ME 408 Lesson 02 Feeders and Silos PDF

MANUFACTURING & INDUSTRIAL PROCESSES FEEDERS AND STORAGE SILOS ENGR. EARL JAN L. SANTOS LESSON OBJECTIVES By the end of the lesson, students will be able to: ▪ Analyze and evaluate the role and functions of feeders and storage silos, critically assessing their impact on material handling proces...

MANUFACTURING & INDUSTRIAL PROCESSES FEEDERS AND STORAGE SILOS ENGR. EARL JAN L. SANTOS LESSON OBJECTIVES By the end of the lesson, students will be able to: ▪ Analyze and evaluate the role and functions of feeders and storage silos, critically assessing their impact on material handling processes and operational efficiency in various industries. ▪ Distinguish between different types of feeders (belt, vibratory, screw, rotary) and storage silos (concrete, steel, plastic), and assess their applications and effectiveness in specific contexts such as agriculture, construction, and manufacturing. ▪ Formulate and implement strategies for ensuring safety and optimizing processes, including developing comprehensive safety protocols, evaluating energy efficiency measures, and applying automation and digital tools to enhance system performance. STORAGE SILOS FUNCTIONS Bulk Storage: Silos are primarily used to store large quantities of bulk materials such as grains, cement, coal, and chemicals. This allows industries to maintain an inventory that can support continuous operations. Material Protection: Silos protect stored materials from environmental factors such as moisture, pests, and contamination, ensuring the quality of the materials is preserved. Efficient Dispensing: Silos facilitate the controlled release of stored materials into production processes or transportation systems, maintaining a smooth and efficient workflow. Space Optimization: By storing materials vertically, silos make efficient use of available space, particularly in facilities where ground space is limited. STORAGE SILOS APPLICATIONS Agriculture: Silos are widely used for storing grains, seeds, and animal feed. They help in preserving the quality of agricultural products over long periods. Construction: In the construction industry, silos store cement, lime, and other fine aggregates used in concrete production. This ensures a steady supply of materials for construction projects. Chemical and Pharmaceutical Industries: Silos are used to store raw materials and intermediate products, such as chemicals, powders, and granules, ensuring these materials are kept in optimal conditions for manufacturing. Energy and Mining: Silos store coal, ore, and other mined materials. They are integral to the operation of power plants and mining facilities, where large quantities of raw materials are required. STORAGE SILOS EXAMPLES Wooden Silos Concrete Silos Steel Silos Plastic Silos WOODEN SILOS Description: Wooden silos are traditionally built from timber and are less common today. They are cylindrical or square and are often constructed using interlocking wooden boards. Function: Wooden silos serve as storage for dry materials like grains and seeds, providing a natural, breathable storage solution. Application: Historically used in agriculture for grain storage, wooden silos are now less prevalent but still found in some rural areas or used for specific traditional applications. CONCRETE SILOS Description: Concrete silos are robust and durable storage structures typically constructed from reinforced concrete. They are usually cylindrical in shape and can be either above ground or partially buried. Function: Concrete silos are designed to store large quantities of bulk materials like cement, aggregates, and grains, providing a long-term storage solution that protects materials from external elements. Application: Commonly used in the construction industry for storing cement and other building materials. They are also used in agriculture for grain storage and in the mining industry for storing minerals and ores. STEEL SILOS Description: Steel silos are made from high-strength steel, which makes them lightweight and easy to install. They often come in prefabricated sections that are assembled on-site. Function: Steel silos are used to store various bulk materials, offering protection from moisture and pests while ensuring easy loading and unloading of materials. Application: Widely used in agriculture for storing grains, seeds, and animal feed. In industrial settings, steel silos store chemicals, plastics, and other materials that require protection from environmental factors. PLASTIC SILOS Description: Plastic silos are constructed from high-density polyethylene (HDPE) or other types of durable plastics. They are corrosion- resistant, making them ideal for storing materials that could react with metal. Function: Plastic silos provide a lightweight and corrosion-resistant option for storing sensitive materials, particularly where hygiene and contamination prevention are crucial. Application: Commonly used in the food and pharmaceutical industries for storing food-grade materials, chemicals, and other substances that require strict sanitary conditions. BAG SILOS