Industrial Processes

Module no. 1

Methods, processes and

equipment involved in
handling of solids
(Feeders and Storage Silos)

Engr. Augusto A. Avanceña

Instructor

Alba, Edgar Luigi T.

BSME-5B
Industrial processes
Module No. 1 Methods, processes and equipment involved in handling of solids (Feeders and
Storage Silos)
LEARNING OBJECTIVES:
At the end of this module, you should be able to;
1. Know what is feeders and storage silos
2. Understand the application if feeders and storage silos in industrial
plant
3. Understand the manufacturing process of feeders and storage silos
4. Know the equipment involved in the manufacturing process of feeders
and storage silos
5. Understand the design concept of feeders and storage silos

ACTIVITY:
1. Research Work: Write your discussion about the Methods, processes and
equipment involved in handling of solids (Feeders and Storage Silos).
Follow the following outline.
a. Introduction
b. Processes involved in handling of solids (Feeders and Storage Silos).
c. Equipment involved in handling of solids (Feeders and Storage Silos).
d. Application of feeders and storage silos
e. Safety protocols
f. References
Introduction
Feeders
Feeders are machineries used in assembly and manufacturing applications, to move or transport
materials or products to a designated storage or to other processing equipment.
Feeders are devices mounted at the outlet of storage units such as bins, bunkers, silos or hoppers
which are used to control and meter the flow of bulk materials from a storage unit to meet the
specified discharge flow rate. The feeder decides the magnitude of load on the handling system.
There are many types of feeders available to handle bulk solids and they can be divided into two
categories: volumetric and gravimetric. A volumetric feeder discharges a volume of material as a
function of time while a gravimetric feeder weighs material.
Silo
A silo is a structure for storing bulk materials. Silos are used in agriculture to store grain or
fermented feed known as silage. Silos are more commonly used for bulk storage of grain, food
products. Three types of silos are in widespread use today: tower silos, bunker silos, bag silos and
silage piles.

Processes involved in handling of solids

There are many types of feeders available to handle bulk solids and they can be divided into two
categories: volumetric and gravimetric. A volumetric feeder discharges a volume of material as a
function of time while a gravimetric feeder weighs material.

Volumetric Feeding Principles

The bulk material is discharged from a hopper with a constant volume per unit of time by
regulating the speed of a feeding device. The actual volume of material fed is determined through
calibration. The feeding accuracy is dependent on the uniformity of the material flow
characteristics and the bulk density.

Applications:

Simple, economical solutions where a high degree of feed rate accuracy is not required.

Gravimetric Feeding Principles- Loss in Weight

Gravimetric feeding systems generally use a volumetric feeder associated with a weighing system
to control the discharge of powder from a storage hopper at a constant weight per unit time
(kg/min). The weight signal is used as a feedback control system to constantly monitor the feed
rate and compensate for variations in bulk density, porosity etc.

Equipment involved in handling of solids

Types of Storage Silos

Depending on the raw material to be stored, the types of silos vary and are classified into 3
types: tower silos, bunker silos, and bag silos.

Tower Silos

They are the most common structures and can measure from 4 to 48 meters in diameter and 3
to 40 meters in height. They can be constructed of wood, cement, concrete or steel, among
other materials.

Silos storing grain, cement and woodchips are typically unloaded with air slides or augers. Silos
can be unloaded into rail cars, trucks or conveyors. Tower silos containing silage are usually
unloaded from the top of the pile using mechanical unloaders.
Bunker Silos

Bunker silos are trenches, usually with concrete walls, that are filled and packed with tractors
and loaders. The filled trench is covered with a plastic tarp to make it airtight. These silos are
usually unloaded with a tractor and loader.

They are recommended when large quantities of material have to be stored and are used in
agriculture and in other types of industries. In fact, nowadays, the military has also adopted the
use of this type of silos for the deposit and handling of missiles.

Bag Silos
They are plastic and hermetic bags or tubes that are used for the storage of grains and fodder in
the field. They usually measure from 2 to 21 meters in diameter. The length varies according to
the material that is going to be stored.

They are usually very heavy and they are compacted using a machine made for the purpose,
and sealed on both ends. These silos are also the most economical.

Advantages and Disadvantages of Storage Silos

Advantages

The use of storage silos presents several advantages:

– They need less area to store the same amount of material than if it were stored in a
horizontal warehouse.

– Products are stored in optimal conditions.

– Its cost is lower than that of other storage systems.

Disadvantages

One of the biggest disadvantages of storage silos is that when it comes to handling them, there
are many risks involved. The most common are:

– The risk of fire and explosion, unfortunately very common in grain elevators.

– Accidents due to suffocation and risks of poisoning. This circumstance occurs when inhaling
the flammable vapors that are generated with the decomposition of grains.

– Risk of intoxication due to the use of fumigants and pesticides.

– Risk of suffocation when opening the silos by accumulation of carbon dioxide.

Types of Feeders

Rotary Feeders

• rotating element or vane discharges powder or granules at a predetermined rate

• often used with large amounts of solid material

• power comes from an internal combustion engine or an electrical motor

Vibratory Feeders

• use both vibration and gravity to move material

• used to transport a large number of smaller objects

 • uncontrolled recovery of the material from top of feeder

• controlled delivery of the material from bottom of feeder

Screw Feeders

• used for handling bulk materials, in which a rotating helicoid screw moves the material
forward, toward and into a process unit

• very similar to screw conveyors in their basic structure, both of which are based on the
principles of the Archimedean screw

• capable of delivering dense slurries and dry granular products with great accuracy at a
range of operational speeds

• drive is controlled by servo motors capable of precise stop-start and speed control
Apron Feeders

• a limited-length version of apron conveyor

• also known as plate-belt feeder; plate feeder
• allows automatic control the volume of materials that are added to a process
• construct is from heavy, durable materials like steel
• the belt portion of the apron feeder is made from thick steel trays or pans and can be
found in mining operations, factories, and concrete plants

• cannot be used in applications where precise feeding and measuring is required

Bowl Feeders

• used to feed parts to an assembly line or piece of manufacturing equipment

 • individual components exit the feeder at specific intervals and enter the next step in the
assembly process

• Each bowl feeder uses special sensors to spot jams or parts that may be misaligned

• one drawback is its precise operation.

