1. Conical hopper analysis and optimisation for improved flow reliability
Context Problem Analysis
Flow Property Tests Analysis of Results Recommendations
Project for BEng (Hons) Mechanical Engineering. Student: Vivek Ganesh 1110196, Supervised By: Karl Gregory. For More Information on Project Please drop a mail : Vg1aes@bolton.ac.uk
 Determine flow properties of
Bulk material.
(Wall friction Angle, Wall angle,
Minimum Hopper outlet, Bulk
Density)
 Design Hopper Geometry.
 Design insert and fabricate.
 Test for flow patterns and flow
rate.
Static Material (Deteriorates in time)
Mass flow
(Reliable)
Funnel
Flow
Rat hole
Common Flow problems
occurred in hoppers to
class the flow as unreliable.
The results on two hoppers with the Bates Insert were suc-
cessful in changing the flow pattern, However the flow relia-
bility only improved in 55° Hopper.
 Further research is needed to secure
optimum performance data and design
parameters.
 The tests consume a lot of time, materials
and resources.
 To simplify these test procedures and to
save the material and time, simulation soft-
ware.
 An alternate way to reduce the testing
time would be of having a universal data
bank for Bulk material properties, this
could benefit the Bulk material handling
industries overall.
Live Project In Association With Ajax Equipment
The project aims to improve the flow
reliability of bulk material in conical hoppers.
The project uses the Ajax Equipment’s
patented design to improve the flow reliability.
The work on the project was carried out in the
company premises. The Company Located in
Bolton specialises in designing Bulk material
handling equipment.
Wall Friction Angle Test
Flow Rate TestBulk Density Tap Test
1 2
3
5
Ajax Vertical Shear cell test
Design Hopper And Insert
4
Change in Flow Pattern
 Yields excessive operation and
maintenance (O&M) costs.
 Loss of production.
 Inconsistent operation.
 Difficult to control.
 Create safety hazards.
By changing the flow pattern
with the aid of an insert in the hopper,
flow from hoppers can be made reliable.
Unreliable Flow
Images courtesy of Ajax Equipment
Potential to offer headroom savings, increases a hoppers hold-
ing capacity, minimise segregation, reduce radial velocity gra-
dients, reduce the danger of ‘flushing’, produce a more uniform
discharge density, convert a hopper flow regime from funnel
flow to mass flow and reduce the hazard of cohesive arching.
Benefits of Improving Flow Reliability