FLOW PROPERTY REPORT INTERPRETATION

TUNRA Bulk Solids

in association with
Centre for Bulk Solids & Particulate Technologies
The University of Newcastle

Particle Size Distribution

TUNRA Bulk Solida 4.1

 Particle Size Distribution (PSD)

z The PSD for a bulk material is usually determined using a dry

sieving technique

z For bulk materials with large particle sizes , the sample is

sieved to obtain a sub-sample of -4mm for testing

100

80
Sieved Sample
for Testing
60
Percent
Finer
40

20

0
0.01 0.1 1 10 100
Sieve Opening Size - mm

3 © 2007 TUNRA Ltd

Moisture Content Determination

TUNRA Bulk Solida 4.2

 Saturation Moisture Content
Motivation

z Non-standard test to measure the free moisture holding

capacity of a bulk solid

z Along with the as-received moisture determination, it is the

‘1st’ step in the general flow properties test work

z Gives an indication of how the as-received moisture content

compares to the saturation moisture – expressed as a
percentage of saturation

z This is used a starting point for worst case moisture

determination, which often occurs at approximately 50%-80%
of saturation (moisture content) – however one needs to be
very careful with this assumption

5 © 2007 TUNRA Ltd

Saturation Moisture Tester

Test Preparation

z Enclosure in environmentally controlled

room (20deg C, 65% relative humidity)
z 40micron Stainless Steel Mesh Funnel
z Filled with –4mm bulk material
z Submerged in water for 30min

6 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.3

 Saturation Moisture Tester
Free Draining Procedure

z Sample is automatically lifted after

30 minutes
z Weight of draining sample is
recorded every 15 minutes
z Final weight is reached when the
change between individual
saturation moisture content
readings is less than 1%

7 © 2007 TUNRA Ltd

Saturation Moisture Tester

Extract: Sample Results Sheet

z Sample is automatically lifted after

30 minutes Saturated Moisture Content Test
z Weight of draining sample is Date: 03-Dec-06 Project No : 6724 ID:
recorded every 15 minutes
z Final weight is reached when the Client: Pilbara Iron Sample Fraction: Full Size
change between individual saturated
moisture content readings is less Bulk Material: RM17885 As Supplied MC: 15.1%
than 1% As Change
Cone Cone + Saturated
Supplied Calc Dry in
Time Cone Dry + Sample Moisture
Interval Moisture Sample Moisture
(min) Dry (g) Sample Saturated Content
Content (g) Content
(g) (g) (%)
(%) (%)
1 15 56.9 633.1 780.2 15.1% 489.1 32.4 0.00
2 30 56.9 633.1 761.6 15.1% 392.0 30.60 5.51
3 45 56.9 633.1 748.6 15.1% 392.0 29.30 4.26
4 60 56.9 633.1 739.7 15.1% 392.0 28.38 3.15
5 75 56.9 633.1 734.5 15.1% 392.0 27.83 1.94
6 90 56.9 633.1 733.2 15.1% 392.0 27.69 0.50
7 105 56.9 633.1 732.9 15.1% 392.0 27.7 0.12
8 120
9 135
10 150
11 165
12 180

8 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.4

 Moisture Correlation

z Most flow properties test work is 35

conducted on the –4mm size fraction,
being the dominant size fraction in view 30 Saturated
of flowability of a bulk sample.

Moisture Content (%)

25

-4mm Size Fraction

z In view of likely process moistures it is
important to correlate between the full 20
size process moisture and the tested
–4mm size fraction moisture content. 15 As Supplied
z The saturation and as-received
moistures of both the –4mm and full 10
size fractions are measured (see
sample table and graph) 5

0
Size ‘as Saturated 0 5 10 15 20 25 30 35
Fraction supplied’ Full Size Fraction Moisture Content (%)
-4mm 14.7% 29.4%

Full 13.0% 21.1%

9 © 2007 TUNRA Ltd

‘Worst Case’ Moisture Determination

TUNRA Bulk Solida 4.5

 Jenike Shear Tester
The most widely used instrument for determining flow
properties of bulk solids

Has been used extensively over the past 30 years at the University of
Newcastle to test many thousands of bulk solid materials, the results of
which have been utilised in the design of a great number of materials
handling plants throughout Australia and the world.

