Screw conveyor componentS & deSign Conveyor Engineering & Manufacturing introduction PDF

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Screw Conveyor components & design Version 2.20 1345 76th Ave SW Cedar Rapids, IA 52404 PH 319.364.5600 / 800.452.4027 FAX 319.364.6449 www.conveyoreng.com [email protected] [email protected] Copyright © 2012 by Conveyor Eng. & Mfg. Co. All rights reserved. This manual and all ...

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Screw Conveyor components & design Version 2.20

1345 76th Ave SW Cedar Rapids, IA 52404 PH 319.364.5600 / 800.452.4027 FAX 319.364.6449 www.conveyoreng.com [email protected] [email protected]

Copyright © 2012 by Conveyor Eng. & Mfg. Co. All rights reserved. This manual and all items included may not be reproduced in any form without written permission from CEMC.

Conveyor Engineering & Manufacturing

introduction

Conveyor Engineering & Manufacturing would like to thank you for expressing interest in our products. We specialize in stainless steel screw conveyors, mixers and screw presses used in a variety of industries. The cornerstone of our success for over three decades has been our ability to provide a quality product at a reasonable price in a timely manner. Service

REFERENCES

Our commitment to outstanding service has been the main reason for our consistent growth since 1977 as we recently built a much larger manufacturing facility to maintain this level. When it comes to service, we have one goal — to provide the best in the industry. Absolutely no one ships hot jobs quicker. We can do this by stocking the raw materials we need and operating only one full shift in our manufacturing plant. This allows us the flexibility to extend hours when needed and greater access to key equipment and material when hot jobs are ordered. We have a full engineering staff on hand capable of performing system simulations, finite element analysis, etc. and discuss any questions you may have.

Our customer base has grown over the years primarily by word of mouth through satisfied customers. This has given us the opportunity to work with companies such as:

QUALITY When it comes to quality, we will put our products up against anyone in the industry. Prior to manufacturing, all custom conveyor designs must pass a computer stress analysis covering bolts, flights, pipe and shafts. On request, this information can be provided at time of quotation. Our components are manufactured in-house allowing us to keep tight reign on quality control and must pass a full inspection prior to shipping.

PRICE Our stainless conveyors are built entirely under our roof. You will not pay multiple markups for subcontracted parts. We handle complete manufacturing and engineering functions through our facility in Cedar Rapids. This means that, even with industry leading standards for quality and service, we can still offer very competitive pricing.

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• • • • • • • • • • • • • • • • • • • • • •

3M ADM AGP Amalgamated Sugar American Crystal Sugar Amoco Chemical Anheuser-Busch Barr-Rosin Bunge Cargill Con-Agra Dow Chemical DuPont Excel General Foods General Mills Georgia-Pacific Hershey's Hormel Foods ICM International Paper Kellogg's

• • • • • • • • • • • • • • • • • • • • • •

Kimberly-Clark Kraft Foods M & M Mars Michigan Sugar Monfort Monitor Sugar Monsanto Nabisco Brands National Starch Nestle Penford Products Poet PPG Procter & Gamble Quaker Oats Ralston Foods Roquette America Southern Minn. Beet Sugar Tate & Lyle Tyson Foods Wausau Paper Western Sugar

Again, thank you for the opportunity to get to know us better — we are very proud of the work we do and look forward to working with you.

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Conveyor Engineering & Manufacturing

table of contents

Engineering

components

other

Advantages of Screw Conveyors............. 4 Conveyor Design Steps............................ 4 Material Classification Codes................... 5 Special Materials and Applications......... 15 Conveyor Size and Speed...................... 16 Conveyor Capacity................................. 17 Material Lump Size................................. 18 Horsepower Calculation......................... 19 Drive Efficiency....................................... 20 Component Sizing.................................. 23 Torsional Rating, Torque Calculation...... 24 Screw Deflection.................................... 26 Thermal Expansion................................ 26 Abrasion................................................. 27

Conveyor Component Diagram.............. 28 Conveyor Layout.................................... 29 Screws.................................................... 30 Coupling Bolts/Bolt Pads........................ 41 Shafts..................................................... 42 Troughs.................................................. 46 Mounting Feet........................................ 51 End Plates.............................................. 52 Covers.................................................... 58 Hangers.................................................. 64 Hanger Bearings.................................... 70 Internal Collars....................................... 71 Shaft Seals............................................. 72 End Bearings.......................................... 78 Inlets....................................................... 81 Discharges............................................. 82 Trough End Flanges............................... 84 Flange Bolt Patterns............................... 86 Slide Gates............................................. 88

