Weight Feeder System

CLASS : EQUIPMENT
TITLE : GRINDING
CODE : MOX-2

Learning & Development Department of

Holcim Academy
 Content
1. Theory of dosing
2. Repeatablity and accuracy
3. Types of feed system
4. Feeder Equipment
5. Belt Scale & Weight Feeder

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 Theory of dosing
 Proportioning means to adjust (a part or thing) in size
relative to other parts or things. In our case normally
relative to other processes or process parameters
 A process requires a certain amount of material per time
mass/time = [t/h] or [kg/h]
or
 Volume per time
volume/time = [m3/h]

or m3

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 Teori pendosisan
Apakah perbedaan antara feeding, mengukur (measuring)
dan pendosisan (dosing)?

Mengukur (Measuring) Mengatur Dosis (Dosing)

Menyuplai (Feeding)
  Feeding + Measuring = flow
 Hanya secara Hanya sebagai sensor
control
volumetrik misalnya Coriolis  Mengukur peralatan dengan
(screw feeder ) Impact flow meter control loop

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 Quality of dosing
A dosing device is used to provide material to a
subsequent process, either:
 A certain total amount of material (totalizer, inventory
control)
 A certain mass flow, stable and close to the set-point
(e.g. dosing of fuel or cement admixture)
 A stable mass flow with low fluctuation, where the actual
rate is not of primary importance (e.g. raw mill feed, as
quality control adjusts tonnage according to actual
material chemistry)

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 What is Repeatability?
An example:
 An archer shoots his arrows at a target. He can see the
target but not where the arrows stick, so he aims always
at the bull’s-eye, without any correction

He shows a constant performance:

all the arrows are close together.
We call that a good Repeatability
But is he a good marksman?

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 Repeatability
Statement:
Measured sample weight  Measures the expected
variability of a discharge rate
 Nothing to do with desired
Typical feed
target feed rate
rate (average)
Measurement:
 12 consecutive samples of
10min (= m1…m12)
Occurrence
s v  repeatability
1 1 z
  m i  m  100%
2   average weight of samples
m
sv  
m z  1 i 1  i  weight of one sample (i  1...12)
m
z  number of samples
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 What is Accuracy?
An example:
 Another archer shoots his arrows at a target. He also
can not see where the arrows stick. But his result is
different:

The center of his shots is in the

middle of the bull’s-eye.
We call that a good Accuracy
Is he a good marksman?

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 Accuracy

Measured sample weight

Statement:
 Measures the deviation
mean value between delivered mean value
and requested target value
target value
Measurement:
 Minimum 12 consecutive
Occurrence
catch samples

sm  accuracy
m  msetpoint
sm  100%   weight of single sample
m
msetpoint m setpoint  setpoint of system

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 Time base of Accuracy / Repeatability
 In order to assess the
performance of a dosing
Measured rate

mt equipment, it is important to
define the relevant time basis
G(t)
(over which time the average is
being built)
 The relevant time basis has to
time be chosen according to the
process needs (residence time,
time basis t blending within the process
etc.)
Example:
 Time base for weigh feeder dosing to raw mill = 10min

 The mill is able to blend (compensate) fluctuations in mass and

quality within this 10min
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 Different types of feed systems
There is a multitude of dosing equipments, based on
different physical effects. We discuss here the following
material proportioning systems:
 Volumetric feed systems
 Screw feeder
 Apron feeder
 Rotary valve

 Gravimetric feed systems

 Weigh feeder
 Rotor scale
 Coriolis feeder
 Impact flow meter

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 Volumetric feed systems
Are used where accuracy / repeatability is not of
importance
Are not used in modern, automated processes

Advantages:
 Low investment cost
 Few electrical signals
Disadvantages:
 No feed-back whether material flows or not
 Low accuracy and repeatability
 Changes in material density are not considered
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 Volumetric feed systems
 Screw feeder for low tonnage of fine to coarse material.
With a combination of conical shaft and increasing pitch
it is possible to activate the outlet over its full length
(max. 6x screw diameter) and maintain mass flow in the
bin.

