FACILITY DESIGN MAXIMIZING EFFICIENCY AND THROUGHPUT KURT - - PowerPoint PPT Presentation

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FACILITY DESIGN MAXIMIZING EFFICIENCY AND THROUGHPUT KURT - - PowerPoint PPT Presentation

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FACILITY DESIGN MAXIMIZING EFFICIENCY AND THROUGHPUT KURT ROSENTRATER IOWA STATE UNIVERSITY DISTILLERS GRAINS TECHNOLOGY COUNCIL TODAYS OUTLINE Todays objectives Introduction/goals Historical perspectives Facility overview

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SLIDE 1

KURT ROSENTRATER

IOWA STATE UNIVERSITY DISTILLERS GRAINS TECHNOLOGY COUNCIL

FACILITY DESIGN

MAXIMIZING EFFICIENCY AND THROUGHPUT

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SLIDE 2

TODAY’S OUTLINE

  • Today’s objectives
  • Introduction/goals
  • Historical perspectives
  • Facility overview
  • Efficiencies in design, construction, & operations
  • Final thoughts

2

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SLIDE 3

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TODAY’S OBJECTIVES

  • Many existing facilities upgrade each year
  • Many new facilities constructed each year
  • Continual need to service grain industry
  • Design data, information & procedures vital
  • Substantial focus on farm-scale
  • Commercial-scale scientific knowledge needs more
  • Anecdotal
  • Proprietary
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SLIDE 4

INTRODUCTION

  • 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 poor quality (deterioration)
  • Repository for local grain supplies
  • Shipping point to end-use destinations via
  • Trucks, rail cars, ships

4

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SLIDE 5

HISTORICAL PERSPECTIVES

  • 1842
  • Buffalo, NY
  • Joseph Dart
  • First wood elevator
  • 50,000 bu
  • 1899
  • Minneapolis, MN
  • F.H. Peavey & C. F. Haglin
  • Experimental slip-formed concrete silo
  • 68 ft high, 20 ft diameter
  • “Peavey’s Folly”

5

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HISTORICAL PERSPECTIVES

  • The Young Mill-Wright and Miller’s Guide
  • Oliver Evans & Thomas Ellicott, 1795

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FACILITY OVERVIEW

  • Modern facilities have much greater
  • Storage capacities
  • Equipment capacities
  • Yearly throughputs
  • Dust control systems
  • Automations & controls
  • Safety measures
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SLIDE 8

FACILITIES – FARM SCALE

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FACILITIES – FARM SCALE

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FACILITIES – CO-OP SCALE

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FACILITIES – COMMERCIAL SCALE

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FACILITIES – COMMERCIAL SCALE

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13

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FACILITY OVERVIEW

  • 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 operation
  • Commercial facilities
  • Typically handle more than 20,000 bu/hr
  • Can store from several thousand, up to several million, bushels at one

time

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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

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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
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18

FACILITY OVERVIEW

Receiving Distribution Storage Reclaim Loadout Incoming Grain Outgoing Grain

Large Grains Elevator Reclaim Receiving Loadout Storage Distribution

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FACILITY OVERVIEW

Receiving Loadout Storage Reclaim Distribution Small Grains Elevator

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FACILITY OVERVIEW

  • Many types, arrangements, and sizes are available for commercial
  • perations
  • Choices depend on
  • Individual client needs and requirements / opinions
  • Operational flexibility
  • Future expansion
  • Creativity and imagination
  • Cost
  • Efficiencies in design, construction, & operations
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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 1000 bu or more
  • Capacity: ~ 20,000 bu/hr
  • Orifices, gates, spouts, conveyors
  • Valley angle: > angle of repose
  • Limiting factor, not side/face slopes
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SLIDE 22

RECEIVING SYSTEMS

Aerodynamic

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RECEIVING SYSTEMS

  • Design considerations

Above ground vs. underground Grate opening area Probe & scale location

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SLIDE 24

RECEIVING

  • 2 most common types
  • Tradeoffs
  • Gravity
  • Deeper pit, or
  • Higher receiving floor
  • Conveyor
  • Shallower pit
  • Carryover
  • Maintenance

