Flexco Grain Transfer Chutes

PRESENTER:

Matthew J. KocaPrincipal Flowpath Engineer

10/9/2015

Flexco Grain Transfer Chutes

Comparative Discrete Element

Model Study of a Typical Grain

Transfer

Flexco Grain Transfer Chutes

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Presentation Outline

• Traditional Grain Chutes vs Flexco Chutes

– Degradation

– Dust

– Central Loading

• Design Methodology

– Continuum Method

– Discrete Element Modeling (DEM)

• Grain Breakage/Degradation White Paper

• Results and Conclusions

• Question & Answers

Flexco Grain Transfer Chutes

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Traditional Grain Chutes

• Traditional Grain Chutes

– Cutoff Gates

– “Dead Boxes”

– High Impact Angles

• Requires material on material

impacts to reduce degradation of

grain shells

• Creates non-uniform material flow

– Non-uniform material flow

• Increased dust levels

• Side loading at load zones

Flexco Grain Transfer Chutes

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Traditional Grain Chutes

• Traditional Grain Chutes

– Impact / stalling at end of incoming

slide

– Impact / stalling at cutoff gate

– Dead Box after cutoff gate

– Material not going in direction of belt

– Contained within Hi-Roller Conveyor

• Out of site, out of mind

• Spillage in Hi-Roller means more

tail pulley clean out

• More maintenance required

Flexco Grain Transfer Chutes

510/9/2015

Flexco Chutes

• Flexco Chutes

– Alternate diverter gate technology

– Low Impact Angles

• Does not require material on

material impacts

• Less degradation of grain shells

due to impacts

– Continuous “ribbon” of material

throughout the chute

– Uniform material stream

• Traps fines & dust inside stream

• Central loading in the direction of

receiving belt

• Highly predictable

Flexco Grain Transfer Chutes

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Flexco Chutes

• Flexco Chutes

– No stalling at impacts

– Low Impact Angles

– Continuous “ribbon” of

material throughout the

chute

– Uniform material stream

– Loads material in the

direction of the receiving

belt

Flexco Grain Transfer Chutes

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Flexco Design Methodology

• Continuum Method

– Takes a macro scale approach to bulk

solids modeling

– Flexco’s Preferred Method

• 30+ years experience

– 2D design based on the centerline of a

uniform stream of material

– Provides predictable, repeatable

results for “free-flowing” bulk materials

– Flexco’s proprietary design manual

including documented case studies

throughout our 30+ years of designs

insure a uniform stream is maintained

throughout the chute

Flexco Grain Transfer Chutes

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Flexco Design Methodology

• Discrete Element Modeling (DEM)

– Takes a micro scale approach to bulk

solids modeling

– Models each individual particle within

the bulk material

• Calculates reaction forces on particles

– Particle on particle

– Particle on chute

• Provides visual of expected material

paths through chute

– Can analyze non-uniform material

streams

– Used to analyze what is going on

“inside” the stream at the particle level

– Much more time intensive vs

Continuum Method

Flexco Grain Transfer Chutes

910/9/2015

Grain Breakage/Degradation White Paper

• Purpose of White Paper

– Provide a method of calculating numerical predictions

for breakage reduction without requiring capital

expenditures from clients

– Justify ROI to the grain industry

– Validate the use of Tasman Warajay Technology in

the grain industry vs traditional handling methods

Flexco Grain Transfer Chutes

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Grain Breakage/Degradation White Paper

• US Department of Agriculture

Baseline Data

– “Grain Breakage Caused By

Commercial Handling Methods”

(G.H. Foster, L.E. Holman, 1973)

– Pertinent data used was based

on corn kernels

– Provides an actual % of particles

broken in real life tests

• Free fall from 3 different heights

• Impact on concrete at 45

degree angle

• Measured amount of broken

kernels after test

Note: Breakage results at 12.6% moisture at 25oF

Flexco Grain Transfer Chutes

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Grain Breakage/Degradation White Paper

• DEM Control Analysis

– Replicate historical USDA drop tests

• 40ft drop onto 45deg plate

• 70ft drop onto 45deg plate

• 100ft drop onto 45deg plate

– Record all particle forces from

simulations

– Calibrate DEM particle force outputs

to actual breakage percentages

from USDA research

Flexco Grain Transfer Chutes

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Grain Breakage/Degradation White Paper

• DEM Chute Analysis

– Use same material properties and

simulation settings from Control

Analysis

– Analyze existing transfers

– Analyze Flexco proposed transfers

– Compare particle forces to theoretical

breakage force limit

– Provides estimated breakage

percentage due to transfer point

Flexco Grain Transfer Chutes

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Grain Breakage/Degradation White Paper

Flexco Grain Transfer Chutes

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Results and Conclusions

• There would be an expected 84% decrease in

exposure to theoretical breakage forces

– 2.16% breakage in traditional transfer chute

– 0.34% breakage in Flexco transfer chute

• This analysis represents a single impact within the

chute, and material impacting the receiving belt

– Consider how many impacts and spouts material passes

through in a typical facility

– Cumulative effect of single impact breakage rates could

lead to large loss of product value

– Breakage rates do not decrease as grade of material

drops (as stated in USDA research)

• Currently, before and after sampling is underway at

an installation in the New Orleans vicinity to

validate controlled flow transfers in the grain

industry.

Flexco Grain Transfer Chutes

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Thank You For Your Time & Attention

Questions & AnswersPRESENTER:

Matthew J. KocaPrincipal Flowpath Engineer