Weld Finishes......................................... 31 Screw Part Numbers.............................. 32 Shaft Run-Out........................................ 40 Engineered Products.............................. 93 Safety..................................................... 97 Installation and Maintenance.................. 98 Coupling Bolt Torque Limits.................... 99 Conveyor Spec Sheet.......................... 100 Engineering Reference Data................ 102 Component Part Number Index............ 105 Index..................................................... 106

(process system example, screw conveyors in yellow)

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Conveyor Engineering & Manufacturing

Conveyor design The screw conveyor is one of the oldest methods of conveying materials known to mankind with the original design dating back to more than two thousand years. Since the screw conveyor came into general use a little over a century ago for moving grains, fine coal and other bulk material of the times, it has come to occupy a unique place in a growing area of material handling processing. Today, modern technology has made the screw conveyor one of the most efficient and economical methods of moving bulk material.

What are the advantages?

Conveyor Design Steps:

Screw Conveyors...

Note: If you need a conveyor designed/quoted you can simply fill out the spec sheet on p.100, send it to us and we will work through the design steps for you or you can do it yourself using the following steps:

• are compact and easily adapted to congested locations. • can be used to control the flow of material in processing operations which depend upon accurate batching. • are versatile and can be employed in horizontal, inclined and vertical installations. • can be used as a mixer or agitator to blend dry or fluid ingredients, provide crystallization or coagulant action, or maintain solutions in suspension.

1. Establish conveying requirements (see below) 2. Identify the material and the corresponding material code (see p.5) 3. Determine conveying capacity, conveyor size and speed (see p.16)

• can be sealed to prevent the escape of dust or fumes from inside the conveyor; or keep dust or moisture from entering from outside the conveyor. • can be jacketed to serve as a drier or cooler by running hot or cold water through the jacket.

4. Calculate required horsepower — select motor size (see p.19) 5. Determine the recommended size of components (see p.23) • can be made out of a variety of materials to resist corrosion, abrasion or heat, depending upon the product being conveyed. • can be outfitted with multiple discharge points. Many years of experience in the design and practical application of screw conveyors has resulted in the refinement of conveyor design. This design procedure, outlined in the Engineering Section of this catalog, makes it possible to calculate size, speed and required power with a minimum of mathematical calculations. Using the following steps, in conjunction with the tables and graphs on the following pages, you will be able to estimate the specifications for a horizontal screw conveyor. We can provide a more thorough design including stress analysis, etc. that are beyond the scope of this engineering section so specifications should be established with the assistance of our engineering department.

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6. Check the torsional ratings of components (see p.24) 7. Check deflection, thermal expansion and abrasion (see p.26)

Step 1: Establish conveying requirements To properly design a conveyor to meet your needs it is important to know several parameters surrounding the application. Fortunately, to begin, you only need to know a few. These are: • Type of material to be conveyed • Required flow (lbs per hour or cubic feet per hour) • Distance material will be conveyed

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Conveyor Engineering & Manufacturing

materials Step 2: Identify material and corresponding material code The type of material being moved can have a significant affect on the size and type of conveyor needed. The following charts will help you classify your material and will help in selecting the proper conveyor components.

Table A: Material Classification Code category: material characteristics

code designation

Density: Bulk Density

avg. lbs/CF

Size: Very Fine — 100 mesh and under Fine — 1⁄8” mesh and under Granular — 1⁄2” mesh and under Lumpy — containing lumps over 1⁄2” Irregular — fibrous, stringy, etc

A B C D E

Flowability: Very free flowing Free flowing Average flowability

1 2 3

Sluggish

4

Abrasiveness: Mildly abrasive Moderately abrasive Extremely abrasive

5 6 7

For screw conveyor design purposes, conveyed materials are classified in accordance with the code system shown in Table A. This system conforms to that of the Conveyor Equipment Manufacturers Association (CEMA) which ranks each material in 5 categories. Table B lists the codes for many materials that can be effectively conveyed by a screw conveyor. If a material is not listed in Table B, it must be classified according to Table A, or by referring to a listed material that is similar in weight, particle size and other characteristics. Example: Gluten, Meal = 40B35P (from table B) 40 = Density (40 lbs per cubic foot) B = Size of material (fine, 1⁄8” mesh and under) 3 = Flowability (average) 5 = Abrasiveness (mild) P = Other Characteristics (contaminable)

