DETERMINING FLOW PROPERTIES OF PARTICULATE MATERIALS

Abstract: Apparatus and a test method for bench scale determination of whether a particulate material will flow under the action of gravity alone from an outlet in the bottom of a container. The apparatus includes a test cell (12) having inclined conical side walls (14), and that is closed at its larger end by a plug (10) having an inwardly-facing surface (18) that is concave. In this way, cylindrical surfaces are avoided, and the shape of the space within the test cell offers minimal interference with the plastic stress field of the material. The testing method includes the novel step of inverting the test cell after consolidation of the test material but prior to application of the failure load.

Description: DESCRIPTION DETERMINING FLOW PROPERTIES OF PARTICULATE MATERIALS Technical Field The present invention is in the field of bulk particulate solids and more specifically relates to an apparatus and testing method for determining on the basis of bench scale testing whether particulate matter will flow under the action of gravity through an outlet in the bottom of a container. Background Art Bulk solids in a divided state such as flour, sugar, ores, dry chemicals and coal are generally handled in silos or containers that require gravity flow for dis¬ charge. One of the problems of designing such containers is sizing of the outlet so that the solids do not form an obstruction by arching across the outlet. The size of outlet required to prevent arching is a function of the unconfined yield strength of the material, the density of the material, and the shape of the outlet. There are basically two methods for determining this critical dimension. First, one could construct a full size hopper, load it with the material, and observe whether flow takes place from the outlet. The other approach known in the art is to measure the unconfined yield strength, and then to use this unconfined yield strength as a function of consolidation pressure to analyze the results to predict the hopper outlet dimen¬ sion. This latter approach has been described in the following technical papers: Jenike, A. W. , P. J. Elsey, and R. H. Woolley. "Flow Properties of Bulk Solids." Proc. A er. Soc. Test. Mater. 6 :1168-1181, 1960; Jenike, A. W. "Gravity Flow of Bulk Solids." Univ. of Utah Engineering Experiment Station Bulletin No. 108, 1961; Johanson, J. R. "Know Your Material—How to Predict and Use the Properties of Bulk Solids." Che . Eng., October 30, 1978, pp. 9-17. This latter method is usually accomplished by means of a direct shear tester and therefore it is rather cumbersome and time-consuming to obtain the results. A quicker and easier method is needed, particularly for use in the field, where portable testing equipment would be especially handy. Disclosure of the Invention It is an object of the present invention to provide apparatus and a bench scale test method to determine whether flow will occur through a given outlet under the action of gravity alone. It is a further object to provide apparatus and a test method for determining the unconfined yield strength of a particulate material. A further objective is to provide an apparatus and test method that is applicable to conical containers as well as to containers of rectangular horizontal cross section. These objectives are accomplished by a novel test chamber. The portion of the test chamber in which the material is tested includes no cylindrical walls that contact the material, and in this way the uncertainty associated with the frictional effects of cylindrical walls is eliminated. The side walls of the test chamber conform to the surface of a cone, and the larger end of the conical section is closed by a plug that includes an inwardly facing coaxial concave surface. This unique shape of the test chamber affords minimum interference with the plastic stress field present in the material. During the consolidation phase of the test, the conical walls provide an increasing cross sectional area in the direction of motion so as to minimize the frictional effects of the walls. During the failure phase of the test, the same conical walls provide a decreasing cross sectional area in the direction of motion to insure an arching condition similar to that occurring in a hopper during failure conditions. In a novel aspect of the testing method, the material to be tested is consolidated in the test cell with the concave plug at the bottom of the test cell, and then the entire test cell including the concave plug is turned upside down for the failure loading portion of the test. These and other objectives and advantages of the present invention will become clear from the detailed description given below in which several preferred embodiments are described, in relation to the drawings. The detailed description is presented to illustrate the present invention, but is not intended to limit it. Brief Description of the Drawings Figure 1 is an elevational view in cross section showing the apparatus of a preferred embodiment of the present invention at the initial consolidation phase of the test procedure; Figure 2 is an elevational view in cross section showing the apparatus at a later stage of the test procedure; Figure 3 is an elevational view in cross section showing the apparatus at a later stage of the test procedure; Figure 4 is a perspective view showing a rectangular test apparatus; Figure 5 is an elevational view in cross section showing the apparatus of a second preferred embodiment of the present invention at the initial consolidation phase of the test procedure; and. Figure 6 is an elevational view in cross section showing the