Bulk Materials Handling Handbook

500 Pages·1988·28.35 MB·English

by  Jacob Fruchtbaum (auth.)

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, elec
tronic, or mechanical, including photocopying, recording, taping, or infor
mation 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.
ISBN 978-1-4757-4697-6 ISBN 978-1-4757-4695-2 (eBook)
DOI 10.1007/978-1-4757-4695-2
1. Bulk solids handling-Handbooks, manuals, etc. I. Title.
TSISO.S.B8F78 1988
621.S'6-dcI9 87-20715
CIP
Contents
llIustrations xiii 2.12 Training of Belt on Conveyor, 29
Tables xix 2.12.1 Belt-Training Idlers, 30
Preface xxiii 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
Section 1: Introduction 1 2.13.1 Location of Scale, 31
2.13.2 Weigh Larries, 32
1.1 Standardization in the Industry, 1 2.14 Shuttle Belt Conveyor, 34
1.2 Computation Standards, 1 2.15 Pinion-Swivel Arrangement for Foot of Belt
1.3 Properties of Materials, 1 Conveyor, 34
1.4 Handling Special Materials, 2 2.16 Troughing and Return Idlers, 34
1.5 Properties of Chains Referred to in This 2.17 Snspended Idlers, 38
Book, 2 2.17.1 Catenary Type, 38
1.6 References, 4 2.17.2 Garland Type, 38
1.7 Abbreviations, Letter Symbols; SI and Other 2.18 Belt Cleaners, 39
Equivalents, 4 2.19 Transfer of Material from Belt to Belt, 41
2.20 Takeups and Backstops, 41
2.20.1 Takeups,41
Section 2: Belt Conveyors 15 2.20.2 Backstops, 43
2.21 Cover, 43
2.1 General, 15 2.22 Safety Protection at Pulleys, 43
2.2 Information Reqnired for Designing or 2.23 Tension for Various Layouts, 43
Estimating Belt Conveyors, 15 2.24 Recommended Belt Speeds and Belt Widths, 48
2.3 Angle of Incline, 16 2.25 Design of a Belt Conveyor, 48
2.4 Belt Conveyor Elements, 17 2.25.1 Data, 50
2.4.1 Belt Characteristics, 17 2.25.2 Belt Tension Method (Using the
2.4.2 Rating of Multiple-Ply Belts, 17 CEMA Formulas for Belt Tension), 50
2.4.3 Reduced-Ply Belting, 17 2.25.3 Belt Flexure, 51
2.4.4 Steel Cable Belting, 17 2.25.4 Slack Slide Tension (T2)' 55
2.4.5 Troughing Empty Belts and Load 2.25.5 Pulleys, 56
Support, 18 2.25.6 Graphic Solntion, 57
2.4.6 Lagging of Pulley, 18 2.25.7 Jeffrey Formula, 60
2.4.7 Belt Splices, 18 2.25.8 Comparison of Methods, 61
2.5 Selection of Belt; Size and Spacing of 2.25.9 Friction Factors, 61
Idlers, 19 2.25.10 Conveyor Bill of Material, 61
2.6 Drive, 22 2.25.11 Conveyor Drive Bill of Materials, 61
2.7 Greasing ofIdlers, 23 2.25.12 Alternative Drive Bill of Material, 61
2.8 Belt Trippers, 23 2.26 Belt Conveyor Calculation, 62
2.9 Plow Versus Tripper, 25 2.26.1 Data, 62
2.10 Magnetic Pulley, 25 2.26.2 Horsepower Calculation, 62
2.11 Skirtboards, 29 2.26.3 Belt Selection, 63
v
vi CONTt:NTS
2.26.4 Head Pulley Selection, 63 3.14 Centrifugal-Discharge Bucket Elevators
2.26.5 Tail Pulley Selection, 63 (Vertically Spaced), 100