Safety Protocols for Feeders and Storage Silos

Silo storage is essential to many operations, and it is one of the biggest hazards. Falls, engulfment,
entanglement in machinery, and exposure to silo gases, dusts, and molds are some of the main
causes of silo injuries, illnesses, and deaths. Silos can be used to store a wide variety of materials,
but when hundreds or thousands of tons of material are stored in one place, safety needs to be
a priority.

• Avoid entering silos when possible and prevent unauthorized entries.

• Warning signs around the silo should be easy to read, in good condition, and list the
hazards. Secure silos to prevent unauthorized access.

• Ladders up the side of the silo should start at least 7 feet off the ground and portable
ladders that could provide access should not be stored in the area. To avoid falls from or
around a silo, ensure that the ladders are in good condition. Enclose ladders with a safety
cage or use fall protection systems when free-climbing.

• When you must enter a silo, confined space procedures ensure that there is a rescue plan,
emergency equipment, and crews at the ready if you need them. A qualified person
should certify that the silo is safe to enter and that the entry plan is acceptable. A three-
person team is necessary to provide the maximum safety to the entry. Always wear a
safety belt and harness so you can be rescued quickly if need be.

• To avoid entanglement in the auger mechanisms of a silo, use lockout / tagout procedures
to isolate the power and activation switch before you enter.

• Inspect and maintain augers and other silo machinery to ensure that they work properly.
 • Guards around the moving parts can help avoid caught or crush injuries from the auger
machinery. Always check that there is no one in the silo before you start an auger that
you cannot see.

• To avoid engulfment during silo filling or emptying, never allow people to be in or around
it.

• Never assume that an emptied silo is truly empty. Hundreds of tons of materials can
remain adhered to the sides.

• If you are trying to clear a jam or adhered materials, stay above the level of the materials
while you are dislodging them.

• If you become trapped in a silo, try to stay near the outer edge and keep moving to “swim”
your way to the top and edge of the material. Ladders installed inside the silo can serve
as a way to exit if necessary.

• Silage materials can create dust, mold, and gasses that can be hazardous to your health.
Breathing plant dust and mold can cause allergies and respiratory diseases. Be aware of
the symptoms such as coughing, shortness of breath, and tightness in the chest. Proper
storage procedures, wetting down the top layers of silage before disturbing them and
respiratory protection can reduce your dust and mold exposure.

• Silo gases such as nitrogen dioxide and carbon dioxide can build up in a silo during the
first three weeks of storage and displace the air that you need to breathe. Nitrogen
dioxide can be seen as a red or yellow-brown haze. Always wear an air-supplying
respirator and run the blowers at maximum power if you must enter a silo within 4-6
weeks of filling it.

Machine safety

1. Never remove or try to defeat machine safeguards.

2. Don’t create new hazards, such as allowing objects to fall into the moving parts or by creating
a new pinch point.

3. Report problems with machine safeguards to your supervisor immediately.

4. Never leave machines unattended with parts still moving. Remember that parts may still be
moving after the machine has been turned off.

5. Remove guards only when the machine has been locked out and tagged out.

6. If possible, lubricate machine parts without removing the safeguard; otherwise, turn the
machine off and lock it out before lubricating.

7. Operate equipment only when guards are in place and properly adjusted.

8. Do not use unauthorized or damaged guards.

9. Do not wear loose clothing, jewelry, or long hair around machines—these increase the risk of
being caught in the machinery.

10. Ask your supervisor if you have any questions about a machine safety or how to work with
machine guards safely.
References:

Introduction

https://www.coursehero.com/file/55836967/1feederssilosINDUSTRIALpptx/?fbclid=IwAR2E2PjGNDAcly
5PeZBi4JZ01HmvFjI1BjwtVrp_B5SP5ISTVSpdd14t5WQSilos

https://forages.oregonstate.edu/oregon/topics/storage/silos#:~:text=A%20silo%20is%20a%20s
tructure,bag%20silos%20and%20silage%20piles

Processes involved in handling of solids

Erano, M. (2015). FEEDERS AND STORAGE SILOS –

MECHANICAL.https://prezi.com/u1fld56plbqr/feeders-and-storage-silos-mechanical/?fbclid=IwAR3-
qsbr4XH3d8LqxojD3wT5vjx5c7GZBClVmi98-nPcyz4Fic-8soqhLaE

Equipment involved in handling of solids and Applications

(2019). Storage Silos: What they are, types, advantages and disadvantages. https://elebia.com/storage-
silos/

(2011). Feeders and Storage Silos. https://www.slideshare.net/physics101/feeders-and-storage-silos

Safety Protocols

(2015). Silos Storage Safety.

https://content.statefundca.com/safety/safetymeeting/SafetyMeetingArticle.aspx?ArticleID=43
0

Kilbourne, C. (2012). 10 Rules for machine safety. https://ehsdailyadvisor.blr.com/2012/12/10-

rules-for-machine-safety/