apparatus of Figure 5 at the start of the failure loading phase of the test procedure. Best Mode for Carrying Out the Invention In the first part of this section, the structure of the apparatus will be described in detail. Next, the methods of using the apparatus in carrying out various tests will be discussed. Finally, several alternative embodiments and variations will be described. Turning now to the drawings in which like parts are denoted by the same reference numeral throughout, there is shown in Figure 1 a preferred embodiment of the apparatus that is used for performing the tests described below. The apparatus includes a consolidation base 20 which rests on the floor or on a bench. The conical plug 10 rests on the base 20 with its conical surface 18- facing the inside of the test cell 12. The shape of the space enclosed by the test cell 12 and by the conical plug 10 is an important aspect of the present invention, as will be described below. The test cell 12 is a unitary sleeve-like part having a conical inside surface 14 shaped to conform to a truncated cone joined at its larger diameter to a cylindrical inside surface 16. The conical inside surface 14 is inclined to the vertical by approximately six degrees, so that it could also be said that the cone to which the surface 14 conforms has a vertex angle of twelve degrees, in the preferred embodiment. If the semi-angle is less than four degrees, the convergence will be insufficient to form an arch during the failure step of the test procedure. On the other hand, the angle must not be so great that it becomes incompatable with the mass flow stress field in the test cell during the failure step of the test procedure. The conical plug 10 is slightly smaller in diameter than the cylin¬ drical inside surface 16 so that the plug 10 can, at a later stage of the test, move freely in the axial direction with respect to the test cell 12. The height of the conical plug 10 in the axial direction is slightly less than the height of the cylindrical inside surface 16 to accommodate some movement by the plug in the axial direction. The apparatus further includes a mold ring 24 that rests upon the test cell 12 and that has a diameter approximately equal to the diameter of the opening at the top 34 of the test cell. In a typical test, the test cell 12 and the mold ring 24 are filled with the material 32 under test, and the material 32 is then consolidated to a specific degree. In the best mode for carrying out the invention, the consolidation is accomplished by placing the flat disk 26 on top of the material 32 under test. The diameter of the flat disk is slightly less than the inside diameter of the mold ring 24 to permit the disk 26 to move downwardly into the mold ring 24 without contact¬ ing the mold ring. In the best mode, a consolidation load container 28 is then rested upon the disk 26 and is slowly filled with a particulate ballast material 30 to a specific pre-calculated depth H. All of the parts of the apparatus are made of steel in the preferred embodiment, although in other embodiments any strong durable non-absorbent material may be used. Because the material in the full-size hopper typically includes a degree of moisture, the material 32 under test also contains moisture, and it is important to prevent the loss of this moisture, since it affects the accuracy of the results. For this reason, a metal or rubber keeper ring 22 tightly encircles the crack between the test cell 12 and the base 20. The length of time during which the consolidation load is applied should approximate the dead time of the material in the proposed hopper, and if this amounts to an appreciable amount of time, it may be essential to take the additional step against moisture loss shown in Figure 2. In Figure 2, a moisture seal 40 is inserted between the material 32 under test and the disk 26. The moisture seal 40 consists of a thin sheet of pliable plastic, which is held in place by the keeper 42. The keeper 42 in a preferred embodiment consists of a band of metal or rubber. Figure 3 shows the apparatus at a later stage of the test method. After the material being tested has consolidated for the desired length of time, the moisture seals are removed and the test cell 12 is turned upside down and placed on the failure base 48. The failure base 48 is merely a support which does not interfere with the material in the test cell or prevent the material 32 from falling out of the test cell. Note that in Figure 3, the test cell 12 is upside down relative to its position in Figures 1 and 2, and that the conical plug 10 remains in place in the test cell. On top of the conical plug is placed the failure disk 54 which, in a preferred embodiment, is a disk of steel which serves to evenly distribute the applied failure load. The failure load container 50, which is not necessarily the same as the consolidation load container 28, is placed on top of the failure disk 54 and is gradually filled with a • ballast material, such as sand, gravel, or water. At some point as additional failure load material 52 is added, the pressure loading on the material 32 becomes too great to resist, and the material 32 collapses and falls out of the test cell 12. The height H, of the failure load material 52 at the instant of failure is carefully noted and, as will be seen below, is used in calculating the test results. It will be recognized that the conical shape of the test cell is an important aspect of the invention. During the consolidation phase of testing, shown in Figures 1 and 2, this shape provides an increase in area in the direction of flow, insuring a minimum of fric¬ tional reaction from the walls of the