Description: Bag silos, also known as baggers, are large, flexible, plastic tubes that are filled with materials such as silage, grains, or other agricultural products. Function: These silos provide a temporary storage solution that is easy to set up and relocate. They protect materials from moisture and pests while allowing for the controlled release of contents. Application: Primarily used in agriculture, especially for storing silage, grains, and other feed materials. They are also used in emergency situations where quick storage is needed. BUNKER SILOS Description: Bunker silos are large, horizontal storage structures that are built into the ground or on its surface. They are typically made from concrete walls and covered with plastic sheets to protect the contents. Function: Bunker silos are used for storing large quantities of bulk materials, particularly in agricultural settings. They allow for easy access to stored materials and are suited for storing feed like silage. Application: Commonly found on farms, bunker silos store silage, hay, and other feed products. They are also used in some industrial settings for storing raw materials that are consumed in large quantities. FEEDER ▪ Function: A feeder is specifically designed to regulate and control the flow of bulk materials from a storage unit, such as a silo or hopper, into a processing system. It ensures a consistent, measured, and controlled release of materials. FEEDER ▪ Application: Feeders are used at the start of a material handling process to manage the flow of materials into the system. They are crucial for maintaining a steady feed rate and are often adjustable to control the volume of material being fed. FEEDER ▪ Examples: Belt feeders, screw feeders, vibratory feeders, and rotary feeders. BELT FEEDER Description: Belt feeders consist of a belt conveyor system where materials are deposited on the belt, which moves them to the next stage in the process. Function: They provide a continuous and controlled flow of bulk materials such as coal, ores, and aggregates. The speed of the belt can be adjusted to regulate the flow rate. Application: Commonly used in mining, agriculture, and construction industries for handling heavy and bulky materials. APRON FEEDER Description: Apron feeders are heavy-duty feeders that use a series of overlapping metal plates or pans, known as aprons, attached to a conveyor chain. Function: They are designed to handle abrasive, heavy, and bulky materials. The apron design prevents spillage and provides a robust platform for moving materials. Application: Frequently used in mining, quarrying, and heavy industrial applications where large quantities of material need to be transported. VIBRATORY FEEDER Description: Vibratory feeders use vibrations to move and control the flow of materials. The vibrations are generated by an electromagnetic or motor-driven system that causes the materials to move along a specific path. Function: They are used for feeding small, fine, or fragile materials in a controlled manner. The vibration helps to move the materials while also helping in sorting and orienting them. Application: Used in industries such as pharmaceuticals, food processing, and electronics, where precise feeding of small or delicate parts is required. SCREW FEEDER Description: Screw feeders consist of a rotating screw or auger inside a cylindrical tube. The screw rotates to move materials along the tube from the inlet to the outlet. Function: They are ideal for feeding granular or powdered materials at a controlled rate. The rotation speed of the screw determines the flow rate. Application: Widely used in chemical processing, agriculture (for grains and powders), and plastic manufacturing. ROTARY FEEDER Description: Rotary feeders, also known as rotary valves, use a rotating wheel or drum with pockets that capture and move materials from one area to another as it rotates. Function: They are used to feed materials into a system under pressure or vacuum conditions. The rotary motion ensures a consistent feed rate while also serving as a seal between different pressure zones. Application: Commonly used in pneumatic conveying systems, dust collection systems, and in the handling of granules and powders. CENTRIFUGAL FEEDER Description: Centrifugal feeders are bowl feeders that use centrifugal force generated by the rotation of the bowl to move parts along a track. Function: They are designed for high-speed sorting and feeding of small parts. The centrifugal motion helps to sort and align parts efficiently. Application: Used in high-speed assembly lines, particularly in the automotive and electronics industries. PROCESS FLOW 1. Material Loading: Material Received → Screening → Transport to Silo → Silo Loading 2. Material Storage: Level Monitoring → Material Conditioning → Material Settlement 3. Material Discharge Preparation: Flow Activation → Discharge Control 4. Material Discharge: Flow to Discharge Equipment → Weighing and Measurement → Dust Control 5. Material Transport: Loading onto Transport Vehicles → Final Inspection → Transport to Destination 6. Post-Discharge