Is it make sense if I try to optimize screw conveyor?

[kyhln]

Hi everyone. I work in a factory. They have around 200 screw conveyor. The material of this conveyor is steel. As you may understand steel is heavy and there is high energy consumption. My plan is to change the material of screw conveyor. Instead of steel I may use a much more lighter, not heavy material. Than energy consumption will decrease I hope. I couldnot find any research article about it. What do you think about this project? Does it make any sense?

 

[3DDave]

Screw conveyors see a great deal of friction with the material they transport. The weight of the screw is not contributing to the power required. Using a lighter material will mostly make the conveyor wear out faster. Perhaps UHMWPE, but wait until you see the cost.

 

[kyhln]

then it doesn't make much sense to carry out this idea, am i correct? There is alot of corrosion in our screw conveyors, they carry calcite stone. So, i thought may be i can use a different screw with different material. But if it will not affect the energy consumption, it doesnot make any sense. Am I right?

 

[Jboggs]

Yes. You are right. The main consumer of the energy is in the work required to overcome the friction with the material, and to move it. The weight of the screw itself has little impact on energy usage. The weight of the screw would be important of the screw were stopping and starting all the time, but since it runs at a constant speed (zero acceleration) its weight is not a factor.

 

[kyhln]

So if I cover the screw with a material, which can reduce the friction, I will see energy saving. This is the best way right?

 

[EdStainless]

Looking at liners in the screw conveyors may make more sense.


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P.E. Metallurgy, consulting work welcomed

 

[desertfox]

Hi kyhln

Reducing friction would save energy however friction is highly variable and at this point do you have any idea how much energy is used in overcoming friction? If not how will you justify the cost of making parts from different materials, design costs etc.
How long will it take to recuperate the costs of the changes and how long will it be before it improves the profit margin?.

“Do not worry about your problems with mathematics, I assure you mine are far greater.” Albert Einstein

 

[3DDave]

Example study:

https://iopscience.iop.org/article/10.1088/1742-6596/2176/1/012060/pdf

for use on cotton.

If this is for lifting material the main power consumption is adding potential energy to the rock. Then comes friction with the shell and the screw and as individual pieces tumble. Then bearing losses and losses between the motor and the screw if there is a chain and sprocket or belt and pulley drive.

The above saved 20% on a horizontal (no lift) screw.

This is a more general analysis of a horizontal screw conveyor

https://www.sciencedirect.com/science/article/pii/S0263876222006530