test cell during the consolidation phase, thereby permitting a nearly uniform and known compaction of the material tested. During the failure phase of testing, shown in Figure 3, the conical shape of the test cell provides a decreasing cross sectional area in the direction of flow so as to simulate the condition occurring in a full-scale hopper. The apparatus shown in Figures 1-3 is used for determining whether a particulate material in a large container will flow by the action of gravity alone through a circular outlet in the bottom of the container. If, instead of being circular, the outlet is rectangular, the apparatus shown i Figure 4 may be used. That apparatus is in every sense the rectangular analog of the apparatus shown in Figures 1-3. In the apparatus of Figure 4, a trough-shaped plug 60 having the. inclined plane faces 68 extends into the test cell 62. The test cell 62 is rectangular in horizontal cross-section. The right and left walls as shown in Figure 4 each include a vertical portion 66 and an inclined portion 64. The front and rear walls are vertical only, and are provided with removable panels 84 that are held-in place by removable pins of which the pin 72 is typical. Figure 4 is comparable to Figure 1 in that it shows the apparatus in the initial stage of the testing. A rectangular mold frame 74 rests on top of the test cell 62, and is comparable to the mold ring 24 of Figure 1. A consolidation plate 76 is interposed between the con¬ solidation load container 78 and the material 82 under test. The entire apparatus rests on a consolidation base 70. With reference to the apparatus of Figures 1-4 inclusive, it is essential when testing cohesive solids (defined as those in which the ratio R of the compacting pressure to the instantaneous unconfined yield stress is less than 2.0) that the walls of the converging parts of the test cell have a rough finish and that the height- to-diameter ratio C/D should not exceed 0.2 R. If the ratio exceeds 0.2 R, there is a considerable likelihood that recompaction of the material will occur during failure, thereby giving a false reading. Since the ratio R is seldom less than 1.1 for computing pressures of practical interest, in the preferred embodiment, C/D has been chosen to equal 0.22. For the embodiment shown in Figure 4, the critical value of C/D is about twice that for the configurations of Figures 1-3, and in a pre¬ ferred embodiment, the ratio C/D is approximately equal to 0.4 R or 0.44 for R = 1.1. This relatively larger allowable value of C for the rectangular test cell can be very important when testing solids with large particles where C must be several times larger than the particle size. The test procedure is substantially the same for the embodiments of Figures 1 and 4. The apparatus shown and described, when used in accordance with .the test procedure given below, can be used to predict whether a circular or rectangular outlet in the bottom of a con- • tainer partially filled with a particulate material will discharge under the action of gravity alone or whether, instead, arching of the material above, the outlet will develop to prevent the desired flow. It will be seen below, that in addition to determining whether or not flow will occur, the method can be used to determine the size of outlet required to prevent arching and, with some minor modifications, can be used to measure the unconfined yield strength of the material under test. Initially, the test cell 12 with the conical plug 10 are resting on the base 20. The mold ring 24 is assumed to be resting on the test cell 12. The test cell is filled with the material under test to the top of the mold ring. Next, the disk 26 is placed on top of the material 32, the consolidation load container 28 is placed on top of the disk 26, and the consolidation load 30 is poured into the container 28. This causes the material 32 to consolidate, and if the material 32 has consolidated to a level below the top 34 of the test cell, it is necessary to remove the consolidation con- tainer, to refill the mold ring 24, and to apply the consolidation load 30 again to the material 32 until the consolidation level does not sink below the top 34 of the test cell. Next, the mold ring 24 is removed and the material 32 is scraped level with the top 34 of the test cell. Thereafter, the disk 26 and the consolidation load container 28 are replaced as shown in Figure 2, and the consolidation load 30 is applied and allowed to sit for a time equal to the time at rest of the material within the container being simulated. If this time at rest is in excess of a few minutes, it is necessary to cover the test cell with a moisture impermeable seal such as the moisture seal 40 shown in Figure 2. When the apparatus is used to test whether or not flow will occur, the appropriate height H of ballast in the consolidation load container ' 28 is: where ^ι = .bulk density of material in test cell Y t = bulk density of ballast material Λ, = average cross sectional area of test cell A z = cross sectional area of consolidation load container c = weight of the consolidation load container ~ = diameter of circular outlet of a conical container or width of rectangular outlet of a rectangular container f ~ -f = 1 for a conical container ΛTV = 0 for a rectangular container f = overpressure factor The overpressure factor F accounts for the addi¬ tional pressure caused by forces other than gravity that may be operative on the container being simulated. Examples include vibration, the impact of a falling stream of particles entering the container, and the presence of gas pressure gradients within the material in the container such as might be