ARCHBREAKING HOPPER FOR BULK SOLIDS

Abstract: A hopper that greatly reduces the tendency of the particulate material to form bridges within the hopper is shaped so that its walls slope downward more steeply at the bottom of the hopper and slope less steeply with increasing heights above the outlet. In one embodiment the slope decreases continuously with increasing height above the oulet. In another embodiment the hopper is formed of successive sections, each joined around its circumference to the next-lower section, the wall of each section being less steeply inclined than the wall of the adjoining next-lower section. Exact relationships are given, relating the slopes of successive sections, and if the hopper is built in conformity with theses relationships, arching of the particulate material is eliminated.

Description: ARCHBREAKING HOPPER FOR BULK SOLIDS DESCRIPTION Technical Field The present invention is in the field of mechanics and more particularly relates to hoppers for solid particulate matter. The invention permits the design of hoppers that are not subject to the formation of arches in the particulate material and the consequent interruption of flow. Background Art One of the most common problems with bulk solids such as coal, sugar, flour and other various chemicals is arching or bridging at the outlet of a converging hopper. The usual solutions for eliminating bridges include enlarging the outlet beyond the critical size for bridging, and using physical agitation such as air blasters, vibrators, air lances and poke bars to dislodge the solids. While physical agitation works to some extent when arching occurs only after time at rest, the only effective way presently to handle a bulk solid that arches instantly when placed in a hopper is to enlarge the outlet size. This increases the size and cost of the feed device required below the outlet. SUBSTITUTE SHEET (RUL£ 26) Disclosure of Invention An objective of the present invention is to provide a hopper that greatly reduces the tendency of the particulate material to form bridges within the hopper. In accordance with the present invention this is accomplished by shaping the hopper so that its walls slope downward more steeply at the bottom of the hopper and slope less steeply the higher they are above the outlet. In a first preferred embodiment the slope decreases continuously with increasing height above the outlet, whereby the profile of the wall is a smooth curve, and the wall of the hopper flares upward from the outlet, like an upwardly directed trumpet. In a second preferred embodiment, which reflects contemporary construction techniques, the hopper is formed of successive sections, each joined around its circumference to the next-lower section, the wall of each section being less steeply inclined than the wall of the adjoining next-lower section. The present inventor has developed exact relationships between the slopes of successive sections. If the hopper is built in conformity with these relationships, arching of the particulate material is eliminated. The present inventor has found that when the hopper is shaped consistent with the above scheme, the cross section of the hopper in a horizontal plane may have any of the commonly used shapes, such as circular, rectangular, and race track shaped. Examples of these are shown in the drawings. The novel features which are believed to be characteristic of the invention, both as to organization and method of operation, together with further objects and advantages thereof, will be better understood from the following description considered in connection with the accompanying drawings in which several preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. Brief Description of the Drawings Figure 1 is a diagram showing a side elevational view of a converging hopper having similar cross sections at all heights and defining some of the symbols used in the description; Figure 2 is a diagram illustrating the concept of a self-supporting arch; Figure 3 is a diagram showing the relation between certain variables used in the description; Figure 4 is a diagram showing a right conical hopper in accordance with a preferred embodiment of the present invention; Figure 5 is a diagram showing a wedge-shaped long slot hopper in accordance with the present invention; Figure 6 is a diagram showing a one dimensional converging hopper in accordance with the present invention; Figure 7 is a diagram showing a type of chisel-shaped hopper in accordance with the present invention; Figure 8 is a diagram showing a combined chisel and one dimensional convergence hopper in accordance with the present invention; Figure 9 is a diagram showing an offset conical hopper in accordance with the present invention; Figure 10 is a diagram showing an offset one dimensional convergence hopper in accordance with the present invention; and, Figure 11 is a diagram showing an offset wedge-shaped hopper in accordance with the present invention. Best Mode for Carrying Out the Invention The simplest description of the invention is a converging hopper with a similar cross-section throughout with a variable slope angle starting with a steep angle at the outlet progressing to a flatter angle toward the top (as shown in Figure 1). The steeper angle at the bottom decreases the arching potential of the hopper when the cross section is the smallest. At the second slope, the cross section has increased and the hopper slope can decrease and have the same or better anti-bridging capability as the outlet. For the walls to be effective in reducing bridging they must be smooth and slick enough to cause flow at them. The slick and smooth requirement varies somewhat with the geometry of the hopper and the height of solids in the vertical section. For example, at the bottom of the hopper the height of solids in the cylindrical portion of the bin has little effect on flow at the walls and a conical hopper must be very steep to propagate flow at the walls in the uppermost section of the hopper. The pressure concentration associated with the solid is proportional to the head of solids in the vertical cylindrical bin. Consequently, flow occurs at much shallower wall slopes. There is a relation between wall slope, wall friction coefficient and distance from the vertical walls that determines the hopper slopes to maintain flow at the