SOUTHERN AFRICA FEED MANUFACTURING TRAINING ACTIVITY MATERIALS HANDLING. Carlos A. Campabadal

Transcription

1 SOUTHERN AFRICA FEED MANUFACTURING TRAINING ACTIVITY MATERIALS HANDLING Carlos A. Campabadal International Grains Program (IGP) Kansas State University MARCH 9 TH, 2012 MANHATTAN, KANSAS

2 PRESENTATION OUTLINE Materials Handling Important concepts for grain and feed ingredient receiving Types of materials handling equipment Bucket elevator Screw conveyor Pneumatic systems 2

3 GRAIN AND FEED INGREDIENT RECEIVING SYSTEMS AT FEED MILL/STORAGE Manual system Mechanic Gravity Pneumatic

4 WHAT TO DO WHEN RECEIVING GRAIN & FEED INGREDIENTS? 1. Verify that it is the correct ingredient/grain 2. Check quantity 3. Check quality (physical and chemical characteristics) 4. Document: Date, quantity, quality and expiring date 5. Store at the correct location according to grain/ingredient characteristics (micros & medications in bags)

5 WHAT PHYSICAL CHARACTERISTICS CAN BE MEASURE? Grain and coproducts: Moisture content Color, texture & odor Density Particle size Visual presence of contaminants (insects, mold, foreign material, etc) Use microscope if necessary!

6 WHAT CHEMICAL CHARACTERISTICS CAN BE MEASURE? Grain and coproducts: Protein, fat, starch, mineral, fiber content (wet chemistry, NIR) Mycotoxins (ELISA or HPLC) Contaminants (Potassium hydroxide, indicator of overcooked SBM) Contaminants to adultery (salt in fish meal)

7 RECEIVING AREA FOR GRAIN AND FEED INGREDIENTS Dumping pit for bulk ingredients, dock or unloading area for ingredients in bags Dumping pit will have a screw conveyor or pneumatic system to handle the ingredients for storage or usage Storage for bulk grain (silos), bulk coproducts (SBM, DDGS (flat storage or warehouse) with unloading equipment Bag ingredient storage separated from finished product Liquids unload directly to tanks

8 Elevator Loading bins for trucks Grain elevator in the USA Storage silos Dumping pit

9 HOW TO CHOOSE EQUIPMENT FOR MATERIALS HANDLING? Based on the characteristics of the grain and feed ingredients that will be unloaded/loaded: - Particle size - Flowing characteristics - Abrasive, stickiness, temperature, corrosive, compaction, absorbs water easily, can produce dust easily

10 EQUIPMENT USED FOR MATERIALS HANDLING Gravity (spouts important to have minimal angles for proper flow) Mechanical (elevators, screw conveyors, belt or drag conveyors) Pneumatics

11 BUCKET ELEVATORS

12 BUCKET ELEVATORS Main Components

13 HEAD COMPONENTS Base for motor Cover Shaft Pulley Protection for abrasion Belt and buckets Inspection door Unloading

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15 BASE OF ELEVATOR Legs Inspection door Belt and buckets Adjustment for belt Ajustment for elevator Loading opening Door for cleaning

16 AVOID!

17 BUCKET ELEVATOR ADVANTAGES DESVENTAJAS Efficient Low losses due to friction Several sizes Can be use at lower capacities Not noisy and low maintenance Long life Relative high cost Relative high installation cost Maintenance difficulty Cannot be moved Can create mixture of ingredients due to bad usage

18 HOW TO CALCULATE CAPACITY OF A ELEVATOR? Capacity per hour (kg/hr) = V x Vol x D x T (V) Velocity = Velocity of the belt (m/min) (Vol) Volumen = Volumen of the grain in every meter of belt (m 3 /m) (D) Density = Density of the grain (kg/m 3 ) (T) Time = Conversion factor (60 minutes/hour)

19 CAPACITY OF ELEVATOR (V) Velocity of the belt (m/min) = Circumference of the pulley of the head del (meters) x RPM Example: Pulley with a diameter of m y that rotates at 66 rev/min (RPM) (V) = (Diameter x 3.14) * Rotational speed (RPM) (0.762 m * )*66 RPM = (V) = 158 m/min

20 MAXIMUM BELT VELOCITY Pulley Diameter Belt velocity Inches cm RPM ft/min m/min For pellets and seed grain, reduce velocity by 20% to reduce any damage. Reduce 10 to 20% for mash or powder ingredients to avoid over filling the buckets.