caused by a flow of gas through the solids from top to bottom. If vibrations cause a peak vertical acceleration of a, then F - O + T) where g is the acceleration of gravity. A downwardly acting gas pressure gradient of magnitude dp/dx can be accounted for by setting where X is the bulk density of the material in the container and dp/dx is the pressure gradient in the upward direction. The appropriate expression for F in the presence of a falling stream of particles is derived in "New Design Criteria for Hoppers and Bins" by J. R. Johanson and H. Colijn Iron & Steel Engineer, October 1964, pp. 85-104. The consolidation pressure is given by σ = F y -'J- B /rr\, and the consolidation load is After the consolidation time has elapsed, the con¬ solidation load container 28, the disk 26, and the _ _ moisture seal 40 are removed and the test cell 12 along with the base 20, and including the conical plug 10 are turned upside down and placed on the failure base 48 in the position shown in Figure 3. Assuming the material 32 has a measurable cohesion, it should not fall out of the test cell in response to the shocks normally encountered in handling the apparatus, although clearly, shocks are to be avoided. Thereafter, the base 20 is removed and the failure disk 54 and the failure load container 50 are stacked on top of the conical plug 10 as shown in Figure 3. It is important that the disk 54 and the container 50 do not touch the test cell during the remaining phases of the test. Next, the failure load 52 is very gradually poured into the failure load container 50 until failure of the material in the load cell occurs. Typically, such failures are rather abrupt and most of the material with¬ in the test cell will fall out upon failure. Very little actual movement of the conical plug 10 occurs before failure, and this limited movement is permitted by the clearance between the conical plug 10 and the inside of the test cell. The height H, of the material 52 within the failure load container 50 at the time of failure is determined by leveling the material in the failure load container 50 and measuring the height H, shown in Figure 3. If this value of height H, satisfies the following inequality, then flow will occur by gravity from the outlet of diameter B; H. - where C is the height of the test cell and D is the diameter of the test cell, as shown in Figure 1. As an alternative to increasing the value of H^, the force L„ applied to cause failure could be measured and the critical failure condition could be described by the equation: F ≤ (-| - I) C A, Y, The test procedure for the rectangular opening using the apparatus of Figure 4 is identical to the pro- cedure just described with the exception that the value of m is different from that used for the circular opening, and the symbol B is defined to be the width of the rectangular outlet which has vertical inlet walls or is infinitely long, and D is the width of the rectangular test cell. It is seen that these differences affect only the magnitude of the consolidation load and the calcu¬ lated value of H, , but do not otherwise affect the steps of the test procedure. Sometimes it is desirable to measure the unconfined yield strength of the material, and this can be done using a relatively minor variation on the above test procedure. The only differences where the unconfined yield strength is to be determined are that the applied consolidation pressure should equal σ c = -~ + y, - ~ z where the symbols have the same meaning as above, and if the applied load at failure is denoted by L„ then the unconfined yield strength f may be calculated by use of the equation where h is 2.1 for the conical test cell and h is 1.1 for the rectangular test cell. In another minor variation on the method for determining whether bulk solids will or will not flow from an outlet in a container, it is recognized that there are other techniques for applying a consolidation pressure to the material 32 in the test cell. For example, a pneumatic or hydraulic ram could be used, or even a screw jack could be used with a load cell to indicate the force applied. Regardless of the device used to apply the consolidation pressure, the con¬ solidation pressure should equal Likewise the pressure at the time of failure can be determined in other ways than using the failure load container 50 and the failure load 52 of Figure 3. Alter¬ native devices for applying the failure pressure can be employed consistent with the test method, and so long as the measured pressure at failure does not exceed the following quantity, then flow will occur by gravity alone: A second preferred embodiment is shown in Figure 5 and 6, during the consolidation phase and at the begin¬ ning of the failure phase of the test procedure respec¬ tively. In this embodiment, the other parts of the apparatus are supported above the floor 88 or bench top by a bottom spacer ring 100. The test cell in this embodiment includes a ring 92 that has a conical inner surface 94. During the con- solidation phase, the ring 92 is supported on the plug support ring 96, which in turn rests on the bottom spacer ring 100. As shown in the drawings, the height of the ring 92 is C, and D represents the diameter of the larger end of the conical surface 94. The plug 90, which in one version of this embodi¬ ment includes the cylindrical spacer 102, spans the larger diameter end of the conical surface 94 and rests on a beveled portion of the plug support ring 96. In addition to supporting the plug 90, the beveled portion of the ring 96 centers the plug 90. The concave conical surface 98 of the plug 90 faces the interior of the test chamber. In accordance with the present