Lecture Notes

Bulk Material Handling: Properties of Bulk Materials

Khanindra Pathak
What is meant by Bulk Material?
The commonly used term Bulk Solids in the mining and mineral industry refer to the
materials that are mined. Any material that can be stored in a bin or silo are also
generically referred to as a bulk solid. Thus this term indeed encompasses a wide range of
materials varying in size from submicron powders to mine-run ores containing large
boulders, and as chemically different as sugar, cocoa powder, limestone, coal, cement,
sawdust, metal shavings and plastic pellets.
Bulk Material Handling
Bul Material Handling includes mainly transportation, transfer, transshipment and storage.
The behavior of bul solid material can be characterized by the flow function, the flow
factor of the material, and the internal and wall friction angles. These parameters can be
measured by a shear tester.
Characterization of Bulk Solids
!arious tests are conducted to characterize the bul solids. "ome of the terms associated
with bul solid characterization are briefly defined below#
Abrasiveness
The abrasiveness of a material is determined by its hardness factor and the shape of its
particles. $or instance, a material which has a high Moh%s hardness factor and has sharp,
angular-shaped particles will be considered highly abrasive.
Adhesion
Adhering of the material to a surface or particle other than itself. &After material has been
s'ueezed in your hand for one minute, observe the adhesive characteristic by noting
particles sticing to your e(tended fingers.)
Adhesiveness
Adhesiveness can be described as *e(ternal cohesiveness* which is the ability of material
to adhere to other surfaces.
Aeration
The action of introducing air &or gas) to a bul material by any means.
Aeration may cause the material to become fluidized or agitated.
Air Retention
Air retention is the ability of a material to retain air &or other gas) in the void spaces of the
material after the air &or gas) supply to it has been terminated. Air retention capability can
vary between almost zero and several days, depending on the material%s other physical
characteristics.
Angle of Repose
K. Pathak
1
Lecture Notes
The angle of repose of a bul material is the angle formed between the horizontal and
sloping surface of a piled material, which has been allowed to form naturally without any
conditioning.
Bulk Density !luidized"
$luidized bul density is the apparent bul density of a material in its fluidized state. +t is
generally lower than either the paced or loose bul density due to the air absorbed into
the voids.
Bulk Density #oose"
The loose bul density &sometimes called the poured bul density) o a bul material is the
weight per unit of volume &usually pounds per cubic foot) that has been measured when
the sample is in a loose, non-compacted or poured condition. The loose bul density may
be close to the %as conveyed* bul density and is preferred for the purposes of pneumatic
conveying system design.
Bulk Density $acked"
The paced bul density of a bul material is the weight per unit volume &usually pounds
per cubic foot) that has been measured when the sample has been paced or compacted
in. $or instance, a silo or bin or after containerized transportation. The paced bul density
does not compare to the conditions that the loose bul density is preferred for the
purposes of conveying system design.
Bulk Material Co%position
The following table describes the general compositions that may be found in a bul
material.
Term Definition
,niform A single bul material whose particles possess the same
size and shape.
-on-,niform A single bul material whose particle size and shape may
vary.
.ranular A bul material comprised of individual particles which can
be visibly discerned.
/owder A bul material comprised of individual particles which
cannot be visibly discerned.
Mi(ed Two or more different bul materials which have been
combined.
Cohesiveness
0ohesiveness describes the tendency of a material to adhere to itself. The 0ohesiveness of
a bul solid material can be caused by any and sometimes by all of several factors. These
include electrostatic charging, surface tension effects, and interlocing of certain particle
K. Pathak
2
Lecture Notes
shapes, particularly fibrous types of materials. 0ohesiveness in bul solids causes erratic
flow frombins. pipeline feeding problems, and adverse effects in certain inds of valves.
Co%pressibility
Ability of a material to compress under head load &its own weight). "'ueezing material in
hand will reveal this characteristic.
Corrosiveness
"ome materials have chemical properties which will, when combined with other materials
such as moisture and air, cause chemical deterioration to materials of construction.
&'plosiveness
+n certain conditions, some bul materials can form potentially e(plosive mi(tures when
combined with air. These conditions depend on &a) the nature of the material itself, which
would include its ignition temperature, its chemical reaction with o(ygen, its particle size
distribution, and so on1 and &b) the nature of the operation involving the material.
!loodability
2eflects a material%s tendency to aerate and act as a fluid. &"'ueeze material 'uicly in
your fist. +f it s'uirts through your fingers, then it is floodable.) $loodable materials are
difficult to restrain in controlled feeding applications, and deserve conscientious sizing.
!lo(ability
$lowability is the ease with which a bul material flows under the influence of gravity only.
!luidized
$luidized describes the state some bul materials achieve when a gas has been entrained
into the void spaces between the particles of the material. Material in a highly fluidized
state tends to behave more lie a fluid &as the term implies) than a solid bul material.
!riability
$riability describes a bul material where particles are easily crumbled or pulverized.
Hardness
A property of a solid material which contributes to its overall abrasive-ness. The harder a
material is, generally, the greater the erosion for a given velocity on a pipeline. Hardness
is difficult to 'uantify and is somewhat sub3ective when described. Moh%s "cale of Hardness
is used to describe the materials when designing pneumatic conveying systems.
Hygroscopicity
K. Pathak
3
Lecture Notes
The ability of a material to absorb moisture from its surroundings. Moist4ure may be
absorbed from either the ambient air &especially during high humidity conditions) or the
conveying air of the pneumatic system. &After s'ueezing material in hand, it will show a
thin layer coating on opened fingers). "ugar is a good e(ample.