 Rotary valve for fine, non sticky material up to 10mm

with low abrasiveness

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 Volumetric feed systems
 Apron feeder are most common aside weigh feeders.
The apron weigh feeder is in the most cases used as
volumetric feeder for coarse material. Some suppliers
provide gravimetric apron feeders too

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 Gravimetric feed systems
Are used where accuracy / repeatability is of high
importance
Are used in all modern and automated processes

Advantages:
 Feed-back material flow/no-flow and quantity

 Normally high accuracy and repeatability

 Changes in material density are considered

Disadvantage:
 Compared to volumetric feeder increased initial cost
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 FEEDERS EQUIPMENT
 Belt Scale

 Weigh Belt Feeder

 Pfister Rotor weigh feeder

 Schenck Coriolis flow meter

 Impact flow meter

 Air lift feeder, dan

 Loss-in-Weigh feeder

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 Belt Scale
 Belt scales digunakan untuk mengukur bobot yang
dibawa belt conveyor dan digunakan secara luas dalam
berbagai area berbeda dalam plant (mining, quarrying
dan materials handling)
 Sebuah belt scale terdiri dari satu atau lebih roller
sections yang dihubungkan langsung ke satu atau lebih
load cells atau flexure dengan load cell tunggal, lalu
dihubungkan ke dalam belt system dalam rollers yang
ada. Kecepatan belt biasanya diukur dengan sebuah
pulse generator yang dikombinasikan dengan sebuah
friction wheel yang melekat pada belt.

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 Belt Scale
 Menggandakan belt loading dengan belt speed
memberikan flow rate dan kemudian integrasi dalam
control electronics, bobot total dari material yang
dihantarkan pada suatu waktu dapat dikalkulasi/dihitung
 Flow rate = m/s x s/t, dimana m/s = bobot material per
unit panjang dari belt dan s/t = belt displacement per
unit time.
 Accuracy dari skala-skala belt tergantung pada:
 Keseragaman belt, belt tension, belt speed, keseragaman
(uniformity) belt loading, keselarasan (alignment), material
yang dihantarkan, kebersihan belt, efisiensi roller, sudut
belt.

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 Weigh Belt Feeder
 Weigh feeder digunakan dalam sejumlah aplikasi untuk material
yang halus maupun kasar, lengket dan easy flowing.
 Prinsip fungsional:

Fg
 Bobot antara the idler sebelum dan setelah weighing idler
diukur dengan sebuah load cell  Fg = [t per meter]
 Kecepatan belt diukur dengan sebuah measurement pulley
atau pada back pulley dari belt  v = [meter per h]
[t] [m] [ t ]
Feed Rate [t/h]   
[m] [h] [h]
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 Weigh Belt Feeder
Dampak terhadap Akurasi:
 Weigh feeder harus dikalibrasi secara rutin
Dengan loss-in-weight dari up-stream bin on load cells

 Weighing of dosed material on a truck scale
 With a chain laying on the belt
 With a static test weight on the weighing

mechanism
 Belt tension harus konstan
 Keselarasan belt
 Tensioning station yang bersih dan berfungsi
 Free of influence trough inclined belt on belt scales

 Kekakuan belt konstan (constant belt stiffness)

 Tidak ada sambungan logam
 Tidak ada belt yang tergelincir

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 Weigh Belt Feeder
Dampak terhadap akurasi:
 Handal dan sensor kecepatan belt bersih
 Memiliki diameter roda (wheel) 100 mm,
lapisan (coating) selebar 0.5 mm membuat
weighing error-nya berkisar 1% (!)
 Tidak ada penumpukan, tumpahan material dan
equipment pada mekanisme pembobotan (weighing
mechanism)
Akurasi yang dinyatakan oleh supplier berlaku pada
skala-skala terkalibrasi yang baru dan bersih.
Pada jangka panjang, akurasi tergantung pada
rancangan sederhana dan handal, kemudahan untuk
dirawat (maintainability), serta kalibrasi dan
pemeliharaan Anda.
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 Evaluasi terhadap Weigh Belt Feeder
Kelebihan Kekurangan
 Mengukur sekaligus  Akurasi terbatas (at best +/-
menyuplai (feeding) 0.5%, pada prakteknya 1-2%)
 Lebih dari satu supplier,  Tidak tertutup secara
harga rendah menyeluruh
 Memerlukan pemeliharaan
secara meluas
 Tidak cocok untuk aerated
material (seperti raw meal,
fly ash, dsb.)