invention, the inwardly-facing surface of the plug 90 must be concave, but it does not necessarily have to be conical. A mold ring 104 rests on the ring 92. The inside surface of the mold ring is cylindrical and its diameter is the same as the diameter of the smaller end of the conical surface 94, so that the mold ring 104 forms an upward extension of the ring 92. The consolidation pressure is applied, in one version of this embodiment, by applying a weight to the consolidation disk 106 that rests on the particulate material 112. The disk 106 has a diameter slightly smaller than the inside diameter of the mold ring 104, to permit the disk 106 to move freely in the axial direction as the material 112 compacts. In this version of the embodi¬ ment, a spacer 114 supports a consolidation load con¬ tainer 108 a short distance above the disk 106. The _ _ consolidation load may be increased by adding con¬ solidation ballast 110 to the consolidation load container 108. During the consolidation phase, the direction of movement of the particles is downward toward the plug 90. The downwardly-diverging shape of the conical surface 94 prevents friction between that surface and the particulate material from interfering with the movement of the particles. The consolidation load should be applied to the particulate material in the test cell for an interval of time approximately equal to the time at rest of the particulate material in the full-size hopper. If the material is moist and if the time is long, a moisture retaining membrane similar to the membrane Λ 0 of Figure 2 may be employed to prevent loss of moisture. At the end of the consolidation phase, the load is removed. Next the mold ring 104 is removed and the con¬ solidated material above the ring 92 is removed. Thereafter, the rings 92 and 96 along with the plug 90 are inverted, care being taken to prevent relative movement of the rings 92 and 96, and to avoid bumping the exposed portions of the plug 90. The ring 92 is gently lowered onto the bottom spacer ring 100, so that the apparatus then has the configuration shown in Figure 6. The failure load container 116, which may be identical to the consolidation load container 108, is then placed on the spacer 102. The load on the parti¬ culate material is gradually increased by adding ballast to the failure load container 116, until failure occurs. The load at which failure occurs is then noted. Only a small downward movement of the plug 90 occurs before failure, and the failure is catastrophic. with the particulate material abruptly falling from the ring 92 onto the floor 88 or bench top. To accom¬ modate this small motion of the plug 90, the outside diameter of the plug 90 is slightly less than the diameter 5- of the larger-diameter end of the surface 94. This is shown somewhat exaggerated in Figures 5 and 6 for clarity. Likewise, the wall thickness of the plug 90 is exaggerated in the drawings. During the failure phase of the test procedure, 10 the downwardly converging surface 94 simulates the downwardly converging walls of the full-size hopper. As was the case with the first preferred embodiment described above, by the use of appropriate pre-calculated consolidation loads, any of several flow-related 15Ξ properties of the particulate material may be ascertained by use of the apparatus of this second preferred embodi¬ ment.. The equations for the apparatus of this second preferred embodiment are identical to those used in the first preferred embodiment described above. 2D" Thus, there has been described a novel apparatus for scale-model testing to determine whether or not flow will occur under the action or gravity from a circular or a rectangular outlet in the bottom of a container that is partly filled with particulate matter. The 25. shape of the space within the test cell is of particular significance. The test chamber walls conform to the surface of a cone, and the end of the test chamber is plugged by a movable plug having a concave inwardly- facing surface. Accordingly, the material under test 30 never contacts a cylindrical wall and this reduces test error caused by the unknown frictional forces that come into play when the material contacts a cylindrical wall. Also, the shape of the test cell is designed to not interfere with the plastic stress field that develops in the sample during testing. Accordingly, the novel shape of the test cell is highly advantageous and results in greater accuracy. There has also been described in detail a scale model test procedure that allows accurate prediction of whether or not an outlet in the bottom of a container of particulate matter will discharge under the action of gravity alone. This method, which requires the use of the special test apparatus involves the steps of con¬ solidating the material to a specific extent by appli¬ cation of a specific pressure to it and then inverting the test cell prior to determining the pressure required to cause failure of the material. Several embodiments and variations have been des¬ cribed in detail above by way of illustration. Further variations will, no doubt, be apparent to those skilled in the art, and such further variations are regarded as being within the scope of the invention. Industrial Applicability The method and apparatus described above is most helpful in predicting the behavior of full-scale con¬ tainers of particulate materials from small-scale laboratory bench tests. In this way the success of a hopper design can be assured and expensive mistakes can be avoided. The method is applicable to all kinds of particulate materials, from the finest powders to coarse ores, so that the potential applications are innumerable.

