Unfortunately, it’s not quite so simple when it comes to powders and other dry, bulk solids. Powders can develop ratholes and/or cause bridging in a hopper, often inhibiting product flow (this case study on transferring zinc oxide is a perfect example of that). Below are some pictures of what these flow obstructions could look like.
Although it more complicated, determining the flow of a solid can be done. One of the first steps is evaluating certain fundamental properties of your product. These properties are:
Most of these properties can be determined using various types of shear cell testers. Each type of tester comes with its own integral software allowing easy adjustment of testing parameters, ensuring the most reliable results.
Once the information above is determined, relationships between these various properties can be established, providing sound data that can be used to recommend the optimal hopper design and bulk solids storage vessels. Specifically, this data can allow us to determine the following:
As an example of the data obtained when performing shear cell testing, below are some of the graphs showing the relationships between various properties. This data was obtained using a Brookfield PFT (Powder Flow Tester).
Figure 1: Bulk Density Graph – displays the bulk density of a sample of Calcium Carbonate at various consolidation stresses.
Figure 2: Flow Function Graph – displays how the cohesive nature of the material lessens under higher consolidation stresses. Data is plotted over standard flow indices to help determine what sort of properties the product would exhibit at the various consolidation stresses.
Through our experience handling powders and designing solids transfer systems, we've found that one primary way to ensure your solids flow properly is to use a hopper that is designed to maximize the efficiency of powder transfer. DDPS' SureFlow Bag Emptying Station was built to do just that. The unique cylindrical housing and conical hopper shape proves to be a superior alternative to traditional square hopper designs. These hoppers are available to complement our Powder Pump solids transfer system, providing customers with a complete solution for their material transfer needs. Contact us for more information.