuscript until bound copies appear. Thanks are also due Darya and Robert E. Emmens, Sr., for their sub­stantial assistance with the proofreading.

Those who have contributed to the text are mentioned therein.

Great thanks also go to Charles N. Brice, Steven Bu­gay, William N. Carlson, Kenneth McCaskill, Roger Larsh, and Dr. Andrei Reinhorn of our staff for their help.

Thanks are also due

xxiv PREFA CE

Edward Braun and D. J. Hagen of Allis-Chalmers William A. Robinson of Babcock & Wilcox Co. (re­

tired) John A. Klacsmari of Clean Sites Inc. Robert Jorgensen of Buffalo Forge Company and author

of Fan Engineering Dr. Robert A. Person of Elkem Company Clyde E. Ostberg and Harold Swanson of FMC Roger E. Noel of Goodman Company R. W. Milk and M. A. Alspaugh of Goodyear Tire and

Rubber Company John J. Keenan of Hamischfeger H. C. Lautenschlaeger and J. D. DiAntonio of Hewitt­

Robins T. P. Smyre of Jeffrey Manufacturing, Division of

Dresser Industries

Florian Schwartzkopf of Kennedy Van Saun Edward Barnett, formerly of MIT William Neundorfer of National Air Vibrator Company John J. Bradley and Lee Doyer of Pennsylvania Crusher

Corporation Don Rearic and Guido Yanniello of Rexnord, Inc. Arthur Geberin and R. O. Dickey of Screw Conveyor

Corporation Arthur Elmquest of S. K. W. Glenn Runge, formerly of Speer Carbon Company James Voelkel of W. S. Tyler Company Tom Zupo, formerly of Webb Belting T. H. Anderson of Whiting Corporation.

JACOB FRUCHTBAUM