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 Prinsip kerja
Berdasarkan system control dapat dibedakan menjadi 3 bagian yaitu:

Weighfeeder Belt weigher (belt feeder) Belt weigher (belt scale)

Actual value dibandingkan dengan Load konstan, prefeeder dengan Belt speed konstan, prefeeder
setpoint dan perbedaannya akan control terpisah. dikontrol sesuai kalkulasi setpoint
membuat variasi speed motor. dengan actual value.
Feed rate tergantung dari belt
Tidak memerlukan prefeeder, speed, perubahan setpoint juga Feed rate tergantung dari
feeder melalui hopper. merubah prefeeder. perubahan belt load.
Feed rate tergantung dari belt
speed.
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 Komponen Mekanik

Feeding Hopper
Belt Skirt
Roller dan Idler
Head and tail pulley
Mechanical drive
Belt cleaner
Scrapper
Calibration Weight
Tensioning Device. 25
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 Feeding Hopper
Function:
 The feeding hopper forms a small buffer stock between the material
storage and the proportional feeder. It absorbs large flow
fluctuations from preceding equipment.

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 Manual Control Gate
Function:
 It defines the initial setting of the bed height to be in the operating
range of the load cell.
This is simply a thick steel plate positioned and fixed with bolts. By
adjusting the gate position, changes to the height of the material
bed on the belt is possible. The gate is set during the initial
calibration of the weighing device and is fixed once the optimum
height has been determined. The height of material bed determines
also the operating speed range of the weigh feeder – Some weigh
feeders do not have a control gate!

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 Side Skirts
Function:
 Side skirts contain the material within the belt width, avoiding
spillages to the sides

They are generally made of rubber. Care has to be taken that they
do not exert force on the load cell, thus influencing the reading.
In other designs the skirting rubber is an integral part of the belt,
avoiding the above risk.

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 Calibration Weight
Function:
 Calibrated weights are hooked to the weighing mechanism to check
the correct functioning of the load cell.

They must be removed after calibration !!!!!!!!

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 Calibration Methods
Weigh feeders can be calibrated off- or on-line.
Off-line calibration methods include:
 Taring (weigh feeders) or Zero Set (belt weighers)
 Belt Speed Calibration (optional)
 Weight Check
Static test weights


 Test chains

 Material test (if weigh out method is applied)

On-line calibration is:
 Material test (if loss of weight method is applied)

Material test with loss of weight method is the most accurate calibration
method because it uses known standards under actual operating conditions

Back to Main menu

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 Idlers and Idler Support
Function:
 The weigh feeder belt moves on a series of idlers. The idlers
around the load cell must be fixed with precision supports
 Some idlers are mounted on a frame supported by the weighing
mechanism on the load cell

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 Mechanical Drive Parts
Function:
 The drive is the mechanical link between the variable speed motor
and the driving pulley
It consists of a:
 Coupling and a

 Reducer or Chain Drive

Any mechanical problem will obviously disturb the operation of the

weighing device

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 Driving Pulley
Function:
 The drive pulley provides the force to move the belt. It is driven by a
variable speed motor via a reducer or a chain

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 Belt Cleaning Device
Function:
 The belt cleaners ensure that material does not build up on the belt
and alter the calibration
 The cleanliness of the area is highly depended of the proper
functioning
All conveyors are to be equipped with a
suitable belt cleaning system for removing
the maximum amount of carry-back material
from the belt’s surface prior to exiting the
discharge chute enclosure.
In all applications, the minimum requirement
is a dual belt cleaning system, consisting
of a pre-cleaner / primary cleaner and a
multi-bladed secondary cleaner.

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 Tensioning Device
Functions:
 The TD stretches the belt, in order to have a defined zero load on
the load cell
 It forces the belt to remain centered on the pulleys (sometimes
guiding idlers or limit idlers are additionally fitted on the sides)

The device normally consists

of a tensioning screw on
each side of the tail pulley

Back to Main menu 35

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 Komponen Mekanik
Persyaratan mekanis yang perlu diperhatikan:

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 Komponen Electric
Control System
Power Supply 24 VDC
Load Cell
Speed transducer
Signal divider
Drive motor
AC/ DC motor

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 Electrical Components of a Weigh Feeder

DRIVING MOTOR
WEIGH MEASURING CIRCUIT CIRCUIT
(LOAD MEASURE & AMPLIFIER)

FLOW CONTROL CIRCUIT SPEED MEASURING CIRCUIT

(FLOW MEASURING CIRCUIT) (SPEED MEASURE)

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 Maintenance

Cleaning idler terutama pada “weigher influential zone”.

Check kondisi belt
Check dan pertahankan tegangan belt
Check kondisi belt skirt
Kalibrasi; Span dan Zero setting
Periksa pelumasan pada bearing, reducer gear dan motor
Perawatan DC motor
Perawatan belt cleaner dan scraper

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 Troubleshooting
With the tree-diagram of causes in mind, you can rapidly locate the circuit were the
problem lies.
The tree-diagram of causes

FLOW = OK

WEIGHT SPEED

Material Flow Motor Speed

Mechanical Construction Mechanical Connection
Weight Measurement Circuit Speed Measuring Circuit

To identify the defective component, all you have to do is apply the three rules in
the respective circuit.