)nternal !riction Angle
This is the internal first favored vertical flow channel angle the material maes in flowing
downward through itself. +t identifies the first favored flow stream. +t can be appro(imated
by drawing your finger through a mound of the material. +f the angle is 56 degrees or less,
no flow inducement is needed. +f angle is 78 degrees or more &with horizontal), the
material will probably *core* - i.e. plug flow, and will re'uire *cycling* if accompanied by a
feeder.
Material *e%perature
.enerally, most bul materials are handled at ambient temperature conditions. However,
in some cases, the material may be at an elevated temperature. 9levated temperature can
affect both the condition of the material itself and its surroundings - particularly the
e'uipment that is being used to convey it. 0are should be taen, when considering high
temperature materials that the temperature range is clearly and accurately stated, and
any effects on the material &particularly its handling characteristics) should be noted.
The temperature of the bul material, measured in $. or 0., for purposes of pneumatic
conveying design, is the material temperature taen at the point of entry to the system.
Material *e%perature Sensitivity
The temperature at which a bul material changes its characteristics.
Ma'i%u% $article Size
Ma(imum particle size is the ma(imum dimension in inches &in the case of lumpy
materials) or the ma(imum sieve size &in the case of powders and granules) of the largest
lump or particle in the bul material. Ma(imum particle size can be critical in the design of
pneumatic conveying systems.
Median $article Size
The median size or mid-point of the particle size distribution.
$article Density
The mass of a particle divided by its volume. $or a bul material, average particle density
is used, found by dividing the mass of the material by its volume, e(cluding the voids.
$er%eability
The permeability of a bul material is the degree to which air &or other gas) may be passed
through the void spaces between the particles of the material.
$article Shape
The shape and form of the particles of a bul material can vary considerably. The following
K. Pathak
4
Lecture Notes
table specifically describes the individual particle shape only and not the bul material as a
whole.
*er% Definition
-eedle-lie :ong. thin, rigid, straight, and pointed.
Angular "harp-edged or having a multi-faced, irregular shape.
0rystalline of geometric shape or multi-faced regular shape.
;endritic Having a branched, crystalline shape with the branches e(tending from the faces
of the body.
$ibrous 2egularly or irregularly thread-lie with a fle(ible structure.
$lay /aste-lie.
"pherical .lobe-lie.<ut-of-2ound "imilar to spherical but being somewhat deformed or
elongated.
0ylindrical 0ylinder-shaped.
Agglomerated "everal individual particles bonded together.
$article Size Distribution
The particle size distribution of a bul material is a tabulation of the -percentage of
particles by mass in each particle size range. The percentage described is either that
passing or being retained on a specific screen size. +n the ,nited "tates, the screens used
are %,.". "tandard "creens* or *Tyler Test "creens*.
<ther methods of size analysis may be used, particularly in the case of very fine and=or
cohesive powders. These methods include photo sedimentation, optical microscopy,
electrical sensing zone techni'ues &sych as the 0oulter counter), and laser diffraction
spectrometry.
$er%eability
The permeability of a bul material is the degree to which air &or other gas) may be passed
through the void spaces between the particles of the material.
K. Pathak
5
Lecture Notes
Working principle of a shear tester
The bul material is poured into a shear cell. The lid is loaded centrally with a normal force
-. The upper part of the shear cell is displaced horizontally against the fi(ed bottom ring
by a motor driven stem which pushes against the bracet. ;ue to the displacement of the
upper ring and the lid against the bottom ring, the bul solid is sheared. The shear force $
which is e(erted by the stem is then measured and used to characterize the bul solid.
Application of Shear Tester
Product optimization b adding a flo! aid
An important 'uantity, which is measured with the 2ing "hear Tester, is the flowability ffc. The
flowability is a measure for the effort re'uired to initiate flow. The larger the flowability is, the
better a powder flows. To find out the effect of a flow aid on the flowability, mi(tures of the
powder with different flow aid concentrations have been prepared and then tested with a shear
tester.
+n the diagram to the right the flowability ffc of
the product is plotted vs. the concentration of
the flow aid &a very fine powder). The red curve
shows the instantaneous properties, whereby
the blue curve shows the properties after >>
hours storage at rest &e.g. storage of the
product in a silo or a container).
<ne can see clearly that the flowability after the
>> hours storage at rest is smaller. This shows
that the product shows a pronounced time
consolidation effect. Time consolidation is also
nown as *caing*.
The flowability shows a ma(imum at a flow aid concentration of 8.66?, i.e. this flow aid
concentration yields the best flowability. An increase of the flow aid concentration beyond 8.66?
has a negative effect on the flowability.
K. Pathak
6
Lecture Notes
Further application examples:
Quality control: Ensurin a pro!uct "ith oo! !osin beha#iour by limitation o$ the
rane o$ $lo"ability%
Quality control: Ensurin a pro!uct "hich has a su$$icient $lo"ability e#en a$ter
storae at rest o#er a lon perio! o$ time%
&n#estiation o$ the in$luence o$ the particle si'e !istribution on the $lo" beha#iour%
&n#estiation o$ the in$luence o$ the storae temperature on the tiome consoli!ation
e$$ct (ca)in*%
+ptimi'ation o$ pro!uction processes rear!in oo! $lo"ability o$ the pro!ucts%%
+ptimi'ation o$ the po"!er composition $or homoenous $illin o$ the !ies o$ a
tablet press%
K. Pathak
,