Claims: CLAIMS 1. A method of bench scale testing to ascertain a flow-related property of a particulate material, characterized by the steps of: a) providing a hollow test cell that includes a conical section defined by an inwardly-facing surface con¬ forming to a section of height C of a cone, the conical section having a smaller-diameter end and a larger-diameter end of diameter D, and that further includes a plug located adjacent to and spanning the larger-diameter end of the conical section, but slightly smaller in diameter than it, so as to be freely movable axially a limited distance into the space within the conical section, the plug having a concave inwardly-facing surface; b) placing the test cell on a supporting surface with the larger-diameter end of the conical section below its smaller-diameter end and with the plug supported in its aforementioned location adjacent the larger-diameter end of the conical section; c) filling the test cell completely full with the particulate material; d) consolidating the particulate material within the test cell by applying a downward pressure at the smaller-diameter end of the conical section, so that the direction of motion of the particulate material during consolidation is toward the plug; e) inverting the test cell with the plug and the consolidated particulate material still in it, so that after the inversion the larger-diameter end of the conical section is above its smaller-diameter end; f) applying a gradually-increasing downward load to the plug to produce failure motion of the particulate material toward the smaller-diameter end of the conical section; and, g) noting the downward load at which failure occurs. 2. The method of Claim 1 wherein the flow-related property is the minimum diameter B MIN of an outlet in the bottom of a full-size container at which flow of the particulate material will occur by gravity alone; and wherein the step of consolidating the particulate material is further characterized by the step of applying a pres¬ sure to the particulate material at the smaller-diameter end of the conical section equal to the consolidation pressure at the corresponding location in the full-size container; and wherein, following the step of noting the downward load, the method is further characterized by the step of calculating the minimum diameter at which flow will occur by the equation .Λ - c A. y. where Lp is the noted downward load, ^ is the average cross sectional area of the test cell, and Y is the bulk density of the particulate material. 3. The method of Claim 2 wherein the particulate material has been at rest in the full-size container for an appreciable time, and wherein the step of consolidating is further characterized by. applying the consolidation pressure for an interval of time equal to how long the particulate material in the full-size container has been at rest. 4. The method of Claim 1 wherein the flow-related property is whether or not the particulate material will flow, after having been at rest for some time, from a full-size container that requires gravity flow for discharge and that has an outlet of diameter B in its bottom; and wherein the step of consolidating the particulate material within the test cell by applying a downward pressure is further characterized by the step of applying a consolidation load ~c uniformly distri¬ buted over the particulate material at the smaller-dia¬ meter end of the conical section, so that the direction of motion of the particulate material during consolidation is toward the plug, where where F = overpressure factor, Y, - bulk density of the particulate material being tested, A,= average cross sectional area of the test cell; and wherein the method of Claim 1 is further characterized by the step, following the step of noting the downward load, of determining whether the noted load at which failure occurred is less than L F = (-§ - l ) C A, γ , whereby, if it is, then flow from the full-size container will occur by gravity, but if it is not, then flow from the full size container will not occur by gravity. 5. The method of Claim 4 wherein the consolida¬ tion load ^ is applied to the particulate material for an interval of time equal to how long the particulate material in the full-size container has been at rest. 6. The method of Claim 1 wherein the flow-related property is whether or not the particulate material will flow, after having been at rest for some time, from a full-size container that requires gravity flow for dis¬ charge and that has an outlet of diameter B in its bottom; and before the step of filling the test cell, further characterized by the step of providing a mold ring that is hollow and that has a cylindrical inside surface of diameter equal to the diameter of the smaller- diameter end of the conical section; and before the step of filling the test cell, further characterized by the step of resting the mold ring on top of and coaxial with the test cell to form an upward extension of it; and after the step of filling the test cell, further charac¬ terized by the steps of filling the mold ring with the particulate material and placing a consolidation load disk having an outside diameter slightly less than the inside diameter of the mold ring on top of the particulate material in the mold ring; and wherein the step of con¬ solidating the particulate material is accomplished by applying a consolidation load ^-c uniformly distributed over the top of the particulate material in the mold ring by the consolidation load disk, so that the direction of motion of the particulate material during consolidation is toward the plug, where L « ~e c = i2.