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

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

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

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

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)

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!

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)

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

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

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

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

BUCKET ELEVATORS

BUCKET ELEVATORS Main Components

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

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

AVOID!

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

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)

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 0.762 m y that rotates at 66 rev/min (RPM) (V) = (Diameter x 3.14) * Rotational speed (RPM) (0.762 m * 3.1416)*66 RPM = (V) = 158 m/min

MAXIMUM BELT VELOCITY Pulley Diameter Belt velocity Inches cm RPM ft/min m/min 4.5 11.4 160 220 67 11 27.9 113 326 99 18 45.7 95 448 137 24 61.0 71 458 140 30 76.2 66 518 158 36 91.4 60 565 172 42 106.7 56 630 192 48 121.9 56 711 217 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.

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= 0.0046539 m 3 each one - Distance center to center = 20.3 cm

Distance center to center 1 meter

GRAIN DENSITY Type of Grain Density (lb/ft 3 ) Density (kg/m 3 ) Corn 44.8 719 Sorghum 40.0-44.8 642 719 Soybean 48.0 771 Sunflower 19.2 308 Wheat 48.0 771

CAPACITY OF ELEVATOR Capacity per hour (kg/hr) = V x Vol x D x T Capacity (kg/hr) = 158 m/min x 0,020612 m 3 /m x 719 kg/m 3 x 60 min/h = 140,494 kg/hr = 140 TPH

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

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

DESIGN CONSIDERATIONS FOR CALCULATING ELEVATOR HEIGHT ELEVATOR HEIGHT DIFFERENCE WITH BIN Minimal Angle for Flowing: Elevator Height (E): Dry Grain 37 E = B + 0.754 * D Wet Grain 45 E = B + D Pellets 45 E = B + D Soybeans 60 E = B + 1.732 * D Mash (powder) 60 E = B + 1.732 * D

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 + 1.732 * D = 10 m + 1.732 * 12 m E = 30.8 m

AVOID THESE DESIGNS FOR DOWNSPOUTS!!

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

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 = 0.754 * D

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 = 0.754 * D H = 0.754 * 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

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.

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' 400 524 618 700 770 830 885 935 975 1010 1050 1075 10' 570 742 875 990 1090 1180 1255 1320 1380 1435 1485 1520 15' 695 908 1070 1210 1335 1440 1530 1615 1690 1755 1820 1860 20' 805 1047 1235 1400 1540 1665 1770 1870 1950 2025 2100 2150 25' 899 1170 1380 1560 1725 1860 1975 2085 2180 2265 2340 2400 30' 985 1280 1510 1710 1890 2040 2165 2285 2390 2480 2570 2335 40' 1135 1480 1750 1975 2180 2355 2500 2640 2760 2865 2970 3040 50' 1270 1655 1950 2210 2440 2635 2800 2955 3090 3210 3320 3400 60' 1390 1810 2140 2420 2670 2880 3065 3240 3390 3520 3640 3720 70' 1500 1960 2310 2615 2880 3110 3315 3500 3660 3800 3930 4025 80' 1605 2090 2470 2795 3080 3330 3540 3740 3905 4055 4200 4295 90' 1705 2200 2620 2960 3275 3535 3760 3965 4150 4310 4460 4550 100' 1795 2340 2765 3120 3450 3720 3960 4180 4370 4540 4700 4800 125' 2005 2620 3090 3500 3860 4165 4440 4680 4890 5080 5250 5370 150' 2200 2865 3390 3835 4225 4560 4850 5120 5450 5560 5750 5880 Angles of 28º and grain velocities above 1750 ft/min should be avoided

GRAIN VELOCITY REDUCTORS

VELOCITY REDUCTORS FOR PNEUMATIC SYSTEMS NO! Use cyclones!

UNLOADING LADDER FOR PELLETS OR GRAIN SEEDS

SCREW CONVEYORS

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

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

PORTABLE CLOSE CONVEYORS Loading grain bins Typical diameter: 6 12 in (15 31 cm) Length between: 8.8 26 m Maximum capacity 115 TPH Maximum angle 45

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

CALCULATION OF CAPACITY FOR CLOSE CONVEYOR (D 2 d 2 ) * P * RPM Theoretical Capacity (m 3 /h) = ------------------------ 36.6 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

HOW TO CALCULATE THE POWER NEEDED FOR A CONVEYOR C * L * W * F Power (HP) = ---------------- 33,000 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

TABLE OF DENSITY AND FACTOR FOR CONVEYORS Product Density (W) lb/ft 3 Factor (F) Barley 38 0.4 Corn 45 0.4 Oats 26 0.4 Rice 36 0.4 Soybeans 45-50 0.5 Wheat 48 0.4

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

DESIGN TABLE FOR CAPACITY AND POWER FOR CONVEYORS Dry grains (corn, wheat, rice, sorghum) Conveyor diameter (in) Inclined Angle 0 25 35 45 Conveyor Speed (rpm) TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft 4 900 14 0.6 13 0.9 12 0.9 11 1.0 7 0.8 6 600 38 1.0 34 1.5 32 1.6 30 1.6 18 1.3 8 450 55 1.4 50 2.2 47 2.2 44 2.3 26 1.9 10 360 83 2.0 74 3.1 71 3.2 66 3.2 39 2.5 12 300 113 2.5 102 3.9 97 4.0 90 4.0 54 3.2 14 260 156 3.4 140 5.3 134 5.4 124 5.5 74 4.3 16 225 201 4.4 181 6.8 172 7.0 160 7.1 96 5.6 90 1 ft = 0.30 m Source: MWPS-13 T2-3

DESIGN TABLE FOR CAPACITY Conveyor Diameter (in) AND POWER FOR CONVEYORS Wet corn (25%) Inclined Angle 0 25 35 45 90 Conveyor Speed (rpm) TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft 4 900 8 1.7 8 1.8 7 1.7 7 1.8 4 0.8 6 600 23 2.8 20 3.0 19 3.0 18 2.9 11 1.3 8 450 33 3.9 30 4.4 28 4.2 26 4.1 16 1.9 10 360 50 5.6 45 6.2 42 6.1 39 5.8 24 2.5 12 300 68 7.0 61 7.8 58 7.6 54 7.2 32 3.2 14 260 93 9.5 84 10.6 80 10.3 74 9.9 44 4.3 16 225 121 12.3 109 13.6 103 13.3 96 12.8 57 5.6 Fuente: MWPS-13 T2-3 1 ft = 0.30 m

DESIGN TABLE FOR CAPACITY AND POWER FOR CONVEYORS SBM and Mash Feed Conveyor Diameter (in) Inclined Angle 0 25 35 45 90 Conveyor Speed (rpm) TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft TPH HP/10 ft 4 900 13 0.6 11 0.9 11 0.9 10 1.0 6 0.8 6 600 34 1.0 31 1.5 29 1.6 27 1.6 16 1.3 8 450 50 1.4 45 2.2 43 2.2 40 2.3 24 1.9 10 360 75 2.0 68 3.1 64 3.2 60 3.2 36 2.5 12 300 103 2.5 93 3.9 88 4.0 82 4.0 49 3.2 14 260 142 3.4 128 5.3 121 5.4 113 5.5 67 4.3 16 225 183 4.4 165 6.8 156 7.0 145 7.1 87 5.6 1 ft = 0.30 m Fuente: MWPS-13 T2-3

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

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

DRAG CONVEYORS

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

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

PNEUMATIC SYSTEMS Positive Displacement

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

PNEUMATIC SYSTEMS Negative Displacement

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

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

THANK YOU! Carlos A. Campabadal Email: campa@ksu.edu Phone: +1.217.721.1025