Gravity Mechanical

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SLIDE 25

RECEIVING

YOU SHOULD MODEL YOUR SYSTEM MAX THEORETICAL DAILY INBOUND = 200,000 BU Receiving leg too large Receiving leg adequate Receiving leg too small

  • AN EXAMPLE

Can measure these

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SLIDE 26

RECEIVING SYSTEMS

MAX THEORETICAL DAILY INBOUND = 200,000 BU We can examine scale/probe locations Receiving leg too large Receiving leg adequate Receiving leg too small

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SLIDE 27

RECEIVING SYSTEMS

Receiving leg too large Receiving leg adequate Receiving leg too small MAX THEORETICAL DAILY INBOUND = 200,000 BU We can examine size of trucks

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SLIDE 28

RECEIVING SYSTEMS

Receiving leg too large Receiving leg adequate Receiving leg too small MAX THEORETICAL DAILY INBOUND = 200,000 BU We can examine dump time

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SLIDE 29

RECEIVING

Receiving leg too large Receiving leg adequate Receiving leg too small

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DISTRIBUTION SYSTEMS

  • Purpose
  • Transport grain to appropriate storage locations
  • Bucket elevators: vertical transfer
  • Drag or belt conveyors: horizontal transfer
  • Screw conveyors seldom used
  • Distributors & spouting: various transfers
  • Square vs. round; lined vs. unlined
  • Design considerations
  • Equipment must be sized ≥ receiving rate
  • Volumetric throughput (bu/h)
  • Power consumption (hp)
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DISTRIBUTION SYSTEMS

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SLIDE 32

DISTRIBUTION SYSTEMS

  • Which is best?
  • Trade-offs
  • Motor hp vs. tower/support steel vs. grain damage
  • World’s tallest bucket elevator
  • Cement in China
  • 600 t/h
  • H = 575 ft tall
  • P = 450 hp
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33

DISTRIBUTION SYSTEMS

  • Spout angles

Product Min Preferred Whole Grains 37 40 Ground Grains 50 60 Ground Feed 50 60 Wet Pelleted Feed 50 60 Dry Pelleted Feed 40 45 Fines/Dust 50 60 Flux Situation 60 bu/h/in2 40 deg. slope (10 on 12), whole grains 75 bu/h/in2 45 deg. slope (12 on 12,) whole grains 100 bu/h/in2 Vertical spouting

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DISTRIBUTION SYSTEMS

y = 39.15 ln(x) – 79.6 R² = 0.94 20 40 60 80 100 120 20 40 60 80 100 120 Flow Rate Flux (bu/h/in2) Spout Angle Steeper slope = greater flow rate

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DISTRIBUTION

  • Spout angle vs. angle of repose
  • Grain: 40o to 50o
  • Spouting flow rate flux (bu/h/in2)
  • Spout size, shape, length, angle, liner
  • Grain size, shape, length, moisture, friction

with spout wall

  • Steeper slope = greater flow rate
  • Generally industry nomographs for this

information

Round Square

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SLIDE 36

DISTRIBUTION SYSTEMS

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SLIDE 37

DISTRIBUTION SYSTEMS

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STORAGE SYSTEMS

  • Many options are available
  • Silos, bins, flat storage
  • Capacity will be affected by bin fill & grain properties
  • Type of grain
  • Moisture content
  • Angle of repose
  • Number of conveyor discharges
  • Location of conveyor discharges
  • Will never achieve “level full”
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SLIDE 39

STORAGE SYSTEMS

10000 20000 30000 40000 50000 60000 70000 10 20 30 40 50 Volume Lost (ft3) Bin Radius

Corn

20000 40000 60000 80000 100000 120000 10 20 30 40 50 Volume Lost (ft3) Bin Radius

Wheat

AoR Min = 20o AoR Max = 26o AoR Min = 19o AoR Max = 38o Wet bins: design for high AoR Dry grain: design for average AoR

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STORAGE SYSTEMS

  • Will never achieve “level full”
  • Multiple fill points will make more effective fill
  • Decreases unused bin space
  • More effective capacity
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STORAGE SYSTEMS

  • Effective storage volumes
  • Can be optimized by top fill: number of inlets, locations
  • Affected by angle of repose
  • CAD solid modeling essential

Interstice bin Round bin

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SLIDE 42

End of Part 1