- F y , A . & and F = overpressure factor, y, = bulk density of the particulate material being tested, A, = average cross sectional area of the test cell; and wherein, before the step of inverting the test cell, the method is further characterized by the steps of con¬ tinuing to apply the consolidation load for an interval of time equal to how long the particulate material in the full-size container has been at rest, and removing the mold ring and the particulate material contained in it from the test cell; and after the step of noting the downward load, the method is further characterized by the step of determining whether the noted load at which failure occurred is less than L, » (i- -/) C A whereby, if it is, then flow from the full-size container will occur by gravity, but if it is not, then flow from the full size container will not occur by gravity. 7. The method of Claim 1 wherein the flow-related property is the unconfined yield strength of the parti¬ culate material and wherein, in the consolidating step the downward pressure C c is given by σ - -t≤- - i y C σ< " A, + T y, - where l~ c - consolidation load i = average cross sectional area of the test cell y, = bulk density of the particulate material; and, after the step of noting the load, the method is further characterized by the step of calculating the unconfined yield strength by the equation - = *- ( y, + A.C ) where h = 2.1. 8. Apparatus for use in ascertaining the flow properties of a particulate material, characterized by: a hollow test cell that includes a conical section defined by an inwardly-facing surface conforming to a 5 section of a cone, said conical section having a smaller- diameter end and a larger-diameter end; and, a plug located adjacent to and spanning the larger- diameter end of said conical section; but slightly smaller in diameter than it, so as to be freely movable axially 10 a limited distance into the space within said conical section, said plug having a concave inwardly-facing surface. 9. The apparatus of Claim 8 wherein the vertex semi-angle of the conical section is in the range between 15. a minimum of 4 degrees and a maximum of θ c , where θ c is the largest angle compatable with the mass-flow stress field in the test cell. 10. A method of bench scale testing to ascertain a flow-related property of a particulate material, characterized by the steps of: a) providing a hollow test cell that includes a frustrated wedge section defined by an inwardly-facing surface conforming to a section of height of a wedge, the frustrated wedge section having a smaller end and a larger end of width D , and that further includes a plug located adjacent to and spanning the larger end of the frustrated wedge section; but slightly narrower than it, so as to be freely movable a limited distance into the space within the frustrated wedge section; the plug having a concave trough-like inwardly-facing surface; b) placing the test cell on a supporting surface with the larger end of the frustrated wedge section below its smaller end and with the plug supported in its aforementioned location adjacent the larger end of the frustrated wedge section; c) filling the test cell completely full with particulate material; d) consolidating the particulate material with¬ in the test cell by applying a downward pressure at the smaller end of the frustrated wedge section, so that the direction of motion of the particulate material during consolidation is toward the plug; e) inverting the test cell with the plug and the consolidated particulate material still in it, so that after the inversion the larger end of the frustrated wedge section is above its smaller end; f) applying a gradually-increasing downward load to the plug to produce failure motion of the particulate material toward the smaller end of the frustrated wedge section; and, g) noting the downward load at which failure occurs. 11. The method of Claim 10 wherein the flow- related property is the minimum width B M i / of an outlet in the bottom of a full-size container at which flow of the particulate material will occur by gravity alone; and wherein the step of consolidating the particulate material is further characterized by the step of apply¬ ing a pressure to the particulate material at the smaller- diameter end of the conical section equal to the con¬ solidation pressure at the corresponding location in the full-size container; and wherein, following the step of noting the downward load, the method is further charac¬ terized by the step of calculating the minimum width at which flow will occur by the equation f t - P . T) D - c h, y where [_p is the noted downward load, fi is the average cross sectional area of the test cell, and V, is the bulk density of the particulate material. 