Maintenance: Silo Cleaning and Inspection → Recalibration and Readjustment PROCESS FLOW 1. Material Loading into the Silo Receiving Material: Materials, such as grains, cement, or other bulk goods, are delivered to the silo system, usually by trucks, conveyors, or pipelines. Initial Screening: Before entering the silo, materials may pass through a screening process to remove impurities, oversized particles, or foreign objects that could interfere with the silo operation. Material Transport to the Silo: Conveyors, bucket elevators, or pneumatic systems transport the screened materials to the top of the silo. Loading into the Silo: The material is deposited into the silo through an inlet or loading chute. Depending on the design, this could involve distributing the material evenly within the silo to prevent uneven filling and compaction. PROCESS FLOW 2. Material Storage Silo Filling and Level Monitoring: As the silo fills, sensors monitor the material level to prevent overfilling and to ensure optimal storage conditions. Aeration systems, such as centrifugal blowers, may be used to keep materials aerated and prevent compaction. Material Conditioning: If required, conditioning processes such as cooling, drying, or aeration are applied to maintain material quality during storage. Material Settlement: Over time, materials settle within the silo, and compaction might occur, which can be managed using aeration or vibration systems. PROCESS FLOW 3. Material Discharge Preparation Flow Activation: When it’s time to discharge materials, systems such as vibratory feeders, screw conveyors, or air cannons may be activated to initiate material flow. These systems ensure that the material flows consistently and prevents blockages. Discharge Control: Discharge gates or valves at the silo’s base control the rate of material flow. These can be manually or automatically operated, depending on the system's design. PROCESS FLOW 4. Material Discharge Material Flow to Discharge Equipment: The material flows from the silo into discharge equipment such as conveyors, augers, or pneumatic systems, which transport it to the next stage. Weighing and Measurement: During discharge, materials may pass through weighing systems to ensure the correct quantity is being transported. Dust Control: Dust control systems, like dust collectors or ventilation systems, operate during discharge to prevent dust from escaping into the environment. PROCESS FLOW 5. Material Transport Loading onto Transport Vehicles: The discharged material is then loaded onto transport vehicles such as trucks, trains, or ships, depending on the final destination. Final Inspection: Before transport, the material might undergo a final inspection to ensure quality and consistency. Transport to the Next Destination: The material is transported to its next destination, such as a manufacturing plant, processing facility, or customer location. PROCESS FLOW 6. Post-Discharge and Silo Maintenance Silo Cleaning and Inspection: After discharge, the silo is often cleaned and inspected for any residual material, wear, or damage. This maintenance is crucial for ensuring the silo’s long-term functionality. Recalibration and Readjustment: Any sensors, discharge gates, or flow control systems are recalibrated and adjusted as necessary to prepare for the next loading cycle. SILO ISSUES SILO ISSUES DESIGN EFFICIENCY SAFETY PRACTICES FOR SILO SYSTEMS 1. Personal Protective Equipment (PPE): 4. Training and Safety Protocols: Dust Masks and Respirators: To protect against Employee Training: Provide training on silo safety inhalation of dust and airborne particles. procedures, emergency response, and proper handling of Gloves and Safety Glasses: To shield against physical materials. hazards and potential chemical exposures. Emergency Procedures: Establish and communicate Protective Clothing: To prevent contact with hazardous clear emergency protocols for handling accidents, fires, or materials. system failures. 2. Dust and Fire Suppression Systems: 5. Material Handling Safety: Dust Control: Implement dust collection systems to Safe Loading Practices: Ensure proper techniques for manage airborne dust and prevent explosions. loading materials to avoid spillage and accidents. Fire Prevention: Equip silos with fire suppression Fall Protection: Implement safety measures to prevent systems, such as sprinklers and fire extinguishers, and falls during maintenance or inspection activities. regularly inspect for proper operation. 6. Proper Silo Design and Construction: 3. Regular Maintenance and Inspections: Structural Integrity: Ensure the silo is designed and Routine Checks: Perform regular inspections of silo constructed to withstand the pressures and stresses of structures, discharge systems, and aeration equipment to stored materials. detect and address issues early. Ventilation: Design silos with adequate ventilation to Scheduled Maintenance: Conduct preventive prevent the buildup of harmful gases. maintenance to ensure all components are in good working condition and avoid unexpected breakdowns. SAFETY PRACTICES FOR FEEDER SYSTEMS 1. Guarding and Shields: 4. Dust and Material Control: Mechanical Guards: Install guards and shields around Dust Collection: Install dust collection systems to manage moving parts to prevent accidental contact and injuries. airborne dust generated by feeder operations. Access Controls: Restrict access to areas with moving Material Flow Management: Ensure smooth and parts, using barriers or locked enclosures. controlled material flow to avoid blockages and overflows. 