walls and thus ensure the anti-bridging effects of the hopper walls. If we ensure that the wall flow criterion is met, then the anti-bridging potential of a hopper outlet can be determined by looking at the support from the hopper of a self-supporting arch of thickness h (see Figure 2). The weight W in the arch is supported by the vertical component of force for stress < n perpendicular to the hopper walls and shear stress T acting opposite to flow at the hopper wall. where μ = coefficient of friction between the wall and the bulk solid. In general, the hopper angle θ may vary about the periphery P of the hopper. The cross section area A will depend on the hopper geometry and T n may change depending on the hopper geometry. In its most general form, the arch equilibrium is expressed by J σ n ( (TTaann θθ ++ ))ddpp - = J ydA (1) Where V is the bulk specific weight of the solid. If γ $ and C^ are constant the integration produces σ n (Tan θ + μ) P/A = Y σ n = (γA/P)/(Tan Q + μ) For arch failure to occur, the maximum major principal stress at the arch must exceed the unconfined yield stress f c of the solid in the arch. From Mohr circle geometry (see Figure 3), σ n = fc/( 2 + 1) (2) Tan θ = γ(A/P)( 2 + 1 )/fc - μ (3) for a conical hopper A/P = B/4 for a long slot hopper A/P = B/2 When the slot length exceeds three times the width, the end effect becomes negligible and the slot can be considered long. In a theoretical sense one could use the above formula to generate a continuous optimum hopper shape; however, in a practical sense, the hopper is more likely to be constructed of segments. The angle for each segment can be calculated as follows assuming that the lowest segment is designed for the critical arching of the bulk solid using the appropriate fc and that this fc is essentially constant for the remaining segments. Tan β 2 = (B 2 /B 1 )(Tanβ 1 + μ) - (4) Where ^ z is the angle f° r section 2, B α is the outlet size (diameter or width at the bottom of the section 2.), £, is the angle of the next lowest section, and B, is the outlet size for the next lowest section. Equation (4) applies only to hoppers shown in Figures 4, 5, and 7. A more exact method for these hoppers is to use Equation 3 with the appropriate value of f c used. In the most general sense G" n and θ vary around the periphery and the Mohr circle relation applies only to the maximum r n . Furthermore, f c is a property of the solid being handled and is a function of the major principal stress in the hopper. Subsequent hopper slopes can then be calculated using Equation (1) with the prescribed variation of <J n and with Equation (2) used to define the maximum <3 " n , The basic invention of a variable hopper slope angle used to reduce the arching in a converging hopper of similar cross section works equally well with the one-dimensional convergence hopper shown in Figure 5 (see US Patents 4,958,741 and 5,361,945). In the case where the flat side walls are slightly diverging, the flat side walls have a cr n Roughly 0.05 times the σ^ acting in the direction of the converging walls. Equation (1) can be approximated by π σ n max (.342 Tan θ + .425μ) + 0.1 μl σ n max = γ(π w 2 /4 + W L) combining with Equation (2) Tan θ = (γ(πw/4 + L) (u 2 + 1 )/(nf e ) - /lμl_(πw) - .425μ)/,342 (6) This equation can be used as Equation (4) to define subsequent slope angles. Assuming f c and w are constant and f c is determined by the lowest hopper. Angle θ x , then the following relation exists between w and θ '« Uw = .342 π (Tanθ, - Tan θ)/(1.368 Tan β, + 1.Qμ) (?) This equation can be used to optimize the hopper slope angle and position in the hopper. The value of L/w is related to the height of the hopper by In the limit equation (7) can be used to define a continuous curve that optimizes the hopper shape and minimizes the hopper height to prevent arching. If we consider the chisel-shaped hopper in Figure 7, the equivalent of Equation (6) is w=2 (f c /γ)((.683 + Uw) Tan θ + (.711 + LJw) )/((μ 2 +1 )(π/4 + Uw)) (8) This can be used similar to Equation (7) to optimize the hopper shape, except that w is a variable related to w 1 f L, and fl The inventor has found that the slopes used in constructed hoppers can differ from the angles calculated by the above equations by as much as plus or minus 5 degrees without adversely affecting the performance of the hopper. In the claims below, the word approximately should be interpreted to mean within plus or minus 5 degrees. Typical applications of the invention include: a) The conical hopper (Figure 4) where the similar cross sections are circular and arranged symmetrically around a common vertical centerline. b) the wedge-shaped hopper (Figure 5) where the similar cross sections are rectangular and arranged symmetrically about a vertical centerline. c) The one-dimensional convergence hopper, reference U.S. Patent No. 4,958,741 (Figure 6) with similar cross sections composed of a rectangle with semi-circular ends, with the diameter of the semi-circular ends equal or decreasing slightly in the upward direction and the entire cross section arranged symmetrically about a vertical centerline. d) The chisel-shaped hopper, reference U.S. Patent No. 4,958,741 (Figure 7) composed of similar cross sections composed of a rectangular central portion and semicircular ends, with the semi-circular ends arranged so that their outer extremities lie in a vertical line or a line slightly diverging downward. e) The combination of c) and d), reference U.S. Patent No. 4,958,741. f) The conical chisel and one-dimensional convergence hopper shown in Figure 8. g) The offset conical hopper (Figure 9) in which the similar circular cross sections are not symmetric about a vertical axis. h) The offset one-dimensional convergence hopper (Figure 10) in which the essentially vertical parallel side walls are arranged above each other but the semi-circular end walls are not symmetrically arranged about a vertical axis, i) The offset wedge-shaped hopper (Figure 11) in which the end walls are still vertical but the sides are not longer symmetric about a vertical axis. Industrial Applicability Where the hopper feeds downstream equipment, it is highly desirable that interruptions in the flow of particulate material should be avoided. This can be accomplished by designing the hopper in accordance with the criteria set forth above.