Back to Main menu 40

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 Impact flow meter
 The impact flow meter only measures the flow rate, thus
needs a up-stream feed system
 It is suitable for fine to medium coarse, dry and not
adhesive bulk material
Function principle:

 v
Fm
F  Measured force [N]
  Mass flow [t/h]
m
  Deflection angle [ ]
F v  Impact velocity [m/s]

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 Impact Flow Meter
Negative impact in systems accuracy:
 Changing bulk material properties as e.g. coefficient of
friction
 Gas flow through system as from dedusting (cleaning
cycle of filter system), silo aeration or pneumatic
transport
 Material build-ups or wear on impact plate

 Changes in deflection angle

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 Impact Flow Meter
HASLER
 Available rates 2t/h – 60m3
 Accuracy 1%
 Material properties < 5mm
free/moderate flowing, non-caking
 Requires stable material flow to
measurement equipment

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 Impact Flow Meter: Applications
 Nowadays impact flow meter are mainly used for dosing
of minor components and for measuring the returns in
ball mill circuits

Impact flow meter for

measuring returns
from separator

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 Impact Flow Meter: Cause of malfunction &
Solution
 Sensitivity on pressure
differences over the flow meter
is one of malfunction cause
 to overcome pressure
differences over the flow
meter it is recommended to
install a connection from
flow meter feed to discharge
point ( See picture by side).
This will ensure constant
pressure over the flow
meter (a constant under
pressure is also permitted).

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 Evaluation of Impact Flow Meter
Advantages Drawbacks
 Low investment costs  Low accuracy and
repeatability, thus not suitable
 In some cases pressure shock
for fuel and raw meal dosing
proof design available
 Only measuring (need for up-
 Several suppliers
stream feeder)
 Easily influenced by pressure
differences over the system as
e.g. cleaning cycle of
dedusting filter
 Danger of coating and wear

HGRS does not recommended impact flow

meter for coal and raw meal proportioning !
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 Coriolis Type Flow Meter
 The Coriolis Flow Meter only measures, but does not
proportion the material flow. Thus it is combined with a
kind of extraction and flow control device as, rotary
valve, throttle gate or rotary valve with vertical axis
(Schenck Multicell)
 It is suitable for fine, not sticky
bulk materials <5mm
Functional principle:
 The material is being
FR
deflected by a fast F
rotating measurement
Z
F C

wheel. The angular momentum Fc

generated therewith, indicates
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 Coriolis Type Flow Meter
Negative impact on accuracy:
 Not regular material flow from material storage and
proportioning device in case of absence of pre-bin
 Angular momentum of material stream to the coriolis
due to asymmetric feed chute arrangement
 Material build-ups on coriolis measurement wheel

 Wear of measurement wheel

 Large distance between proportioning device and

coriolis flow meter (too large dead time for fast reacting
control loop)

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 Coriolis Type Flow Meter
SCHENCK
 Available rates 0.5t/h - 650t/h
Agitator with  Turndown 1:10
vertical rotary valve  Accuracy +/- 0.5%
“Multicell”  Material properties <
5mm
free/moderate flowing, non-
caking
 Requires stable material flow
Coriolis to measurement equipment
 For applications with
“Multicore”
pulverized fuel or for kiln feed
only to be used with pre-bin

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 Coriolis Type Flow Meter: Applications
 Koromacno, Croatia 1997
main burner, coal 10 t/h
 Alsen, Germany 1995/96
main/calciner burner 22.5 / 2.2 t/h
 Lábatlan, Hungary 1995
fly ash 40 t/h

 No raw meal feed application yet within

Holcim Group
 China Cement Hong Kong 1999
(Green Island Cement)
MULTICOR S300 2 x 210 t/h
(installed above preheater)

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 Evaluation of Schenck Coriolis Flow Meter
Advantages Drawbacks
 Fully enclosed  Only measuring (need for up-
stream feeder)
 Available for raw meal and
other powders  Dead time in control loop limits
short term (<10sec) accuracy
 Pressure shock proof available
for coal  High wear with abrasive
material due to fast moving
 Flumesys is other supplier
parts
 Danger of coating

 Accuracy depends strongly on

even material flow from
feeding device (pre-bin)

