2015PT PowderFlow Kwade

Powder Flow, Measurement, and Silos
(Phenomenology, Design, Problems)
Prof. Dr.-Ing. A. Kwade

Bulk Solids – Introduction
What are bulk solids?
very fine
very coarse convenience

product
Bulk solids consist of a huge number of single particles respectively

identity elements.
Powder Flow, Measurement, and Silos | A. Kwade

Bulk solids technology – what is involveld?
Cereals Silos Avalanches
Food products Tablets Building materials

Powder Flow, Measurement, and Silos | A. Kwade
Examples for bulk solids are

 Gravel, sand, brash,
 Coal, coke, ore,
 Salt, ceramic raw materials (oxides),
 Active pharmaceutical ingredients,
 Synthetic granules, pigments, filling material,
 Animal feed, fertilizer,
 Cereals, flour, sugar,
 Pills, tablets,
 Cleaning agents, laundry detergent,
 Tee, coffee,
 Packaging materials,
 Paints, lacquer.

Why should we concern ourselves with bulk solids?
Knowledge of the behavior of bulk solids is important for

 Storage,
 Transport,
 Filling and emptying of bins, silos and hoppers,
 Process enhancement in plants,
 Packaging of intermediate or final products.

Bulk Solids – Problems

Results of Flow Problems
Personal
motivation
low product
system safety
quality
flow problems
lower
complaints
plant throughput
higher cost

Avoiding Flow Problems
flow property steady flow
process design FIFO
engineering design mass flow

Examples for Damaged Silos
explosion
collapse

History
Janssen (Germany)
 1895: pressure of cereals investigated with silo experiments
 Pressure slope trends to a limit value
Jenike (USA)
 1960; design fundamentals for mass flow and core flow in silos
 Based on experiments

Content of this Lecture
 Flow and load of bulk solids

 Stress-strain behavior
 Measurement of flow properties
 Flow of bulk solids in silos
 Outflow in silos

Behavior of Bulk Solids
Mechanical behavior of bulk solids is

 Determined by inter-particulate forces (e.g. adhesion forces, normal forces,
friction forces).
 Currently described by methods of continuum mechanics .
 Necessary to be known for the design of silos, hoppers and conveyors.
 Examined for classification of flow properties (quality control, e.g.
pharmaceutics).
 Increasing application of the discrete element method (DEM).
Flow properties of bulk solids particularly depend on

 Particle size distribution,
 Particle shape,
 Chemical composition of the particles,
 Humidity,
 Temperature.

Pressure and Stress in a Bin

Experiment von Janssen (1895)

Importance of Shear Stress
The friction between the bulk solids and the surface (wall) material results for non-
ideal horizontal surfaces in shear stresses, which act on the bulk solids.

Forces and Stresses
Forces on the periphery of single volume elements (sufficient large compared to

particle size) are considered.
Force F acting on surface A is being divided into
 Normal force N (force perpendicular to surface A),
 Shear force S (force parallel to surface A).

Sign Convention and Units for Stresses
in Bulk Solids Handling
Definitions in bulk solids handling:
 Compression forces and compression stresses are positive
 Tensile forces and tensile stresses are negativ
Appropriate unit for stresses is pascal (Pa):
 1 Pa = 1 N/m2
 1000 Pa = 1 kPa
5
 100.000 Pa = 10 Pa = 100 kPa = 1 bar

Stress-strain Behavior of Bulk Solids
Definition of the horizontal stress ratio:
h

v
Horizontal stress ratio of bulk solids in comparion to fluids and real

solids:
Solids: h = 0 =0
Bulk solids: v > h > 0 0 <  < 1; usually 0,3 <  < 0,6
Fluids: v = h =1

Force Equilibrium
 Volume element with triangular

cross section
 Normal stresses in vertical and
horizontal direction acting on
sample surface
 Shear stresses just act on sectional
plane

Mohr-Coulomb Yield Criterion
cohesionless bulk solid cohesive bulk solid

Uniaxial Compression Test
Hollow cylinder with frictionless walls filled with fine grained bulk solids
1 := consolidation stress (here the major principal stress )

c := unconfined yield strength

Question I
Uniaxial Compression Test
How does the unconfined yield strength (resistance to plastic deformation)

of a bulk solid change when the consolidation stress is increased?

