Feeder Types Selection & Operation BSH&E SEMINAR

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1 Feeder Types Selection & Operation

2 The Generic Feeder Model UPSTREAM MATERIAL INPUT CONTAINMENT & CONDITIONING METERING DOWNSTREAM MEASURING & SENSING CONTROL

3 Metering Design types Screw Cone Liquid Pump Vibratory Rotary Valves Bulk Solids Pump Belt Smart Flow Meter

4 SCREW FEEDERS

5 Screw Metering Principle of Operation Material enters screw positioned at/near the bottom of the feeder bin Advancing flights move the material through tube to discharge. Design Variables Single or twin screws, open-, or closed-flight, diameter, pitch, speed range, etc. Rate Control Adjustment of screw speed

6 Single Screw Feeders

7 Twin Screw Feeders

8 Screw Feeder Sizing Product bulk density (bd) (kg/m 3 ) Screw capacity (sc) m 3 /rev Screw speed (ss) rev/min Q (kg/min) = bd x sc x ss Set Up 40% < drive command < 60% for constant rate

9 Screw Selection Chart

10 Twin Screw Feeder Screw Chart K2MVT35

11 CONE FEEDERS

12 Cone Principle of Operation Screw-less feeding mechanism Design Variables Stepper motor Low rate tip Vertical discharge option Rate Control 0.2 to 2 dm 3 /hr (0.007 to 0.07 ft 3 /hr) with extension tip: as low as 0.1 dm 3 /hr (0.004 ft 3 /hr)

13 Configurations Volumetric K-CV-MC Gravimetric K-CL-MC K4G-L-MC Micro Cone Feeder on SFS Scale

14 Very Good Accuracy

15 Applications Mainly low rate of granular material, such as color additives Injection Molding Plastic Compounding Fiber and Filament Plastic Wood Profile Plastic Film

16 VIBRATORY FEEDERS

17 Vibratory Principle of Operation A specially configured springmounted metering channel is vibrated causing material to advance through the channel to discharge. Vibration offers gentle handling of free-flowing, granular, friable, abrasive or fibrous materials. Periodic manual or automated refill is required

18 Vibratory Design Variables Hopper design, inlet sizing, tray/tube size and geometry; drive power, spring constant Rate Control Closed-loop modulation of vibrational amplitude based on sensed rate of system weight loss

19 Vibratory Control Principle Feeder signal Controller Setpoint amplitude Amplitude control (fast) Digital/ analog converter Frequency adjustment (slow) Setpoint frequency Drive Current signal Strokesignal Amplifier Vibratorytray Spool

20 Vibratory MF = δ x A m x D x Ω where δ = bulk density A m = area of product on tray D = tray displacement Ω = tray cycles per minute

21 BULK SOLIDS PUMP

22 BSP (Bulk Solids Pump) Principle of Operation Inter-particle forces produce a lock-up condition in multi-channel spool As spool rotates, lock-up forces relax at bottom of feeder and material is pushed to controlled gravity discharge Design Variables Rate Control

23 Lock-Up Principle The BSP principle provides continuous, positive displacement volumetric control by exploiting the phenomenon known as lock-up. LOCK-UP

24 Zone 1:Consolidation ZONE 1: CONSOLIDATION Interparticle forces produce lockup at the end of Zone 1 Zone 1

25 Zone 2: Rotation ZONE 1: CONSOLIDATION Interparticle forces produce lockup at the end of Zone 1 ZONE 2: ROTATION Material is in lock-up condition throughout Zone 2 and rotates as a solid body Zone 2

26 Zone 3: Relaxation ZONE 1: CONSOLIDATION Interparticle forces produce lockup at the end of Zone 1 ZONE 2: ROTATION Material is in lock-up condition throughout Zone 2 and rotates as a solid body ZONE 3: RELAXATION Interparticle forces fall below lock-up threshold Zone 3

27 Zone 4: Active Discharge ZONE 1: CONSOLIDATION Interparticle forces produce lockup at the end of Zone 1 ZONE 2: ROTATION Material is in lock-up condition throughout Zone 2 and rotates as a solid body ZONE 3: RELAXATION Interparticle forces fall below lock-up threshold ZONE 4: ACTIVE DISCHARGE Flexible guide aids material discharge Zone 4

28 BELT FEEDERS

29 Purpose Meter relatively high volumes of granular or freeflowing product into the process with an accuracy of +/- 0.5% with good precision SWB 300 WF 300

30 Belt Principle of Operation Material enters upstream end of advancing belt and is sheared into a shallow, reasonably uniform bed Material discharge by gravity off end of belt. Scraper assures complete discharge Design Variables Belt width, inlet gate geometry, belt speed range Rate Control Continuous feeding according to set point Batch feeding according to batch time Belt speed constant metering of a bulk material flow

31 SWB Control Principle I Single scale version Belt load (q) speed pick-up Speed feedback (v) Weigh bridge Mass flow Controller q Q = q * v Setpoint Drive command Controller Motor drive

32 SWB Control Priniciple II Twin scale version Belt load (q) Weigh bridges Shift register Tare Brutto Netto speed pick-up q Mass flow Q = q * v Setpoint Motor drive Speed feedback (v) Controller Controller Drive command

33 Belt Feeder Sizing Kg/hr Lb/hr dm3/hr ft3/hr SWB SWB Belt Speed controlled to within +/- 1RPM over a 100:1 range full motor speed Inlet SWB-300 SWB-600 Small 75mm (3 ) 300mm (6 ) Medium 150mm (6 ) 375mm (9 ) Large 230 mm (9 ) 450mm (18 ) Material Bulk Densities: 0.5 to 2.5 Kg/l (31 to 156 lb/ft3) Maximum Material Particle Size: 10mm (0.4 ) Drive reducers: 20:1, 40:1, 80:1

34 Weigh Belt Feeding Advantages High gravimetric accuracy on most free flowing materials; suitable for high-rate applications Accommodates larger particle size materials Compact, low headroom Disadvantages Floodable or hard-to-flow materials may require the use of a pre-feeder Requires periodic calibration Relatively mechanically complex; potential cleaning/maintenance concerns

35 Smart Flow Meter

36 Smart Flow Meter The K-SFM provides accurate and reliable gravimetric flow measurement of the resin Models for rates up to 200 m 3 /hr (7,000 ft 3 /hr) Two strategically placed digital Smart Force Transducers are combined to produce the flow rate measurement F R F P

37 Theory vs. Practice Easy Flowing Single screw feeder Twin screw feeder with intermeshing augers Weigh belt feeder with standard shear gate Bulk solids pump Vibration tray Difficult Flowing Single screw feeder that has an undersized screw in reference to the tube Twin screw feeder that has non intermeshing screws Belt feeder with a modified inlet section

38 Theory vs. Practice Floodable (1) Twin screw feeder with concave screws Adhesive & Cohesive (2) Twin screw feeder with augers or twin spirals Belt feeders with screw pre-feeders (1) For refill devices avoid slide gates and butterfly valves. A rotary feeder provides a nice even drop of materials without inducing a lot of air (2) Most difficult material to handle. Most likely require the use of flow-aid devices

Feeder Types Selection & Operation BSH&E SEMINAR

Feeder Types Selection & Operation BSH&E SEMINAR Feeder Types Selection & Operation The Generic Feeder Model UPSTREAM MATERIAL INPUT CONTAINMENT & CONDITIONING METERING DOWNSTREAM MEASURING & SENSING CONTROL Metering Design types Screw Cone Liquid Pump

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