Other Characteristics: Builds up & hardens Generates static electricity Decomposes — deteriorates in storage Flammability Becomes plastic or tends to soften Very dusty Aerates and becomes fluid Explosiveness Stickiness-adhesion Contaminable, affecting use Degradable, affecting use Gives off harmful or toxic gas or fumes Highly corrosive Mildly corrosive Hygroscopic Interlocks, mats or agglomerates Oils present Packs under pressure Very light and fluffy — may be windswept Elevated temperature

F G H J K L M N O P Q R S T U V W X Y Z

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Conveyor Engineering & Manufacturing

materials Table B: Material Characteristics

MATERIAL Adipic Acid Alfalfa Meal Alfalfa Pellets Alfalfa Seed Almonds, Broken Almonds, Whole Shelled Alum, Fine Alum, Lumps Alumina Alumina Fines Alumina Sized or Briquette Aluminate Gel (Aluminate Hydroxide) Aluminum Chips, Dry Aluminum Chips, Oily Aluminum Hydrate Aluminum Ore (see Bauxite) Aluminum Oxide Aluminum Silicate (Andalusite) Aluminum Sulfate Ammonium Chloride, Crystalline Ammonium Nitrate Ammonium Sulfate Antimony Powder Apple Pomace, Dry Arsenate of Lead (Lead Arsenate) Arsenic Oxide (Arsenolite)** Arsenic Pulverized Asbestos-Rock (Ore) Asbestos-Shredded Ash, Black Ground Ashes, Coal, dry, 1⁄2” Ashes, Coal, dry, 3” Ashes, Coal, Wet, 1⁄2” Ashes, Coal, Wet, 3” Ashes, Fly ( Fly Ash) Aspartic Acid Asphalt, Crushed, 1⁄2” Bagasse Bakelite, Fine Baking Powder Baking Soda (Sodium Bicarbonate) Barite (Barium Sulfate), 1⁄2” to 3” Barite, Powder Barium Carbonate Bark, Wood, Refuse Barley, Fine, Ground Barley, Malted Barley, Meal Barley, Whole Basalt Bauxite, Crushed, 3” (Aluminum Ore) Bauxite, Dry, Ground (Aluminum Ore) Beans, Castor, Meal Beans, Castor, Whole Shelled 6

MAT'L CLASS Code

CONV Loading

COMPONENT GROUP

Min

MAX

MAT'L FACTOR Fm

45A35 18B45WY 42C25 13B15N 29C35Q 29C35Q 48B35U 55B25 58B27MY 35A27MY 65D37 45B35 11E45V 11E45VY 17C35

30A 30A 45 45 30A 30A 30A 45 15 15 15 30B 30A 30A 30A

2B 2D 2D 1A,1B,1C 2D 2D 3D 2A,2B 3D 3D 3D 2D 2D 2D 1A,1B,1C

45 14 41 10 27 28 45 50 55 35 65 45 7 7 13

45 22 43 15 30 30 50 60 65 35 65 45 15 15 20

0.5 0.6 0.5 0.4 0.9 0.9 0.6 1.4 1.8 1.6 2.0 1.7 1.2 0.8 1.4

90A17MN 49C35S 52C25 49A45FRS 54A35NTU 52C35FOTU A35 15C45Y 72A35R 110A35R 30A25R 81D37R 30E46XY 105B35 40C46TY 38D46T 48C46T 48D46T 38A36M 42A35XPLO 45C45 9E45RVXY 38B25 48A35 48A25 150D36 150A35X 72A45R 15E45TVY 31B35 31C35 28C35 42B25N 93B27 80D36 68B25 38B35W 36C15W

15 45 45 30A 30A 30A 30B 30B 30A 30A 45 15 30B 30A 30B 30B 30B 30B 30B 30A 30A 30A 45 30A 45 30B 30A 30A 30A 30A 30A 30A 45 15 30B 45 30A 45

3D 3A,3B 1A,1B,1C 1A,1B,1C 3D 1A,1B,1C 2D 2D 1A,1B,1C 2D 3D 2D 1A,1B,1C 3D 3D 3D 3D 3D 1A,1B,1C 1A,1B,1C 2A,2B,2C 1A,1B,1C 1B 1B 3D 2D 2D 3D 1A,1B,1C 1A,1B,1C 1A,1B,1C 1A,1B,1C 3D 3D 2D 1A,1B,1C 1A,1B,1C

60 49 45 45 45 45 — 15 72 100 30 81 20 105 35 35 45 45 30 33 45 7 30 40 40 120 120 72 10 24 31 28 36 80 75 68 35 36

120 49 58 52 62 58

1.8 0.7 1.3 1.0 1.6 1.0 1.6 1.0 1.4 1.2 1.0 2.0 1.0 2.5 3.0 2.5 3.0 4.0 2.0 1.5 2.0 1.5 1.4 0.6 0.6 2.6 2.0 1.6 2.0 0.4 0.4 0.4 0.5 1.8 2.5 1.8 0.8 0.5

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WEIGHT (lbs/CF)

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15 72 120 30 81 40 105 45 40 50 50 45 51 45 10 45 55 55 180 180 72 20 38 31 28 48 105 85 68 40 36

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x x x

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Conveyor Engineering & Manufacturing

materials Table B: Material Characteristics (continued)

MATERIAL Beans, Navy, Dry Beans, Navy, Steeped Bentonite, 100 Mesh Bentonite, Crude Benzene Hexachloride Bicarbonate of Soda (Baking Soda) Blood, Dried Blood, Ground, Dried Bone Ash (Tricalcium Phosphate) Boneblack Bonechar Bonemeal Bones, Crushed Bones, Ground Bones, Whole** Borate of Lime Borax Screening, 1⁄2” Borax, 1-1⁄2” to 2” Lump Borax, 2” to 3” Lump Borax, Fine Boric Acid, Fine Boron Bran, Rice-Rye-Wheat Braunite (Manganese Oxide) Bread Crumbs Brewer’s Grain, spent, dry Brewer’s Grain, spent, wet Brick, Ground, 1⁄8” Bronze Chips Buckwheat Calcine, Flour Calcium Carbide Calcium Carbonate (see Limestone) Calcium Fluoride (see Fluorspar) Calcium Hydrate (Lime, Hydrated) Calcium Hydroxide (Lime, Hydrated) Calcium Lactate Calcium Oxide (Lime, unslaked) Calcium Phosphate Calcium Sulfate (see Gypsum) Canola Meal (Rape Seed Meal)** Carbon, Activated, Dry, Fine** Carbon, Black, Pelleted** Carbon, Black, Powder** Carborundum Casein Cashew Nuts Cast Iron, Chips Caustic Soda (Sodium Hydroxide) Caustic Soda, Flakes Celite (Diatomaceous Earth) Cement, Aerated (Portland) Cement, Clinker Cement, Mortar

MAT'L CLASS Code

CONV Loading

COMPONENT GROUP

Min

MAX

MAT'L FACTOR Fm

48C15 60C25 55A25MXY 37D45X 56A45R 48A25 40D45U 30A35U 45A45 23A25Y 34B35 55B35 43D45 50B35 43E45V 60A35 58C35 58D35 65D35 50B25T 55B25T 75A37 18B355NY 120A36 23B35PQ 22C45 58C45T 110B37 40B45 40B25N 80A35 80D25N

45 45 45 30A 30A 45 30A 30A 30A 45 30A 30A 30A 30A 30A 30A 30A 30A 30A 45 45 15 30A 30B 30A 30A 30A 15 30A 45 30A 30A

1A,1B,1C 1A,1B,1C 2D 2D 1A,1B,1C 1B 2D 1A,1B, 1A,1B 1A,1B 1A,1B 2D 2D 2D 2D 1A,1B,1C 2D 2D 2D 3D 3D 2D 1A,1B,1C 2D 1A,1B,1C 1A,1B,1C 2A,2B 3D 2D 1A,1B,1C 1A,1B,1C 2D

48 60 50 34 56 40 35 30 40 20 27 50 35 50 35 60 55 55 60 45 55 75 16 120 20 14 55 100 30 37 75 70