Flow Functions of Bulk Solids

Measurement of the Unconfined Yield Strength
in the ,-Diagram
Circle A: consolidation
Circle Bi: shear to failure
Circle C: only possible when supported in horizontal direction

Relationship between Mohr‘s Circle,
Failure Plane and Yield Limit

Flowability of Bulk Solids
ffc < 1 not flowing

1 < ffc < 2 very cohesive
2 < ffc < 4 cohesive
4 < ffc < 10 easy-flowing
10 < ffc free-flowing

Question II
Time Dependency of Flow Properties
How does the unconfined yield strength change when bulk solids are
stored under a sustained static load?

Caking
Increase of the unconfined yield strength c during storage time

Time flow function c,t = f(c, t)

Yield Loci for the Description
of Flow Properties

Setup of the Jenike Shear Tester
(Translational Shear Tester)

literature source: D. Schulze, Powders and Bulk Solids
Setup of the Schulze Ring Shear Tester
(Rotational Shear Tester)

Advantages and Disadvantages
Ring shear tester

 Unlimited shear displacement
 No preconsolidation required
 Minor influence of performing personnel on experimental results
 Complete yield locus with one specimen
Jenike shear tester

 Limited shear displacement
 Complex sample preparation
 Several specimen necessary to obtain yield locus
 Performing personnel gains experience in bulk solids handling

Strain, Shear Stress and Density
of an Under-consolidated Specimen

States of Preconsolidation

Execution of a shear test
 Filling of the shear cell with the bulk solid and take-off of the surface
(without consolidation of the bulk solid)
 Hang up of the lid
 Eventually placing of shear cell in tester and applying of normal load
 Pre-Shearing under fixed normal load until stationary flow is achieved
 Sample with defined density and defined stress state
 Endpoint of yield locus is determined

Tensile stress – shear distance – courses for the
determination of the yield locus
Shearing off
Pre-shearing
Time

Execution of a shear test
 Filling of the shear cell with the bulk solid and take-off of the surface
(without consolidation of the bulk solid)
 Hang up of the lid
 Eventually placing of shear cell in tester and applying of normal load
 Pre-Shearing under fixed normal load until stationary flow is achieved
 Sample with defined density and defined stress state
 Endpoint of yield locus is determined
 Shearing-off under smaller normal load until flow starts (sample is
plastically deformed)
 Tensile stress decreases, density decreases
 Point on yield locus is determined

Tensile stress – shear distance – courses for the
determination of the yield locus
Shearing off
Pre-shearing
Time

Question III
Performance of Shear Tests
How can the measurement of a sample, which has been preconsolidated

with a specified normal stress, be continued to acquire a data point of the
yield locus?

Yield Loci for Different Bulk Densities

Question IV
Performance of Shear Tests
How can a shear testing device be used to the measure the time
consolidation of bulk solids?

Measurement of Time Consolidation
In between the preshear and the shear (to failure) procedure the sample is stored
under a static normal load σn,t. This normal load is selected to equal the
consolidation stress σ1 during preshear.

Time Yield Loci

Time Flow Functions

Measurement of Wall Friction
Shear displacement of bulk solids specimen on a wall material sample under

defined normal loads.
In a Jenike shear tester the basis ring is replaced with a wall material sample.

Determination of Wall Friction Angle

Bulk Solids – Problems
What has happened?