21 CAPACITY OF ELEVATOR (Vol) Volumen of the grain (m 3 /m) = Volumen of the bucket (given by manufacturer or calculated ) / Nº of buckets in 1 meter of belt x filling factor Example: - Bucket measurements = 30.5 cm x 15.2 cm x 10 cm= m 3 each one - Distance center to center = 20.3 cm

22 Distance center to center 1 meter

23 CAPACITY OF ELEVATOR (Vol) Volumen of the grain (m 3 /m) = Volumen of the bucket (given by manufacturer or calculated ) / Nº of buckets in 1 meter of belt x filling factor Example: - Bucket measurements = 30.5 cm x 15.2 cm x 10 cm= m 3 each one - Distance center to center = 20.3 cm - Filling factor = 90% (Vol) (m 3 /m) = (0, m 3 / 0,203 m) * 0,90 = (Vol) = 0, m 3 /m

24 GRAIN DENSITY Type of Grain Density (lb/ft 3 ) Density (kg/m 3 ) Corn Sorghum Soybean Sunflower Wheat

25 CAPACITY OF ELEVATOR Capacity per hour (kg/hr) = V x Vol x D x T Capacity (kg/hr) = 158 m/min x 0, m 3 /m x 719 kg/m 3 x 60 min/h = 140,494 kg/hr = 140 TPH

26 ANGLES FOR SPOUTS Unloading height Flowing Angle, Height H tan = = -- Distance D

27 DESIGN CONSIDERATIONS FOR CALCULATING ELEVATOR HEIGHT Calculations for correct height for proper flow: E = B + H E = B + D * tan Flowing Angle, E = Elevator height H = Difference height elevator and bin B = Bin height D = Distance (horizontal) between elevator and unloading inside bin

28 DESIGN CONSIDERATIONS FOR CALCULATING ELEVATOR HEIGHT ELEVATOR HEIGHT DIFFERENCE WITH BIN Minimal Angle for Flowing: Elevator Height (E): Dry Grain 37 E = B * D Wet Grain 45 E = B + D Pellets 45 E = B + D Soybeans 60 E = B * D Mash (powder) 60 E = B * D

29 DESIGN CONSIDERATIONS FOR CALCULATING ELEVATOR HEIGHT Example: Determine the elevator height to unload soybeans by gravity into a bin (Height (B) = 10 m that is located at 12 m (D) from the elevator. Unloading angle for soybeans, = 60 Horizontal distance, D = 12 m Bin height, B = 10 m Elevator Height (E) = B * D = 10 m * 12 m E = 30.8 m

30 AVOID THESE DESIGNS FOR DOWNSPOUTS!!

31 DESIGN CALCULATIONS FOR DOWNSPOUTS Calculation of downspout from elevator to bin (L): L = (D 2 + H 2 ) 1/2 Flowing Angle,

32 Example: DESIGN CALCULATIONS FOR DOWNSPOUTS Determine the height of the elevator (H) and the length of the downspout (L) if the elevator is located a 7.6 m horizontally from the base of the bin for proper handling corn (dry). Angle for flowing dry corn, = 37 Horizontal distance, D = 7,6 m Using formulas from table H = * D

33 DESIGN CONSIDERATIONS FOR CALCULATING ELEVATOR HEIGHT ELEVATOR HEIGHT DIFFERENCE WITH BIN Minimal Angle for Flowing: Elevator Height (E): Dry Grain 37 E = B * D Wet Grain 45 E = B + D Pellets 45 E = B + D Soybeans 60 E = B * D Mash (powder) 60 E = B * D

34 DESIGN CALCULATIONS FOR DOWNSPOUTS Example: Determine the height of the elevator (H) and the length of the downspout (L) if the elevator is located a 7.6 m horizontally from the base of the bin for proper handling corn (dry). Angle for flowing dry corn, = 37 Horizontal distance, D = 7,6 m Using formula from table H = * D H = * 7.6 m H = 5.7 m Length of downspout L = (D 2 + H 2 ) 1/2 L = ((7.6 m) 2 + (5.7 m) 2 ) 1/2 L = 9.5 m

35 CAPACITY TABLE FOR DOWNSPOUTS Capacity is for dry clean grain for each diameter. Velocity is calculated for an angle of 45º for 3 m or more with an average between 280 to 327 m/min.