11 © 2007 TUNRA Ltd

Critical Opening Size vs Moisture Content

Example 3 HV Coals

z Very similar trends at low moisture contents

z Washed samples/blends peak earlier at lower moisture content
z Actual difference between samples is rather small, as evidenced by
small change in saturation moisture content

Sample 1:
Raw Coal (Open Cut)

Sample 2:
As above, but washed

Sample 3:
Blend of 1+2

12 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.6

 Worst Case Moisture Determination
Required test work to ensure that a design is capable
of handling the bulk material across all ranges of moisture

z The Worst Case Moisture is indicative of the moisture level at which the material
exhibits its most difficult flow characteristics.
z A ‘Worst Case Moisture Determination’ involves producing a series of 2-point flow
functions at a increasing moisture contents.
z A ‘typical’ material may reach a peak in unconfined yield strength at a moisture level
of between 40-90% of saturation.
z Testing is performed in steps equal to either 5% or 10% of saturation moisture.

15
11.7% mc
14.6% mc
17.5% mc
Unconfined 10 20.4% mc
Yield
Strength
kPa
5

0
0 5 10 15 20 25 30
Major Consolidation Stress - kPa

13 © 2007 TUNRA Ltd

Jenike Shear Test Results

TUNRA Bulk Solida 4.7

 Low Consolidation Jenike Shear Test Results

Bulk Density (compressibility)

Internal Angles of Friction

Effective
Static

Flow Functions
Instantaneous
Time

15 © 2007 TUNRA Ltd

High Consolidation Jenike Shear Test Results

Bulk Density (compressibility)

Internal Angles of Friction

Effective
Static

Flow Functions
Instantaneous
Time

16 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.8

 Compressibility Test Rig

17 © 2007 TUNRA Ltd

Bulk Density

Bulk Density
1400

1300
Bulk Density - kg/m3

1200

1100

1000

900

800
0 5 10 15 20 25 30
Major Consolidation Stress - kPa

18 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.9

 Bulk Density and Strength Variations
with changing Moisture Content

z Both bulk density and unconfined yield strength are generally a function of the
moisture content
z Dependency of the bulk strength is generally more pronounced at higher
consolidation loads

0.82
2.0 kPa 12
0.80 5.0 kPa
51.5 kPa 2.7 kPa
10
13.4 kPa

UNCONFINED YIELD
BULK DENSITY (t/m3)

0.78 59.7 kPa

STRENGTH (kPa)
8

0.76 6

0.74 4

2
0.72
0
0.70 2 4 6 8 10 12 14 16
2 4 6 8 10 12 14 16 MOISTURE CONTENT - %
MOISTURE CONTENT - %

19 © 2007 TUNRA Ltd

Internal Friction Angles

τ
Effective Angle of Internal Friction (δ):
Unconfined Yield Strength [kPa]

The slope angle of the Effective Yield Locus (EYL) which is a line
from the origin, tangential to the Major Mohr circle. EYL

Kinematic Angle of Internal Friction (φ):

The slope angle of the Instantaneous Yield Locus (IYL) at the point
of intersection with the Mohr circle through the origin.

60.0 δ
(σc ) (σ 1) σ
Effective Angle of Internal Friction
55.0 Major Consolidation Stress [kPa]
Internal Friction Angles (deg)

Kinematic Angle of Internal Friction

τ
50.0
Unconfined Yield Strength [kPa]

45.0 IYL

40.0

Φ
35.0

30.0 (σ1) σ
(σc )
0.0 5.0 10.0 15.0 20.0 25.0 30.0
Major Consolidation Stress [kPa]
Major Consolidation Stress (kPa)

20 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.10

 Low Consolidation Flow Functions

Flow Function
20
Instantaneous
After 3 days storage

15
Unconfined Yield Strength - kPa

ff

10

0
0 5 10 15 20 25 30
Major Consolidation Stress - kPa
Figure A1.1 - Low Consolidation Shear Test Results
ROM Coal @ 18.0% mc.
21 © 2007 TUNRA Ltd

High Consolidation Flow Functions

Flow Function
60
Instantaneous
After 3 days storage
50
Unconfined Yield Strength - kPa

40

30

20

10

0
0 10 20 30 40 50 60 70 80 90
Major Consolidation Stress - kPa
Figure A1.2 - High Consolidation Shear Test Results
ROM Coal @ 18.0% mc
22 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.11

 Wall Friction Test Results

Wall Yield Loci and Wall Friction Angle

24 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.12

 Maximum Effective WFA

φ e = tan−1(sinδ)

25 © 2007 TUNRA Ltd

WFA for Chute Design

26 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.13

 Normal Stress and Major Consolidation
Stress at the Hopper Wall

27 © 2007 TUNRA Ltd

WFA and Major Consolidation Stress

Wall Friction Angle

60
Mild Steel Mill Scale
Stainless Steel 304-2B
50 UHMWPE

40
Angle - degrees

30

20

10
σ σ
w 1
0
0 5 10 15 20 25
Normal Stress (kPa)

28 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.14

 Mass-Flow Hopper Geometry

Mass-
Mass-Flow Hopper Geometry

Conical Mass-Flow Geometry

Plane Mass-Flow Geometry

30 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.15

 Mass-
Mass-Flow Hopper Design

σ 1H(α)
B cr =
ρg

31 © 2007 TUNRA Ltd

Conical Mass-
Mass-Flow Geometry

Half Hopper Angle & Flow Rate vs Outlet Diameter

for a Conical Hopper.
35 175,000
α- Mild Steel Mill Scale Q- Mild Steel Mill Scale
α- Stainless Steel 304-2B Q- Stainless Steel 304-2B
Potential Discharge Rate (Q) - T/hr

30 α- UHMWPE Q- UHMWPE 150,000

Half Hopper Angle (α) - Deg

Instantaneous critical outlet dimension

3 days time storage

25 critical outlet dimension 125,000

20 100,000

15 75,000

10 50,000

Add 10% to 20%

5 for minumum 25,000
outlet dimension
0 0
0 0.5 1 1.5 2 2.5 3 3.5 4
Outlet Diameter (B) - m
32 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.16

 Plane Mass-
Mass-Flow Geometry

Half Hopper Angle & Flow Rate vs Outlet Width

for a Slotted Wedge Shaped Hopper.
40 20,000

Potential Discharge Rate (Q) - T/hr/m(length)

3 days time storage
critical outlet dimension
18,000
35
Half Hopper Angle( α) - Deg

16,000

Instantaneous critical outlet dimension

30
14,000
25 12,000
20 10,000
8,000
15
6,000
10
Add 10% to 20% 4,000
5 for minimum
outlet dimension 2,000
0 0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Outlet Width (B)- m

33 © 2007 TUNRA Ltd

Variable Bin Geometry

σ1H(α )
B= ρg
σ1
ff =
σ1

σ1H(α )
B= ρgff ff

σ 1 = Bρgff
H(α )

34 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.17

 Wall Friction Angle
60
Mild Steel Mill Scale
Stainless Steel 304-2B
50 UHMWPE

40
Angle - degrees

30

20

10
σ σ
w 1
0
0 5 10 15 20 25
Normal Stress (kPa)

35 © 2007 TUNRA Ltd

Mass-
Mass-Flow Limits

AXI-SYMMETRIC OR CONICAL HOPPERS PLANE-FLOW HOPPERS

50 50

δ deg δ deg
70 70
40 60 40 60
50 50
FUNNEL-FLOW
Wall Friction Angle φ (deg)

Wall Friction Angle φ (deg)

40 40
30 FUNNEL-FLOW 30
30 30

δ deg δ deg
30 30
20 40 20 40
50 50
60 60
MASS-FLOW MASS-FLOW 70
70
10 10

0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60 70
Hopper Half Angle α (deg) Hopper Half Angle α (deg)