2.26.6 Design of Drive, 63 3.14.1 General, 100
2.27 Minimum Pulley Diameters for Belts, 63 3.14.2 Buckets, 101
2.28 Bend, Snub, Takeup, and Tail Pulleys, 63 3.14.3 Inclined Elevators, 102
2.29 Enclosures for Belt Conveyors, 64 3.14.4 Centrifugal-Discharge Elevator
2.30 Idler Selection, 64 Buckets, 102
2.31 Conveyor Belt Troubles, 66 3.14.5 Design of Centrifugal-Discharge
2.32 Selected Nomenclature for Section 2, 66 Elevator Handling Sand, 103
2.33 Specification for Inclined 30" Belt 3.14.6 Design of Centrifugal-Discharge
Conveyor, 72 Elevator Handling Salt, 108
2.34 Specification for 24" Shuttle Belt Conveyor, 73 3.14.7 Specification for Vertical Centrifugal
2.35 Specification for 30" Reversible Belt Discharge Elevator, 109
Conveyor, 73 3.15 Continuous-Bucket Elevators, 110
2.36 Specification for 24" Belt Conveyor, 74 3.15.1 General, 110
3.15.2 Speed, 110
3.15.3 Buckets, 111
Section 3: Bucket Elevators 77 3.15.4 Belts, 111
3.15.5 Types of Continuous Buckets, 111
3.1 General, 77 3.15.6 Design of Continuous-Bucket
3.1.1 Centrifugal-Discharge Bucket Elevator, 111
Elevator, 77 3.16 Super-Capacity Continuous Bucket
3.1.2 Continuous Bucket Elevator, 77 Elevator, 119
3.1. 3 Positive-Discharge Bucket 3.16.1 General,119
Elevator, 77 3.16.2 Materials Handled, 119
3.1.4 Combination Elevator-Conveyor, 77 3.16.3 Guide Angles, 121
3.1.5 Full-Volume or Bulk-Flo Elevator- 3.16.4 Takeups, 121
Conveyor Unit, 78 3.16.5 Specification for Super-Capacity
3.1.6 Pivoted-Bucket Carrier, 79 Elevator, 121
3.1.7 Internal-Discharge Elevator, 79 3.16.6 Design of Super-Capacity
3.1.8 Bucket Elevator on Incline,. 79 Elevator, 122
3.1.9 Centrifugal vs Continuous-Bucket 3.17 Positive-Discharge Bucket Elevator, 123
Elevators, 79 3.17.1 General, 123
3.1.10 Preliminary Selection of Type, 79 3.17 . 2 Perfect-Discharge Bucket Elevator
3.2 Casing, 79 Handling Run-of-Mine Bituminous
3.2.1 Drives, 79 Coal (ROM), 124
3.2.2 Inspection Doors, 82 3.17.3 Specification for Positive-Discharge
3.3 Elevator Pits, 82 Bucket Elevator-Conveyor, 125
3.4 Boot Section, 83 3.18 Gravity-Discharge Elevator-Conveyor, 127
3.5 Head Section, 84 3.18.1 General, 127
3.6 Platforms and Ladders, 84 3.18.2 Design of Gravity-Discharge Elevator
3.7 Buckets, 85 Conveyor, 127
3.8 Chain, 87 3.18.3 Specification for Gravity-Discharge
3.8.1 Service Factor, 89 Elevator-Conveyor, 129
3.8.2 Recommended Speeds, 89 3.19 Full-Volume or en Masse Elevator-Conveyor
3.8.3 Chain versus Belt, 89 Unit, 130
3.9 Traction Wheels and Sprockets, 89 3.20 Pivoted Bucket Carrier, 133
3.10 Takeups, 90 3.20.1 General, 133
3.11 Horsepower, 92 3.20.2 Strap Chains, 136
3.11.1 Tension on Chain or Belt, 93 3.20.3 Travel Paths, 136
3.11.2 Horsepower Allowance, 93 3.20.4 Peck Carrier Capacity and Weight,
3.12 Standard Designs, 100 136
3.13 Belts, 100 3.20.5 Cast-Tooth Equalizing Gears, 136
CONTENTS vii
3.21 Selected Abbreviations and Letter Symbols 4.26 Screw Conveyor Handling Petroleum Coke,
Used in Section 3, 136 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
Section 4: Screw Conveyors 139 4.26.5 Components, 168
4.26.6 Finishes, 168
4.1 General, 139 4.27 Lump Size Limitations, 168
4.2 Advantages of Screw Conveyor, 139 4.28 Safety, 170
4.3 Helicoid Versus Sectional Conveyors, 139
4.4 Types of Flights, 140
4.5 Pitch of Conveyor Screw, 140 Section 5: Apron and Mold
4.6 Short Feeder Sections, 142 Conveyors 171
4.7 Supporting Hangers, 142
4.8 Troughs, 142 5.1 General, 171
4.9 Nomenclature, 146 5.2 No-Leak Types, 171
4.10 Handling Food Products, 146 5.3 Heavy Ores and Large Lumps, 171
4.11 Shafts, Couplings, and Coupling Bolts, 146 5.4 Data on Apron Conveyors, 174
4.12 Long Screw Conveyor Design, 146 5.5 Selection of Apron, 174
4.13 Intermediate Hanger Bearings, 148 5.6 Design of Apron Conveyor, 174
4.14 End Bearings, 151 5.6.1 General Data, 174
4.15 Live Bottom Screw Coverings in Refuse 5.6.2 Capacity, 174
Bins, 151 5.6.3 Horsepower, 175
4.16 Inclined Screw Conveyors, 151 5.6.4 Size of Head Shaft, 177
4.17 Screw Conveyors over 20 Feet Long, 155 5.6.5 Drive Layout, 179
4.18 Screw Elevator, 155 5.6.6 Inclined Conveyor, 180
4.19 Jacketed Screws, 156 5.7 Leakproof Conveyors, 181
4.20 Overflow Protection, 156 5.8 Handling Heavy Material, 182
4.21 Screw Conveyor Drive, 158 5.9 Apron Conveyor with Horizontal and Inclined
4.22 Reclaiming Screw Conveyors Handling Sections, 182
Coal, 158 5.10 Design of Apron Conveyor with Horizontal and
4.23 Carbon-Chip Refuse Screw Conveyors, 159 Inclined Sections, 183
4.24 Design of a Screw Conveyor Handling 5.10.1 Data, 183
Sulfur, 159 5.10.2 Capacity, 184
4.24.1 Jeffrey Screw Conveyor, Catalog No. 5.10.3 Loads, 184
951, 160 5.10.4 Motor Selection, 184
4.24.2 Stephens-Adamson Catalog 5.10.5 Head Shaft, 184
No. 66, 161 5.10.6 Layout of Drive, 184
4.24.3 Link-Belt Catalog 1000, 161 5.11 Hinged-Steel Belt Conveyors, 184
4.24.4 CEMA Formula, 161 5.12 Flat-Plate Conveyors, 185
4.24.5 Comparison of Results, 162 5.13 Open-Top Deep-Bucket Carrier, 185
4.24.6 Final Design, 162 5.14 Cooling and Mold Conveyors, 186
4.24.7 Specifications, 162 5.15 Coal-Handling System, 187
4.24.8 Bill of Material, 164 5.16 Specification for 24-Inch Steel-Apron
4.24.9 Drive Equipment, 164 Conveyor, 189
4.25 Design of a Screw Conveyor Handling
Petroleum Coke, 164
4.25.1 Data, 164 Section 6: flight and Drag
4.25.2 Size of the Conveyor, 165 Conveyors 193
4.25.3 Horsepower, 165
4.25.4 Drive, 166 6.1 General, 193
4.25.5 End Thrust, 166 6.2 Uses, 193
viii CONTENTS
6.3 Single-Strand Flight Conveyors, 193 7.4 Apron Feeders, 215
6.4 Double-Strand Flight Conveyor with Roller 7.4.1 Handling Considerations, 215
Suspended Flights, 193 7.4.2 Open-Top Deep-Bucket Carrier, 215
6.5 Drag Conveyors, 194 7.5 Design of Apron Feeder, 217
6.6 Selection of a Scraper Flight 7.5.1 Horsepower, 217
Conveyor, 197 7.5.2 Size of Head Shaft, 217
6.6.1 Data, 197 7.5.3 Capacity,217
6.6.2 Size Selection of Flights, 197 7.5.4 Details, 218
6.7 Design of a Double-Strand Scraper 7.6 Bill of Material, 218
Conveyor, 197 7.7 Design of No-Leak Type Apron Feeder, 219
6.7.1 General Data, 197 7.7.1 Data, 219
6.7.2 Considerations; 197 7.7.2 Actual Capacity, 219
6.7.3 Capacity, 198 7.7.3 Horsepower at Head Shaft, 219
6.7.4 Horsepower, 200 7.8 Selection of Type, 221
6.8 Design of a Drag Conveyor, 201 7.9 Rotary Table Feeder, 221
6.8.1 Data, 201 7.10 Screw Feeders, 222
6.8.2 Size of Trough, 201 7.11 Mechanical Vibrating Feeders, 222
6.8.3 Head Shaft, 201 7.12 Vibrating Feeders-Electromagnetic and
6.8.4 Horsepower, 202 Electromechanical, 225
6.8.5 Design of Drive, 202 7.12.1 General,225
6.8.6 Bill of Material, 202 7.12.2 Design Options, 225
6.9 Scraper Flight Conveyors in a Cannery, 203 7.12.3 Bulk Materials, 225
6.10 Loading Bales of Scrap into Railroad Cars 7.12.4 Typical Designs, 225
Directly from Baling Machine, 203 7.12.5 Capacity Calculations, 225
6.11 Drag and Scraper Flight Conveyors in a Pulp, 7.13 Bar Scraper Feeders, 229
Paper, and Saw Mill, 203 7.14 Weigh Feeders, 229
6.12 Standard Method of Handling Logs by Chain 7.15 Sizing Apron Feeder under Track Hopper, 231
(Scraper) Conveyors, 206 7.15.1 Data, 231
6.13 Cable Drag Scraper (Power Hoe), 206 7.15.2 Design, 231
6.14 Design of Cylinder Conveyor, 207 7.16 Rotary Feed Valves, 231
6.14.1 Data, 207 7.17 Car Loading Devices, 232
6.14.2 Rolling Friction (rf) of Chain, 207 7.18 General-Vibrating (Oscillating)
6.14.3 Load on Run A, 207 Conveyors, 232
6.14.4 Load on Run B, 207 7.19 Light-Duty Oscillating Conveyors (Up to 25
6.14.5 Load on Run C, 208 Tons per Hour), 232
6.14.6 Load on Run D, 208 7.20 Medium-and Heavy-Duty Oscillating
6.14.7 Total Pull at Head Shaft, 208 Conveyors, 235
6.14.8 Rechecking Conveyor Chain 7.21 Natural Frequency, 236
Strength, 208 7.22 Supports, 236
6.14.9 Horsepower, 208 7.23 Isolating Conveyor, 236
6. 14.10 Size of Head Shaft, 208 7.24 Maintenance, 236
6.15 Specification for Chain Drag Conveyor, 208 7.25 Vibrating Drum Packers (Vibrating
Tables), 236
7.25.1 General, 236
Section 7: Feeders and Vibrating
7.25.2 Partial Specification, 236
Conveyors 211
7.1 General-Feeders, 211
7.2 Reciprocating Feeders, 211
7.2.1 Space for Reciprocating Feeder, 211 Section 8: Wire Mesh Conveyors 237
7.2.2 Capacity of Reciprocating Feeder, 212
7.3 Belt Feeders, 215 8.1 General, 237
7.3.1 Material Handled, 215 8.2 Heat-Resisting Alloy Belts, 237
7.3.2 Belt Feeders Under Dump 8.3 Types of Wire Belts, 237
Hoppers, 215 8.4 ANSI Chain Numbers, 237
CONTENTS ix
Section 9: Drives 243 10.23 Typical Industrial Screen Requisition, 275
10.24 Blinding and Plugging, 275
9.1 Speed Reducers. 243 10.25 Water Screens, 276
9.2 Shaft Couplings, 243 10.25.1 General, 276
9.3 Drives, 243 10.25.2 Protection ofIntake, 276
9.4 Torque Limiters, 246 10.25.3 Flow Through Water Screen, 276
9.5 Drive Selection, 246 10.25.4 Loss of Head, 276
9.6 Selection of Shafts Subject to Torsion and 10.25.5 Spray of Nozzles, 278
Bending, 247 10.25.6 Accumulated Sand, 278
9.7 Drive Guards, 251 10.26 Screen in Laboratories, 278
9.8 Selection of Type of V-Belt, 251
9.9 Chain for Drives, 253
9.10 Sprockets for Roller Chain Drives, 253
Section 11: Skip Hoists 279
ILl General, 279
Section 10: Crushers and Screens 255 11.2 Types, 279
11.3 Loading Methods, 279
10.1 Introduction to Crushers, 255 11.4 Manual Loading-Direct Type, 280
10.2 Selection of Crushers, 255 11.5 Manual Loading-Indirect Type, 280
10.3 Hammermills (Swing Hammermills), 255 11. 6 Full Bucket Control System, 280
10.3.1 High-Speed Hammermills, 257 11.7 Balanced Skip Hoist, 281
10.3.2 Slow-Speed Hammermills, 257 11.8 Materials Handled, 281
10.4 Introduction to Roll Crushers, 257 11. 9 Selection of a Skip Hoist, 281
10.5 Single-Roll Crushers, 257
11.10 Specification of a Vertical-Lift Drum
10.6 Double-Roll Crushers, 258
Conveyor, 281
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 Section 12: Hoists and Cranes 283
10.9 Raymond Mill, 261
10.9.1 CO2 System, 262 12.1 General, 283
10.9.2 Flue Gas, 263 12.2 Hoists, 283
10.9.3 Other Raymond Machines, 264 12.2.1 Hoist Sheaves and Cables, 283
10.10 Computation of Horsepower Required for 12.2.2 Hoists on Traveling Bridges, 284
Gyratory Crushers, 264 12.2.3 Hoists-Electrical, 284
10.10. 1 General, 264 12.3 Swinging Jib Cranes, 284
10.10.2 Design Formula, 264 12.4 Gantry Cranes, 284
10.10.3 Design Example, 264 12.5 Crane Classification, 284
10.10.4 Impact Testing, 266 12.6 Conventional Overhead Cranes: Two
10.10.5 Product Analysis of A-C Gyratory Types, 286
Crusher, 266 12.6.1 Dimensions, 287
10.10.6 Examples of Use of Figure 10.8, 268 12.6.2 Diagram Notes, 287
10.11 Gundlach Crushers (Rexnord), 268 12.6.3 Bridge, Trolley, and Hoist Speeds for
10.12 Introduction to Screens, 269 Table 12.2, 299
10.13 Fine Materials, 269 12.6.4 Notes for Tables 12.3 and 12.4, 299
10.14 Vibrating Screens, 269 12.7 Auxiliary Hooks, 299
10 .15 Tyler Screens, 269 12.8 Speed of Travel, 299
10.16 Exolon Screens, 269 12.9 Selection of Crane Rail, 299
10.17 Allis-Chalmers Vibrating Screens, 271 12.10 Explosion-Proof Areas, 299
10.18 Simplicity Vibrating Screens, 273 12.11 Specifications, 299
10.19 Rotex Screens, 273 12.12 Monorail Systems, 300
10.20 Magnetic Separators, 274 12.13 Overhead Trolley Conveyors, 300
10.21 Size of Screen, 274 12.13.1 Uses, 303