36 Downspout Length (ft) TABLE FOR GRAIN VELOCITY INSIDE DOWNSPOUT (ft/min) Flow (Repose) Angle 35º 40º 45º 50º 55º 60º 65º 70º 75º 80º 85º 90º 5' ' ' ' ' ' ' ' ' ' ' ' ' ' ' Angles of 28º and grain velocities above 1750 ft/min should be avoided

37 GRAIN VELOCITY REDUCTORS

38 VELOCITY REDUCTORS FOR PNEUMATIC SYSTEMS NO! Use cyclones!

39 UNLOADING LADDER FOR PELLETS OR GRAIN SEEDS

40 SCREW CONVEYORS

41 TYPES OF SCREW CONVEYORS Tube conveyors (Close) Portable Unloading grain bins Loading grain bins or handling Sweeping for cleaning bin Moving grain or feed in bulk transportation Mixing purposes U conveyors (Open) Indoor for moving grain or feed Maximum angle is 35

42 CLOSE SCREW CONVEYORS More economical Need to work a full capacity, if not can damage pellets or grain Limits incline angle, loose capacity Can load/unload at any location a long the conveyor Cross Section

43 PORTABLE CLOSE CONVEYORS Loading grain bins Typical diameter: 6 12 in (15 31 cm) Length between: m Maximum capacity 115 TPH Maximum angle 45

44 CLOSE CONVEYOR TubE Nota: Minimal opening is equal to diameter of tube

45 CALCULATION OF CAPACITY FOR CLOSE CONVEYOR (D 2 d 2 ) * P * RPM Theoretical Capacity (m 3 /h) = D = Diameter of conveyor, cm d = Diameter of shaft, cm P = Pitch (Distance between flights, cm RPM = Rotational speed of conveyor, rev/min Real Capacity depends on inclined angle, speed, friction Real Capacity = 30 to 50% Theoretical Capacity

46 HOW TO CALCULATE THE POWER NEEDED FOR A CONVEYOR C * L * W * F Power (HP) = ,000 C = Capacity of conveyor (ft 3 /h) L = Length of conveyor (ft) W = Bulk density of product (lb/ft 3 ) F = Factor for product (table) ADJUST FOR REAL POWER WITH TABLE

47 TABLE OF DENSITY AND FACTOR FOR CONVEYORS Product Density (W) lb/ft 3 Factor (F) Barley Corn Oats Rice Soybeans Wheat

48 ADJUSTMENT TABLE FOR POWER NEEDED FOR A CONVEYOR If calculated power is: Real power is: <1 HP = 2 * HPC 1 HPC <2 HP = 1.5 * HPC 2 HPC <4 HP = 1.25 * HPC 4 HPC <5 HP = 1.1 * HPC HPC 5 HP = 1.0 * HPC

49 DESIGN TABLE FOR CAPACITY AND POWER FOR CONVEYORS Dry grains (corn, wheat, rice, sorghum) Conveyor diameter (in) Inclined Angle Conveyor Speed (rpm) TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft ft = 0.30 m Source: MWPS-13 T2-3

50 DESIGN TABLE FOR CAPACITY Conveyor Diameter (in) AND POWER FOR CONVEYORS Wet corn (25%) Inclined Angle Conveyor Speed (rpm) TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft Fuente: MWPS-13 T2-3 1 ft = 0.30 m

51 DESIGN TABLE FOR CAPACITY AND POWER FOR CONVEYORS SBM and Mash Feed Conveyor Diameter (in) Inclined Angle Conveyor Speed (rpm) TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft ft = 0.30 m Fuente: MWPS-13 T2-3

52 SCREW CONVEYORS Advantages Initial costs is economical Can be use horizontally, vertically and inclined Can be use for mixing purposes Can have multiple inlets and outlets Maintenance cost is economical

53 SCREW CONVEYORS DISADVANTAGES Can damage the product There is product accumulation at the outlets Cannot be self-cleaningh Are not efficient Can only be use in a straight line

54 DRAG CONVEYORS

55 DRAG CONVEYORS ADVANTAGES Initial cost is not that expensive Can move product vertically and horizontally Can move product in 90 angles Self-cleaning capacity Se autolimpian Minor damage to product

56 DRAG CONVEYORS DISADVANTAGES Are not that efficient Pallets will wear out fast Have difficulty moving dense products Maintenance is more difficult

57 PNEUMATIC SYSTEMS Positive Displacement

58 POSITIVE PNEUMATIC SYSTEMS ADVANTAGES: Do not need filters Can unload product at any point Can be use to move high dense products at high pressure DISADVANTAGES: Use a lot of energy and produce heat Can dry the product Due to high velocity can damage product Difficult to have multiple inlet points

59 PNEUMATIC SYSTEMS Negative Displacement

60 NEGATIVE PNEUMATIC SYSTEM ADVANTAGES: Negative pressure controls fines and dust Can have multiple inlet points Can be use for products sensible to heat DISADVANTAGES: Are not efficient Maintenance is difficult Blower needs filter to avoid dust entry Only one outlet point

61 SUMMARY Know the characteristics of the product Choosing equipment based on the volume of movement Equipment does need to damage product to be efficient Do not overload equipment

62 THANK YOU! Carlos A. Campabadal Phone: