FACILITY DESIGN - Amazon S3...• Power required:. > @ )

transcript

COPYRIGHT

KURT ROSENTRATERIOWA STATE UNIVERSITY

DISTILLERS GRAINS

TECHNOLOGY COUNCIL

ASSOCIATE PROFESSOR

FACILITY DESIGN

MAXIMIZING EFFICIENCY AND THROUGHPUT

COPYRIGHT

TODAY’S TOPICS

• Facility goals

• Overview of facilities

• Historical perspectives

• Efficiencies in design, construction, & operations

• Recap from 2018

• Receiving

• Loadout

• Conveyors

• Final thoughts

COPYRIGHT

FACILITY GOALS

COPYRIGHT

FACILITY GOALS• Existing facilities upgraded/expanded each year• New facilities constructed each year• Continual need to service grain, feed, food, biofuels

industries

• Design data, information & procedures are critical• Substantial focus on farm-scale

• Commercial-scale scientific knowledge needs more• Anecdotal

• Proprietary

• Official standards

• Cost reductions

COPYRIGHT

FACILITY GOALS

• Overarching goals for grain storage facilities

• Protect grain

• Weather, insects, rodents, birds, mold

• Maintain quality after harvest

• Storage cannot improve upon quality

• But: poor storage can result in reduction in quality (deterioration)

• Repository for local grain supplies

• Storage for processing operations

• Shipping point to end-use destinations via

• Trucks, rail cars, ships

COPYRIGHT

OVERVIEW OF FACILITIES

COPYRIGHT

• Modern facilities have much greater

• Storage capacities

• Equipment capacities

• Yearly throughputs

• Dust control systems

• Safety measures

• Automations & controls

• Efficiencies

COPYRIGHT

COPYRIGHT11

COPYRIGHT

• Regardless of type, arrangement, or size

• Proper selection, sizing, and location are essential to successful grain storage

• All components must work together

• Only as strong as the weakest link

• Only as fast as your slowest operation

• Want an efficient, cost-effective operation

• Commercial facilities

• Typically handle more than 20,000 bu/hr

• Can store from several thousand, up to several million, bushels at one time

COPYRIGHT

FACILITY OVERVIEW

• Many common components and systems

• Primary components

• Receiving

• Distribution

• Storage

• Reclaim

• Loadout

• All facilities utilize these components

• Many of these can drive design choices

Receiving

Distribution

Storage

Reclaim

Loadout

Incoming Grain

Outgoing Grain

COPYRIGHT

FACILITY OVERVIEW

• Many common components and systems

• Secondary components

• Cleaning

• Aeration

• Drying

• Dust control

• Sampling

• Instrumentation and controls

• Not all facilities utilize these components to the same degree

• Don’t drive the design choices

COPYRIGHT

FACILITY OVERVIEW

Receiving

Distribution

Storage

Reclaim

Loadout

Incoming Grain

Outgoing Grain

Large Grains Elevator

Reclaim

Receiving

Loadout

Storage

Distribution

COPYRIGHT

FACILITY OVERVIEW

Receiving

Loadout

Storage

Reclaim

Distribution

Small Grains Elevator

COPYRIGHT

FACILITY OVERVIEW

• Many types, arrangements, and sizes are available for commercial operations

• Choices depend on

• Individual client needs and requirements / opinions

• Operational flexibility

• Future expansion

• Creativity and imagination

• Cost

COPYRIGHT

HISTORICAL PERSPECTIVES

COPYRIGHT

• The Young Mill-Wright and Miller’s Guide

• Oliver Evans, 1795

COPYRIGHT

EFFICIENCIES IN DESIGN, CONSTRUCTION & OPERATIONS

COPYRIGHT

RECAP FROM 2018

• Receiving systems

• Distribution systems

• Storage systems

• Reclaim systems

• Loadout systems

Specifically timing

studies & throughput

This year:- More specifics about design

COPYRIGHT

RECEIVING SYSTEMS• Purpose

• Introduce incoming grain into the storage facility• Transfer grain to distribution system

• Grain typically delivered with wagons or trucks (rail cars)

• Design considerations• Maximize throughput; minimize wait (esp. harvest)

• Hopper volume: up to 1200 bu or more

• Capacity: ~ 20,000 bu/hr• Orifices, gates, spouts, conveyors

• Valley angle: > angle of repose • Limiting factor, not side slopes

• Want to minimize height of hoppers• Minimize costs ….bucket elevator height & boot pit depth

COPYRIGHT

RECEIVING SYSTEMS

COPYRIGHT

RECEIVING SYSTEMS

tan b = h/b

cot b = b/h

b = h*cot b

tan a = h/a

cot a = a/h

a = h*cot a

tan q = h/c

cot q = c/h

c = h*cot q

a2 + b2 = c2

(h/tan a)2 + (h/tan b)2 = (h/tan q)2

(tan q)2 = (tan a)2 * (tan b)2

(tan a)2 + (tan b)2

q = tan-1 (tan a)2 * (tan b)2

(tan a)2 + (tan b)2

* Note: h does not matter

COPYRIGHT

RECEIVING SYSTEMS

• Valley angles:

• http://bulksolidsflow.com.a

u/free_programs/valley_an

gles/valley_angles.html50

COPYRIGHT

RECEIVING SYSTEMS

• Valley angles:

• http://bulksolidsflow.com.a

u/free_programs/valley_an

gles/valley_angles.html50

COPYRIGHT

RECEIVING SYSTEMS

• Capacities:

V = L * w * h V = h/3 * (B1 + B2 + (B1 * B2)1/2)

http://www.mathinary.com/pyramid__frustum_the_volume_of_a_frustum_of_a_pyramid.jsp

COPYRIGHT

RECEIVING SYSTEMS• 2 most common types = gravity vs. mechanical

• Tradeoffs

• Gravity hopper only

• Deeper pit, or

• Higher receiving floor (ramp/earth work), and

• Taller bucket elevator

• Hopper + conveyor

• Shallower pit

• Potential carryover/cleanout issues

• Maintenance

• Potential grain damage

COPYRIGHT

RECEIVING SYSTEMSGravity Mechanical

COPYRIGHT

RECEIVING SYSTEMS

Mechanical: Above ground vs. underground

Gravity

COPYRIGHT

RECEIVING SYSTEMS

Tower:

12” x 0.23” x 6.5” = $50/ft

4 columns x 1ft x $50/ft = $200 / 1 ft height

Boot Pit:

10 ft x 10 ft x 1 ft thick

= 44 ft3 / 1 ft depth

Concrete = $3.7 / ft3

$163 / 1 ft depth

10 ft x 10 ft x 0.5 ft thick

= 21 ft3 / 1 ft depth

Concrete = $3.7 / ft3

$78 / 1 ft depth

COPYRIGHT

LOADOUT SYSTEMS• Purpose

• Transfer grain to shipping containers

• Typically rail cars (sometimes trucks)

• Design considerations

• Equipment sized for speed and labor efficiency

• Typically ≥ reclaim rate (≥ 50,000 bu/hr)

• 110-car unit trains in < 15 hr

• Typical equipment used

• Overhead surge bins within support structures vs. mechanical fill

• Can be system bottleneck

• Bulk weigh scales

• Spouting

• 3 common options

COPYRIGHT

LOADOUT SYSTEMS• 3 common types

Mechanical Overhead surge Mechanical

COPYRIGHT

LOADOUT SYSTEMS

Gravity Mechanical

Mechanical

COPYRIGHT

LOADOUT SYSTEMS

• Example: 80,000 bph

• Upper garner = 1400 ft3 (143%)

• 1125 bu

• Scale hopper = 980 ft3

• 788 bu

• Lower garner = 1200 ft3 (122%)

• 964 bu

COPYRIGHT

LOADOUT SYSTEMS

• Mechanical loadout

• 60,000 bph

• Use shipping bin as upper garner

• 14,000 bu / 60,000 bph = 14 min

COPYRIGHT

LOADOUT SYSTEMS• Use upper annex bin as upper garner

• 172,000 bu / 60,000 bph = 2.9 hr

• Still have to mechanically lift

• 60,000 bph x 12.5 hr = 726,000 bu

• Bucket elevator size = ?

• 20,000 bph x 12.5 hr = 250,000 bu

• 40,000 bph x 12.5 hr = 500,000 bu

• 50,000 bph x 12.5 hr = 625,000 bu

• 55,000 bph x 12.5 hr = 687,000 bu

• 60,000 bph x 12.5 hr = 750,000 bu

COPYRIGHT

LOADOUT SYSTEMS

• Use upper annex bin as upper garner

• 320,000 bu / 60,000 bph = 5.3 hr

• Still have to mechanically lift

• 9.7 hr x 60,000 bph = 580,000 bu

• Bucket elevator size = ?

• 40,000 bph x 9.7 hr = 388,000 bu

• 50,000 bph x 9.7 hr = 485,000 bu

• 60,000 bph x 9.7 hr = 582,000 bu

COPYRIGHT

CONVEYORS

• Bucket elevators

• Drag conveyors

• Belt conveyors

COPYRIGHT

Bucket Elevator Calculations

• For engineers, 2 key calculations include:

• Capacity – determines how much grain you can move/transport

• Power required – determines how big a motor you need

COPYRIGHT

Bucket Elevator Calculations• Capacity

• Q is the volumetric capacity of the bucket elevator (bu/h),

• Cc is the capacity of each cup (in3/cup),

• Cf is the fill of each cup (%, expressed as a decimal),

• Cs is the linear spacing of cups per unit length of belt (number of cups/ft),

• Cr is the number of cup rows across the width of the belt,

• V is the linear belt speed (ft/min),

• C1 is a conversion factor of 60 (min/h),

• C2 is a conversion factor of 2150.42 (in3/bu)

CVCCCCQ

COPYRIGHT

Bucket Elevator Calculations• Power

• P is the power required to drive the elevator shaft (hp),

• Q is the volumetric capacity of the elevator (bu/h),

• Tw is the grain test weight (lb/bu),

• H is the total vertical distance between the head and tail shafts of the elevator (ft),

• Sf is an empirical service factor of 1.1(-),

• C1 is a conversion factor of 33,000 (ft.lb/min/hp),

• R1 is the efficiency of the motor speed reducer (which typically ranges from 0.75 to 0.95)

• An additional 10% is added to empirically account for friction losses within the elevator

=Potential energy

(mgh / time)

COPYRIGHT

Bucket Elevator Calculations• Power

• Q is the volumetric capacity of the elevator (ft3/h),

• BD is the bulk density of the grain (lb/ft3),

• H is the total vertical distance between the head and tail shafts of the elevator (ft),

HBDQ1.1P

Potential energy Friction

COPYRIGHT

Bucket Elevator Calculations

• Power

• Q is the volumetric capacity of the elevator (bu/h),

• H is the total vertical distance between the head and tail shafts of the

elevator (ft),

• Da is an additional distance of 5 ft, which empirically accounts for frictional

losses within the elevator

( ) 000036.0DHQP a += (simplified)

COPYRIGHT

Drag Conveyor Calculations

• Capacity:

• Q is the volumetric throughput (bu/min) of the conveyor,

• V is the linear chain speed (ft/min),

• h is the height of the grain mass at a given cross section inside the

conveyor (ft),

• is a function of the height of the flighting/paddles used,

• w is the width of the conveyor (ft),

• C1 is a conversion factor of 0.8036 (bu/ft3)

1CwhVQ =

COPYRIGHT

Drag Conveyor Calculations• Power required: [book’s approach] – theoretical

• P is the power required to drive the conveyor (hp),

• L is the conveyor length, from head shaft to tail shaft (ft),

• Wc is the weight of the chain and flighting per unit length of conveyor (lb/ft),

• Fc is the coefficient of kinetic friction between the chain and flights and the conveyor floor (-),

• q is the slope of the conveyor relative to a horizontal plane (o),

• Wm is the weight of the grain per unit length of conveyor (lb/ft),

• Fm is the coefficient of kinetic friction between the grain and the conveyor floor (-),

• h is the average depth of the grain in the conveyor (ft),

• V is the linear chain speed (ft/min),

( ) ( ) ( )( ) V

h044.0sincosFWsincosFWsincosFWL1.1P

ccmmcc

+q−q+q+q+q+q=

COPYRIGHT

Drag Conveyor Calculations• Power required: [industry approach]

• (for horizontal use with soybeans, this equation has been empirically adapted to a simpler form)

• Q is the volumetric capacity of the conveyor (bu/h),

• L is the length of the conveyor (ft)

1*56000 R

COPYRIGHT

• (for horizontal use with corn or small grains, this equation has been empirically adapted to a simpler form)

• L is the length of the conveyor (ft)

1*75000 R

COPYRIGHT

• If the conveyor is at an incline, then previous empirical equations must be modified to account for the change in potential energy in the system.

• This is accomplished by increasing them by adding an additional power requirement

• Pa is the additional power required due to the conveyor’s incline (hp),

• H is the change in elevation from the conveyor’s tail shaft to head shaft (ft)

COPYRIGHT

Belt Conveyor Calculations

• Capacity (bu/h or bu/min):

• How would you calculate this?

Angle of Surcharge

COPYRIGHT

• Capacity:

• Q is the volumetric throughput (bu/min) of the conveyor,

• A is the cross-sectional area of grain on the belt (which will assume the shape of a combination of trapezoidal area with a circular segment area on top [ft2]),

• Circular area depends on surcharge/slump (grain & moisture)

• C1 is a conversion factor of 0.8036 (bu/ft3)

1CAVQ =

COPYRIGHT

Belt Conveyors

https://www.cemanet.org

COPYRIGHT

Belt Conveyor Calculations• Power required:

• P is the power required to drive the conveyor head shaft (hp), THIS IS THE MOTOR SIZE

• L is the conveyor length, defined from head pulley shaft to tail pulley shaft (ft),

• Kt is the temperature correction factor, which is related to belt thermal expansion and flexibility (-),

• Kx is the frictional resistance factor that accounts for the interaction between the belt and the idlers (lb/ft),

• Ky is the factor that accounts for the resistance of the grain load to flexure as it passes over the idlers (-),

• Wm is weight of the grain per unit length of belt (lb/ft),

• Wb is the weight of the belt per unit length (lb/ft),

• H is the change in vertical height from the tail shaft to the head shaft (ft),

• Tp is the tension force resulting from the belt’s resistance to bending around the head and tail pulleys (lb),

• Tam is the tension force resulting from the force necessary to accelerate grain as it is fed onto the belt (lb),

• Tac is the tension force resulting from conveyor accessories such as plows, trippers, and belt cleaning devices (lb),

( ) ( ) V

TTTHKLWW015.0WKKKLP

acampymbbyxt

++++++=

Te = effective tension, lb

P = (Te x V) / (C1 x R1)

COPYRIGHT

• Power required:

• P is the power required to drive the conveyor (hp), MOTOR SIZE

• L is the conveyor length, defined from head pulley shaft to tail pulley shaft (ft),

• Wm is weight of the grain per unit length of belt (lb/ft),

• Wb is the weight of the belt per unit length (lb/ft),

• H is the change in vertical height from the tail shaft to the head shaft (ft),

( ) ( ) V

225HL035.0W58.0W05.0W00068.0LP

(simplified)

Te = effective tension, lb

P = (Te x V) / (C1 x R1)

COPYRIGHT

FINAL THOUGHTS

COPYRIGHT

FINAL THOUGHTS

• Make sure everyone reads the blueprints CORRECTLY

• Contractors

• Subcontractors

• Equipment vendors

• Field staff

COPYRIGHT

FINAL THOUGHTS

COPYRIGHT

FINAL THOUGHTS

COPYRIGHT

FINAL THOUGHTS

COPYRIGHT

FACILITY DESIGN

• Dynamic process

• 5 main stages

Flow Diagram

Bin Layout/Arrangement Bin Sizes/Capacities

Facility Layout

Process Design

Primary Systems

Secondary Systems

Client Req. Building Codes Standards

Structural Design

Final Design

COPYRIGHT

FINAL THOUGHTS

• Brief overview of design & operation considerations

• Each commercial facility is unique

• Many styles, layouts, and options

• Many common features and equipment

• Ultimately, design and operation based on client’s preferences

• Detailed knowledge of design processes is extremely important

• Hopefully these thoughts will be useful

COPYRIGHT

THANK YOU!

Questions?

FACILITY DESIGN - Amazon S3...• Power required:. > @ )

Documents