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 Rotor Weigh Feeder
 Rotor scales proportion and weigh material and feed it
by gravimetric or pneumatic transport to the process
 Powdery to coarse and free- to difficult-flowing material
can be handled enclosed by the rotor scale
 Function principle:
The rotor scale works like a high sophisticated “circular”
weigh feeder but the belt is replaced by a rotor with cells

Application
ANIMATION
(Animation Pfister.exe)

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 Rotor Weigh Feeder
Negative impact on accuracy:
 No constant mass flow from feed bin (funnel flow)

 Missing pre-bin

 Missing agitator in pre-bin (with AFR, pet-coke and coal)

 Material build-up, foreign body on rotor casing

 Modifications or failures hampering free movement of

rotor casing (e.g. wiring, stiff seals etc.)
 Miss-alignment of in-/outlets and casing bearings

 Worn rotor leading to by-passing material

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 Rotor Weigh Feeder
PFISTER
 Rate 0.2t/h - 500t/h
 Accuracy +/- 0.5%
 Material properties < 5mm
free/moderate flowing, non-caking
 Special models for AFR
applications on demand
 Requires stable material flow to
measurement equipment

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 Rotor Weigh Feeder: Application
PFISTER
 Holcim Apasco, Orizaba
DRW coal / petcoke 12.4t/h
 Holcim US, Devil’s Slide
DRW coal / petcoke 6.5 / 7t/h
 Cementos Progresso
FRW 2.2 270t/h
 Holcim Maroc, Oujda
FRW 3.14 200t/h
 Holcim Brasil, Pedro Leopoldo
FRW 3.20 400t/h
 Holcim España/Torredonjimeno 4 t/h
TRW- D 2.14 different solid fuels
 Holcim Brasil Cantagalo 165 t/h
TRW 2.18/6 clinker

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 Evaluation of Pfister Rotor Weigh Feeder
Advantages Drawbacks
 Fully enclosed  Relatively high price

 Measuring and feeding in one  Ratio weight of equipment to

measured product mass
 No delay between measuring
and adjustment of feeder  Coating of rotor with product
between feed point and outlet
 Available for raw meal and
can cause errors
other powders
 Accuracy depends on feeding
 Pressure shock proof design
device (pre-bin) of rotor scale
available
 Available for AFR

 Available for clinker

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 Poldos Air lift Feeder
 The Poldos air lift (Fig. 1)
(7) (8) (6)
comprises a conveying (1) and
(5)
storage vessel (2) with aerated
bottom (3) a conveying pipe
(5) (4), a conveying nozzle (at
bottom of the conveying
pipeline). It is suspended from
(1)
weighing load cells (5) and
in/out going duct work
(4) equipped with expansion joints
(2)
(6). The venting pipe (8) of the
storage vessel is fitted whit a
(3)
control valve (7), which can
modify pressure conditions in
the vessel
Fig. 1: Transport and proportioning
system Poldos
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 Poldos Air lift Feeder
 The material is introduced from above into the vessel, fluidized by
aeration and discharged upwards with aid of air throughout the
pipeline to heights of anything up to about 100 m, for example
 Due to the conveying rate and the air pressure under the aeration
bottom of the vessel are directly proportional to the level (height of
filling) of the material in the vessel, this bottom pressure can serve
as the controlled variable for the conveying rate. Enabling high
accuracy of feeding

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 Evaluation of Poldos Air Lift Feeder
Advantages Drawbacks
 Good accuracy (± 1% of the  Volumetric control concept
present flow rate) as result of
 High power consumption (0.8
the possibility for frequent
– 1 kWh/t or nearly double
calibration
compared to a bucket
 Good sensitivity to feed rate elevator/air slide arragement)
adjustment
 Required elevated
 Completely sealed design arrangement for the blending
silo (for Kiln feed application)
 Low maintenance required

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 Loss-in-Weigh Feeder
 The weigh-in-loss feeder with its weighing vessel and feed
screw is an unit which is directly supported on weighing
load cells (Fig.1). The vessel is filled intermittently and
partly emptied, in a rhythm determined by the required rate
of feed
 During short filling time (about 5 - 15 seconds) the loss-in-
weigh feeder is switched over to volumetric feeding.

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 Evaluation of Loss-in-Weigh Feeder
Advantages Drawbacks
 Good accuracy (± 1% of the  Susceptibility to uncontrolled
present flow rate) in case of flushing of the aerated material
fine coal feeding out of refilling bin
 Completely sealed design  Limited accuracy (not better
than ±2% of the present value)
during refilling period due to
fluctuations on raw meal
density
 Limited sensitivity to feed rate
(set point) adjustments

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