12. The method of Claim 11 wherein the particulate material has been at rest in the full-size container for an appreciable time, and wherein the step of consolidating is further characterized by applying the consolidation pressure for an interval of time equal to how long the particulate material in the full-size container has been at rest. 13. The method of Claim 10 wherein the flow- related property is whether or not the particulate material will flow, after having been at rest for some time, from a full-size container that requires gravity flow for discharge and that has an outlet of width B in its bottom; and wherein the step of consolidating the parti¬ culate material within the test cell by applying a down¬ ward pressure is further characterized by the step of applying a consolidation load L c uniformaly distributed over the particulate material at the smaller end of the frustrated wedge section, so that the direction of motion of the particulate material during consolidation is toward the plug, where L c = F y . A, & where » = overpressure factor, ι = bulk density of the particulate material being tested, A,= average cross sectional area of the test cell; and wherein the method of Claim 11 is further charac¬ terized by the step, following the step of noting the downward load, of determining whether the noted load at which failure occurred is less than L F = (-§- - |) CA. y , whereby, if it is, then flow from the full-size container will occur by gravity, but if it is not, then flow from the full-size container will not occur by gravity. 14. The method of Claim 13 wherein the consolida¬ tion load L c is applied to the particulate material for an interval of time equal to how long the particulate material in the full-size container has been at rest. 15. The method of Claim 10 wherein the flow- related property is whether or not the particulate material will flow, after having been at rest for some time, from a full-size container that requires gravity flow for discharge and that has an outlet of width B in its bottom; and before the step of filling the test cell, further characterized by the step of providing a mold frame that is hollow and that has a rectangular inside surface of dimensions equal to those of the smaller end of the frustrated wedge section; and, before the step of filling the test cell, further characterized by the step of resting the mold frame on top of and registered with the test cell to form an upward extension of it; and, after the step of filling the test cell, further chara- terized by the steps of filling the mold ring with the particulate material and placing a consolidation load plate having outside dimensions slightly less than the inside dimensions of the mold frame on top of the particu¬ late material in the mold frame; and wherein the step of consolidating the particulate material is accomplished by applying a consolidation load ^-c uniformly distributed over the top of the particulate material in the mold frame by the consolidation load plate, so that the direction of motion of the particulate material during consolidation is toward the plug, where L c = F ir, A, B and F = overpressure factor, Vι = bulk density of the particulate material being tested, and. A, = average cross sectional area of the test cell; and wherein, before the step of inverting the test cell, the method is further characterized by the steps of continuing to apply the consolidation load for an interval of time equal to how long the particulate material in the full-size container has been at rest, and removing the mold frame and the particulate material contained in it from the test cell; and, after the step of noting the downward load, the method is further characterized by the step of determining whether the noted load at which failure occurred is less than whereby, if it is, then flow from the full-size container will occur by gravity, but if it is not, then flow from the full-size container will not occur by gravity. 16. The method of Claim 10 wherein the flow- 110 related property is the unconfined yield strength of the particulate material and wherein, in the consolidat¬ ing step the downward pressure O^ is given by σ « = -±s- + y, C where L c = consolidation load 15 A ι = average cross sectional area of the test cell and Y j = bulk density of the particulate material; and, after the step of noting the load, the method is further characterized by the step of calculating the unconfined yield strength by the equation 0 f. • ■ * ■ (' ■ * *5r) where π = 1.1. 17. Apparatus for use in ascertaining the flow properties of a particulate material, characterized by: a hollow test cell that includes a frustrated wedge section defined by an inwardly-facing surface con- forming to a section of a wedge, said frustrated wedge section having a smaller end and a larger end; and, a plug located adjacent to and spanning the larger end of the frustrated wedge section; but slightly narrower than it, so as to be freely movable a limited distance into the space within the frustrated wedge sec¬ tion; said plug having a concave trough-like inwardly- facing surface. 18. The apparatus of Claim 17 wherein the vertex semi-angle of the frustrated wedge section is in the range between a minimum of 4 degrees and a maximum of θ , where θ is the largest angle compatable with the mass-flow stress field in the test cell.

Inventors: JOHANSON JERRY RAY, JOHANSON KERRY DEE, JOHANSON, JERRY, RAY, JOHANSON, KERRY, DEE
Applicants: JOHANSON J R INC
Application year: 1986
Main classification: G01N15
IPC codes: G01N1, G01N3, G01N11, G01N33