10.22 Specification for Sifter Screen, 274 12.13.2 Chain and Trolley, 303
x CONTENTS
12.13.3 Power and Free Trolley Conveyors, 14.23 Perlite and Expanded Perlite, 360
304 14.24 Petroleum Coke, 360
12.13.4 Floor Conveyors, 304 14.25 Plastic (Fine) Material, 362
12.13.5 Design Data for Overhead Trolley 14.26 Rice, 362
Conveyors, 304 14.27 Salt (Mineral-Halite), 362
12.14 Number of Cranes, 304 14.28 Sand and Gravel, 365
12.15 Aerial Cableways, 305 14.29 Shale, Kaolin (Clay), 366
12.16 35/l5-Ton Radwaste Handling Crane, 306 14.30 Soapstone, Talc, Asbestos, and Mica, 366
14.31 Soda Ash, 367
14.32 Steel or Cast-Iron Chips, 367
Section 13: Gates, Chutes, and 14.33 Sulfur, 369
Spouts; Bins and Hoppers 307 14.34 Wood: Chips, Flour, and Sawdust, 370
14.35 Zirconium, 375
13.1 Introduction to Gates, Chutes, and Spouts, 307
13 .1.1 Types of Gates, 307
13.1.2 Linings, 307 Section 15: Overhead and Portable
13.2 Feeding More Than One Location, 307 Car Shakers 377
13.3 Flexible Spouts, 314
13.4 Introduction to Bins and Hoppers, 315 15.1 General, 377
13.5 Types of Bins and siios, 316 15.2 Noise, 377
13.6 Track or Truck Hoppers, 320 15.3 Heating Cars, 377
13.7 Weigh (Scale) Hoppers, 320 15.4 Hewitt-Robins Shakers, 377
13.8 Hopper Spouts, 320 15.5 Allis-Chalmers Car Shakers, 379
13.9 Storing Hot or Cold Covered Material, 320 15.6 Portable Vibrators, 379
13.10 Bin Accessories, 324 15.7 Large-Scale Car Unloaders, 379
Section 14: Handling Special Section 16: Heating, Cooling, and
Materials 327 Ventilating Furnace Buildings 381
14.1 General, 327 16.1 General-Heating and Cooling, 381
14.2 Ashes, 327 16.2 Types, 381
14.3 Bauxite Ore, 328 16.3 Cooling of Lime, 381
14.4 Carborundum, 329 16.3.1 Data, 381
14.5 Carbon Chip Refuse, 329 16.3.2 Cooling Air Requirements, 383
14.6 Cement, 329 16.4 Requisition for Coke Dryer, 383
14.7 Charcoal, 333 16.5 Design of Coke Dryer, 383
14.8 Chrome Ore, 333 16.5.1 Data,.383
14.9 Coal, 334 16.5.2 Internal Heat Required, 384
14.10 Coke, 339 16.5.3 Required Air, 384
14.11 Crushed Ice, 340 16.5.4 Thermal Efficiency, 384
14.12 Crushed Stone (Limestone-Dolomite), 340 16.5.5 Inlet Air, 384
14.13 Explosive Materials, 342 16.5.6 Exhaust Air, 385
14.14 Feed, Flour, and Grain, 351 16.5.7 Furnace Heat Required, 385
14.15 Foundry Sand-Green Sand Molding, 353 16.6 Operation of the Roto-Louvre, 385
14.16 Graphite, 354 16.7 Heating Material in Bins, 385
14.17 Gypsum, 354 16.7.1 General,385
14.18 Lead and Zinc Ores, 357 16.7.2 Volumes and Areas, 387
14.19 Lime, 357 16.7.3 Properties, 387
14.19.1 Apron Conveyor Design, 358 16.7.4 Heat Transfer Equations, 388
14.19.2 Horsepower at Head Shaft, 358 16.7.5 Sample Computations for
14.20 Logs, 359 Section 1, 389
14.21 Metallurgical Coke, 359 16.7.6 Details of Bin Design, 390
14.22 Pencil Pitch, 360 16.7.7 Nomenclature for Paragraph 16.7,392