2. Proper Training and Operation: 5. Emergency Stops and Safety Devices: Operator Training: Train operators on the correct use of Emergency Stop Buttons: Equip feeders with accessible feeders, including startup, shutdown, and emergency emergency stop buttons to quickly halt operations in case procedures. of an emergency. Operational Safety Checks: Perform pre-operation Safety Alarms: Install alarms and warning systems to alert checks to ensure equipment is functioning properly before operators of potential hazards or malfunctions. use. 6. Inspection and Safety Checks: 3. Regular Maintenance: Routine Inspections: Regularly inspect feeder systems Scheduled Maintenance: Conduct routine maintenance for signs of wear, damage, or misalignment. to keep feeders in good working condition, including Safety Audits: Conduct safety audits to review compliance lubrication and inspection of wear parts. with safety standards and identify areas for improvement. Immediate Repairs: Address any malfunctions or signs of wear promptly to prevent accidents. ENVIRONMENTAL CONSIDERATIONS 1. Dust Control Automated Controls: Implement 4. Environmental Impact of Materials automated control systems to optimize Dust Collection Systems: Implement dust energy use based on real-time material Sustainable Materials: Choose materials collectors or cyclones to capture airborne flow and operational needs. and components that are environmentally dust generated during material handling friendly, such as those with lower and transfer, reducing air pollution and Energy Recovery: Explore opportunities environmental footprints or that are improving indoor air quality. for energy recovery or recycling, such as recyclable. using excess heat for other processes. Regular Maintenance: Ensure dust control Lifecycle Analysis: Conduct lifecycle systems are regularly maintained and 3. Waste Reduction assessments to understand the cleaned to prevent dust buildup and environmental impact of materials from equipment malfunctions. Material Recovery: Design systems to production to disposal and make informed minimize material spillage and losses, decisions. Enclosed Systems: Use enclosed allowing for efficient recovery and reuse of conveyors and feeders to minimize dust materials. 5. Water Management emissions and contain dust within the system. Accurate Measurement: Use precise Minimize Water Use: Implement water- measurement and control systems to saving technologies and practices to 2. Energy Efficiency reduce waste generated during material reduce water consumption during cleaning handling and processing. and maintenance of silo systems. Efficient Motors and Drives: Utilize energy-efficient motors and drives to Recycling Systems: Implement recycling Proper Drainage: Ensure effective reduce power consumption and lower systems for waste materials or by-products drainage systems are in place to manage greenhouse gas emissions. to reduce landfill use and promote and control runoff and prevent sustainability. contamination of surrounding areas. ENVIRONMENTAL CONSIDERATIONS 6. Noise Control environmental aspects, and maintain Continuous Monitoring: Use accurate records for regulatory continuous monitoring systems to Noise Reduction Measures: Install reporting. track emissions, dust levels, and other noise-reducing equipment or environmental parameters in real time. enclosures to minimize noise pollution 8. Site Management generated by feeder and silo 10. Sustainability Initiatives operations. Proper Siting: Select locations for feeders and silos that minimize Green Certifications: Seek Regular Monitoring: Conduct noise environmental impact, such as certifications for environmental level assessments and make avoiding sensitive areas or habitats. performance and sustainability, such adjustments to equipment or as ISO 14001, to demonstrate operations to stay within acceptable Landscaping and Buffer Zones: commitment to environmental noise limits. Implement landscaping and buffer stewardship. zones around silo systems to mitigate 7. Regulatory Compliance visual impact and provide natural Innovation: Invest in research and filtration for dust and runoff. development of new technologies and Environmental Regulations: Ensure practices that enhance environmental all systems comply with local, national, 9. Environmental Monitoring performance and sustainability. and international environmental regulations and standards. Regular Inspections: Perform regular environmental inspections to assess Permits and Reporting: Obtain the impact of silo and feeder systems necessary permits for emissions, on the surrounding environment. waste disposal, and other