36 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.18

 Constant Hopper Half Angle

Half Hopper Angle & Flow Rate vs Outlet Diameter

for a Conical Hopper.
30 80,000
α- Arcoplate Q- Arcoplate

Potential Discharge Rate (Q) - T/hr

α- Bisalloy 360 Q- Bisalloy 360 70,000
α- NiHard Q- NiHard
Half Hopper Angle (α) - Deg

25
60,000
3 days time storage
20 critical outlet dimension
Instantaneous critical outlet dimension

50,000

15 40,000

30,000
10
20,000
5
10,000

0 0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Outlet Diameter (B) - m
37 © 2007 TUNRA Ltd

Mass Flow Rate Estimate Q

Average Terminal
Outlet Area Velocity

(1+m) (1−m) ⎛ π ⎞
m
B ⎡ ff ⎤
Q = ρB L ⎜ ⎟ g⎢1− ⎥
⎝4⎠ 2(m +1) tanα ⎣ ffa ⎦
Acceleration
Where: J.R. Johanson (1965)
m = 0 for plane-flow hopper and 1 for axi-symmetric or conical hopper
B = Width of slot or diameter of circular opening
L = Length of slot in case of plane-flow hopper
α = Actual hopper half-angle
ff = Critical flow factor based on minimum arching dimensions
ffa = Flow factor based on actual outlet dimensions
ρ = Bulk density
g = Gravity
38 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.19

 Basic Symmetrical Mass-
Mass-Flow Bin Shapes

D
D

Cylinder αp αc αp
H H
Bp Bp

L
L
Hopper αp
αc (a) Transition Hopper (b) Chisel-Shaped Hopper

Gussets
Bp
B L
(a) Axi-Symmetric (b) Plane-Flow
Conical Hopper Wedge-Shaped Hopper

αc Valley
Angle Plan View Showing Gussets
Bc

(c) Pyramid Hopper

39 © 2007 TUNRA Ltd

Increasing Half Angle

Half Hopper Angle & Flow Rate vs Outlet Width

for a Slotted Wedge Shaped Hopper.
Potential Discharge Rate (Q) - T/hr/m(length)

40 50,000
NiHard
35 Bisalloy
Half Hopper Angle( α) - Deg

Ceramic Tile 40,000

30
Instantaneous critical outlet dimension

25 30,000
20

15 20,000

10 NiHard - Q
Bisalloy - Q 10,000
Ceramic Tile - Q
5

0 0
0 0.5 1 1.5 2 2.5 3
Outlet Width (B)- m
Figure A3.1
40 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.20

 Funnel-Flow

Critical Piping Diameter

Critical Piping Diameter

15
Upper Bound Df (Instantaneous)
Upper Bound Df (Time)
Mean Df (Instantaneous)
Mean Df (Time)

10
Diameter - Metres

0
0 5 10 15
Effective Head - Metres
Figure A4.1 - Critical Piping Diameter
ROM Coal @ 18.0% mc
42 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.21

 Critical Piping Diameter

Critical Piping Diameter

0

Upper Bound Df (Instantaneous)

Upper Bound Df (Time)
Mean Df (Instantaneous)
Mean Df (Time)

5
Effective Head - Metres

10

15
0 5 10 15
Diameter - Metres
Figure A4.1 - Critical Piping Diameter
ROM Coal @ 18.0% mc
43 © 2007 TUNRA Ltd

Critical Piping Diameter

σ c G(φ t )
σ 1 = hfρg Df =
ρg
12

10

G( φt)

2
30 35 40 45 50 55 60 65 70
φt

44 © 2007 TUNRA Ltd

TUNRA Bulk Solida 4.22

 Critical Piping Diameter

Critical Piping Diameter

0

Upper Bound Df (Instantaneous)

Upper Bound Df (Time)
Mean Df (Instantaneous)
Mean Df (Time)

5
Effective Head - Metres

10

15
0 5 10 15
Diameter - Metres
Figure A4.1 - Critical Piping Diameter
ROM Coal @ 18.0% mc
45 © 2007 TUNRA Ltd

THANK YOU!

TUNRA Bulk Solida 4.23