48 60 60 40 56 55 45 30 50 25 40 60 50 50 50 60 60 60 70 55 55 75 20 120 25 30 60 120 50 42 85 90

0.5 0.8 0.7 1.2 0.6 0.6 2.0 1.0 1.6 1.5 1.6 1.7 2.0 1.7 3.0 0.6 1.5 1.8 2.0 0.7 0.8 1.0 0.5 2.0 0.6 0.5 0.8 2.2 2.0 0.4 0.7 2.0

40B35LM 40B35LM 28D45QTR 63B35U 45A45

30A 30A 30A 30A 30A

2D 2D 2A,2B 1A,1B,1C 1A,1B,1C

40 40 26 60 40

40 40 29 65 50

0.8 0.8 0.6 0.6 1.6

? ?

38 100D27 36B35 35C45 165C45 88B35RSU 47C45RSUX 14A36Y 68A16M 85D36 133B35Q

? 15 30A 30A 30A 30A 30A 30B 30B 30B 30A

? 3D 2D 2D 2D 3D 3A,3B 3D 2D 3D 3D

34 100 36 32 130 88 47 11 60 75 133

41 100 36 37 200 88 47 17 75 95 133

0.8 2.0 3.0 1.6 0.7 4.0 1.8 1.5 1.6 1.4 1.8 3.0

? ? ?

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WEIGHT (lbs/CF)

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Vert.* ? ? x ? ? x x x x x x x

x x

x

x ?

?

? x

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Conveyor Engineering & Manufacturing

materials Table B: Material Characteristics (continued)

MATERIAL Cement, Portland Cerrusite (Lead Carbonate) Chalk, Crushed Chalk, Pulverized Charcoal, Ground Charcoal, Lumps Chocolate, Cake Pressed Chrome Ore Cinders, Blast Furnace Cinders, Coal Clay (Marl) Clay (see Bentonite, Diat. Earth) Clay (see also Fuller’s Earth, Kaolin & Marl) Clay, Brick, Dry, Fines Clay, Calcined Clay, Ceramic, Dry, Fines Clay, Dry, Lumpy Clinker, Cement (Cement Clinker) Clover Seed Coal, Anthracite (River & Culm) Coal, Anthracite, Sized, 1⁄2” Coal, Bituminous, Mined Coal, Bituminous, Mined, Sized Coal, Bituminous, Mined, Slack Coal, Lignite Cocoa Beans Cocoa, Nibs Cocoa, Powdered Coconut, Shredded Coffee, Chaff Coffee, Green Bean Coffee, Ground, Dry Coffee, Ground, Wet Coffee, Roasted Bean Coffee, Soluble Coke, Breeze Coke, Loose Coke, Petrol, Calcined Compost Concrete, Pre-Mix Dry Copper Ore Copper Ore, Crushed Copper Sulphate, (Bluestone, Cupric Sulphate) Copperas (Ferrous Sulphate) Copra, Cake Ground Copra, Cake, Lumpy Copra, Lumpy Copra, Meal Cork, Fine Ground Cork, Granulated Corn Cobs, Ground Corn Cobs, Whole* Corn Fiber, Dry Corn Fiber, Wet 8

MAT'L CLASS Code

CONV Loading

COMPONENT GROUP

Min

MAX

MAT'L FACTOR Fm

94A26M 250A35R 85D25 71A25MXY 23A45 23D45Q 43D25 133D36 57D36T 40D36T 80D36

30B 30A 30A 45 30A 30A 30A 30B 30B 30B 30B

2D 2D 2D 2D 2D 2D 2B 3D 3D 3D 2D

94 240 75 67 18 18 40 125 57 40 80

94 260 95 75 28 28 45 140 57 40 80

1.4 1.0 1.9 1.4 1.2 1.4 1.5 2.5 1.9 1.8 1.6

110C36 90B36 70A35P 68D35 85D36 47B25N 58B35TY 55C25 50D35LNYX 48D35QV 47C45T 41D35T 38C25Q 35C25 33A45XY 21E45 20B25FZMY 29C25PQ 25A35P 40A45X 25C25PQ 19A35PUY 30C37 30D37 40D37 40D45TV 103C36U 135D36 125D36 85C35S 63C35U 43B45HW 28D35HW 22E35HW 43B35HW 10B35JNY 14C35JY 17C25Y 14E45NV 14B46P...