Question V
Flow Problems
Which different flow problems

appear in hoppers?
And in which type of hoppers

might these problems occur?

literature source: D. Schulze, Powders and Bulk Solids
Flow Profiles in Silos

Silo design for flow
Stresses at the silo outlet determine if

 Mass flow is achieved
 Arching occurs.
Course of stresses in the hopper has to be determined at passive stress

state for
 Wedge-shaped hopper (plain stress and strain state)
 Conical hopper (axial-symmetric stress and strain state)
2. März 2015 | A. Kwade | Schüttguttechnik | Seite 50

Axial-symmetric and Planar Flow

Conditions at the Outlet
(Radial Stress Field)

Boundaries Between Mass Flow and Core Flow

Question VI
Hopper Shapes
Why may a wedge-shaped mass flow hopper be flatter than a conical

mass flow hopper?

Design against arching (principal method)
In order to avoid an arch at the outlet the stresses acting on the bulk solid
at the outlet must be higher than the strength of the bulk solid. The
stresses acting on the bulk solid are determined by the bearing stress
No arch, if bearing stress > yield strength of bulk solid

Major Principal Stress, Consolidation Stress
and Stable Bulk Solid Arch

Determination of the Flow Factor
For a known set of values e, x and  the flow factor can be read (interpolate if
necessary)

Design against arching (principal method)
In order to avoid an arch at the outlet the stresses acting on the bulk solid
at the outlet must be higher than the strength of the bulk solid. The
stresses acting on the bulk solid are determined by the bearing stress
No arch, if bearing stress > yield strength of bulk solid
By comparison of bearing stress (= 1 / ff) and yield strength of bulk solid
as function of major principal stress a critical yield strength or bearing
stress respectively can be achieved, at which both stresses have the
same value.
With the critical yield strength and an adaption parameter the minimum
outlet size of the silos can be determined based on the knowledge of the
stress field in the hopper:
c,krit
d krit  H0 
g  b

Hopper Shapes

Influence of Flow Properties on Silo Design

Rule 1 - Junction to Connected Devices

Rule 1 – Example Gate/Flap:
Walls has to be designed steep enough for mass flow

Rule 2 – Example Screw conveyor:
Principle of increasing capacity
Dead zone
How can screw conveyor be designed to achieve an

increasing capacity in direction of flow?

Rule 2 – Example Screw conveyor:
Principle of increasing capacity

Rule No. 5
Discharge Over the Whole Outlet Diameter
Caution:
Problems if hanging hopper is completely filled with bulk solids
Discharge of bulk solids just from a partition of the outlet
Drive hanging hopper at intervals, check filling level if possible

Rule No. 5
Discharge Over the Whole Outlet Diameter

Pneumatic Discharge Aids

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Powder Flow, Measurement, and Silos

(Phenomenology, Design, Problems)

Prof. Dr.-Ing. A. Kwade

What are bulk solids?

very coarse convenience

Bulk solids consist of a huge number of single particles respectively

Powder Flow, Measurement, and Silos | A. Kwade

Cereals Silos Avalanches

Food products Tablets Building materials

Examples for bulk solids are

Powder Flow, Measurement, and Silos | A. Kwade

Why should we concern ourselves with bulk solids?

Knowledge of the behavior of bulk solids is important for

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

flow property steady flow

process design FIFO

engineering design mass flow

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

 Flow and load of bulk solids

Powder Flow, Measurement, and Silos | A. Kwade

Mechanical behavior of bulk solids is

Flow properties of bulk solids particularly depend on

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Forces on the periphery of single volume elements (sufficient large compared to

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Definition of the horizontal stress ratio:

Horizontal stress ratio of bulk solids in comparion to fluids and real

Powder Flow, Measurement, and Silos | A. Kwade

 Volume element with triangular

Powder Flow, Measurement, and Silos | A. Kwade

cohesionless bulk solid cohesive bulk solid

Powder Flow, Measurement, and Silos | A. Kwade

1 := consolidation stress (here the major principal stress )

Powder Flow, Measurement, and Silos | A. Kwade

How does the unconfined yield strength (resistance to plastic deformation)

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

ffc < 1 not flowing

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Increase of the unconfined yield strength c during storage time

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade

Ring shear tester

Jenike shear tester

Powder Flow, Measurement, and Silos | A. Kwade

Powder Flow, Measurement, and Silos | A. Kwade