Claims: CLAIMS 1. A hopper that eliminates bridging of a particulate material it contains, comprising: an outlet; a wall extending upward from said outlet at an angle of inclination that decreases with increasing height above said outlet. 2. A hopper that eliminates bridging of a particulate material it contains, comprising: an outlet; a wall extending upward from said outlet and including a plurality of sections, each section joined to the next-lower section and less steeply inclined than the adjoining next- lower section. 3. The hopper of Claim 2 wherein the angles of inclination of said plurality of sections are such as to satisfy approximately the equilibrium of forces expressed by equation (1) with the constraint of equation (2). 4. The hopper of Claim 2 wherein the hopper is conical and wherein the angles of inclination of said plurality of sections approximately satisfy equation (4). 5. The hopper of Claim 2 wherein the hopper is conical and wherein the angles of inclination of said plurality of sections approximately satisfy equation (3). 6. The hopper of Claim 2 wherein the hopper has a long slot configuration and wherein the angles of inclination of said plurality of sections approximately satisfy equation (4). 7. The hopper of Claim 2 wherein the hopper has a long slot configuration and wherein the angles of inclination of said plurality of sections approximately satisfy equation (3). 8. The hopper of Claim 2 wherein the hopper is a one-dimensional convergence hopper and wherein the angles of inclination of said plurality of sections approximately satisfy equation (7). 9. The hopper of Claim 2 wherein the hopper is a one-dimensional convergence hopper and wherein the angles of inclination of said plurality of sections approximately satisfy equation (6). 10. The hopper of Claim 2 wherein the hopper is a chisel-shaped hopper and wherein the angles of inclination of said plurality of sections approximately satisfy equation (4). 11. The hopper of Claim 2 wherein the hopper is a chisel-shaped hopper and wherein the angles of inclination of said plurality of sections approximately satisfy equation (3). 12. The hopper of Claim 2 wherein the hopper includes an upper chisel portion and a lower one-dimensional convergence hopper and wherein the angles of inclination of said plurality of sections in the upper portion approximately satisfy equation (4) and the angles of inclination of said plurality of sections in the lower portion approximately satisfy equation (7). 13. The hopper of Claim 2 wherein the hopper includes an upper chisel portion and a lower one-dimensional convergence hopper and wherein the angles of inclination of said plurality of sections in the upper portion approximately satisfy equation (3) and the angles of inclination of said plurality of sections in the lower portion approximately satisfy equation (6). 14. The hopper of Claim 2 wherein the hopper is an offset cone hopper and wherein each of said plurality of sections includes a maximum angle of inclination, a minimum angle of inclination and an average angle of inclination, and wherein the average angles of inclination of said plurality of sections approximately satisfy equation (4). 15. The hopper of Claim 2 wherein the hopper is an offset cone hopper and wherein each of said plurality of sections includes a maximum angle of inclination, a minimum angles of inclination, and an average angle of inclination, and wherein the average angles of inclination of said plurality of sections approximately satisfy equation (3). 16. The hopper of Claim 2 wherein the hopper is an offset slot hopper and wherein each of said plurality of sections includes a maximum angle of inclination and a minimum angle of inclination which when averaged define an average angle of inclination for each section, and wherein the average angles of inclination of said plurality of sections approximately satisfy equation (4). 17. The hopper of Claim 2 wherein the hopper is an offset slot hopper and wherein each of said plurality of sections includes a maximum angle of inclination and a minimum angle of inclination which when averaged define an average angle of inclination for each section, and wherein the average angles of inclination of said plurality of sections approximately satisfy equation (3). 18. The hopper of Claim 2 wherein the hopper is an offset one-dimensional hopper and wherein each of said plurality of sections includes a maximum angle of inclination and a minimum angle of inclination which when averaged define an average angle of inclination for each section, and wherein the average angles of inclination of said ! plurality of sections approximately satisfy equation (7). 19. The hopper of Claim 2 wherein the hopper is an offset slot hopper and wherein each of said plurality of sections includes a maximum angle of inclination and a minimum angle of inclination which when averaged define an average angle of inclination for each section, and wherein the average angles of inclination of said plurality of sections approximately satisfy equation (6).

Inventors: JOHANSON JERRY R, JOHANSON, JERRY, R.
Applicants: JOHANSON JERRY R, JOHANSON, JERRY, R.
Application year: 1997
Main classification: B67D5
IPC codes: B65D88