Project: - Prepared By : S.

Dutta
Client: Sapoorji & Pallonji Ltd. Aprroved By : R.S. Ghosh
DESIGN OF STEEL SILO Date : 31/8/13

Meterial :Structural Steel Conforming to IS :2062 Grade Fe :410

Standard : IS:9178 (Part-1)-1979
IS:9178 (Part-2)- 1979
IS:800 -1984
Loads:
A) Horizontal Load due to Horizontal Pressure(Ph) of the stored material acting on wall .
B) Vertical Load due to Vertical Pressure(Pv) of the stored material acting on cross sectional area of the Bin .
C) Frictional Wall Load due to Frictional Wall Pressure (Pw) of the stored material acting on wall of the Bin .
Basis : Janssensen 's theory has been used for assessment of bin load considering constant value of
pressure ratio ( λ ) ,Angle of wall friction (∂ ) & Bulk Density of material ( W ) along the bin height .
Design Data :
1) Stored Material = Lime & Dolomite 6.50 m
2) Material Type = Granular
3) Diameter of Silo (L) = 6.50 m
4)
5) Height of the Silo above waist level = 4.04 m 4.04 m
6) Depth of the Bunker below waist level = 6.69 m
7) Total height of the Bunker(H) = 10.73 m
8) Length of opening at bottom(l) = 0.40 m
9) Breadth of opening at bottom(b) = 0.40 m
10) Corrosion Allowence(Assumed)= = 0.00 mm
11) Angle of hopper w.r.t horizontal ( α ) = 65.49 Degree 6.69 m 1.143
12) Hydraulic Radius (R) = 1.63 m
13) Gross Volume of bunker = 213 m3
14) Net Volume of bunker = 168 m m
15) Bulk density of the material(W) = 1.10 T/m3 3.05 m 3.05 m v1 = 25.35
16) Weight of stored material = 235 T 0.40 v2 = 63.21
17) Angle of Internal friction (Ø) = 35.00 Degree / 0.61 Rad = v3 = 79.45
Static Condition :
18) Angle of pressure co-efficient (k) = 0.27 { k = (1-sinΦ)/(1+sinΦ) }

Variation of pressure along depth Pi( Z ) = Pi ,max (1-e-z/z0)

During Filling:
19) Angle of wall friction (∂f) = 26.25 { ∂f = 0.75Φ }
20) Pressure Ratio (λf) = 0.5 { λf = Ph/Pv }
21) Coefficient of wall friction (μf) = 0.493 { μf = tan(∂f) }
22) Pw max = 1.79 T/m2 { = WR }
23) Ph max = 3.63 T/m2 { = WR/μf }
24) Pv max = 7.25 T/m2 { = WR/μf λf }
Zof = 6.59 m { = R/μf λf }
During emptying:
25) Angle of wall friction (∂e)= = 21.00 { ∂e = 0.60Φ }
26) Pressure Ratio (λe) = 1 { λe = Ph/Pv }
27) Coefficient of wall friction (μe) = 0.384 { μe = tan(∂e) }
28) Pw max = 1.79 T/m2 { = WR }
29) Ph max = 4.66 T/m2 { = WR/μe }
30) Pv max = 4.66 T/m2 { = WR/μf λe }
Zoe = 4.24 m { = R/μe λe }
DESIGN OF RING BEAM :
Weight of material = 205 T
Self-weight of Bin = 35 T
Total Weight (Wd) = 240 T
3 No of Suport @ 120 Radius (r2) = 3.25 m
Load on each support = 80 T
Maximum Shear = 40 T 350

Ms = -0.06293 Wdr2 = -49.1 T-m

Mm = 0.03329 Wdr2 = 26.0 T-m
Mt = 0.01317 Wdr2 = 10.3 T-m 800

Box Geometry
Top Flange = 350 x 20
Bottom Flange = 350 x 20
Web 1 = 16 x 760
Web 2 = 12 x 760
Width of Box = 350-((16+12)/2) = 336 mm
Depth of Box = 800-((20+20)/2) = 780 mm

Moment Capacity = 2whfstw = 6289920 kg-cm = 62.9 T-m

Actual Shear Stress = 1000 x10.28 / 62.9 = 163.3 kg/cm2

fst = 312.5 kg/cm2

fs = (163.32+312.5) = 475.8 kg/cm2

Ixx = 315414 cm4 Zxx = 7885 cm3

f bc = (26x 10^5 / 789) = 329

Bearing Stress ( fb )= 1000 kg/cm2

f equivalent = sqrt( (fbc^2) + (fb^2 )+ (fbc x fb) +(3fs))
= 1455 < 2250 (0.9 x 2500 kg/cm2) Hence Ok

A 2.00 m

B 2.04 m
E 2.00 m

C 0.00 m
F 2.00 m

D 0.00 m
G 2.69 m

H 0.00 m

Cyclindrical Portion Conical Portion

DESIGN OF PRISMATIC PORTION :

Design of Hopper Plate Thickness :

Assume , Palte Thickness = 8 mm
S Pwe = p DWR [ Z -Zoe (1- e^(-Z/Zoe))]
S Pwe = 14.81 T Z= 2.00 m
S Pwe = 67.89 T Z= 4.70 m

Load on Hopper wall = 67.89 / ( 3.14 x 6.5) = 3.33 T/m

Zone At Z= Ph Pv Pw
( T/m2 ) ( T/m2 ) ( T/m2 )
A 2.00 1.75 1.75 0.67
B 4.04 2.86 2.86 1.10
C 4.04 2.86 2.86 1.10
D 4.04 2.86 2.86 1.10

Hoop Tension , TH= Ph x d/2 = 9.31 T

Design of Cylindrical Part

1) Live load on roof of Silo = 250 kg/m2
2) Self wt of roof of Silo = 100 kg/m2
Load on Roof = 350 kg/m2
Total Load on Roof = 11.61 T
Loand on Cylindrical Wall = 0.57 T/m

3) Self weight of 8 mm thk Plate = 0.25 T/m

Total Vert. Load = (3.33+0.57+0.26) = 4.15 T/m

Axial Compr. = ((4.15 x 1000 ) / (100 x 0.8) = 51.86 kg/cm2

Axial Tension = ((9.31 x 1000 ) / (100 x 0.8) = 116.36 kg/cm2
seqv = sqrt((51.86^2)+(116.36^2)+(51.86 x 116.36))
= 149 kg/cm2 < 2250 (0.9 x 2500 kg/cm2) Hence Ok

DESIGN OF HOPPER PORTION:

Design of Hopper Plate Thickness :
Normal pressure(Pn) & Tangential pressure (Pt) at any point on hopper Filling Condition Empty Condition
Pn= (Pvcos2α+Ph sin2α+Ws cosα) Ph,max = 3.63 T/m2 4.66 T/m2
Pt= (Pv-Ph) sinα cosα +Ws sinα Pw,max = 1.79 T/m2 1.79 T/m2
Assume, Plate Thickness = 8 mm Zof = 6.59 m 4.24 m

For Filling Condition

Zone Depth (m) Ph(T/m2) Pv (T/m2) Ws (T/m2) Pn (T/m2) Pt (T/m2) d1 (m) TH(T/m2) V mat. A plate Wt TL(T/m2)
4.040 1.661 3.323 0.063 1.687 0.653 6.500 6.03 301.488 75.620 336.386 18.11
E 2.000 6.040 2.176 4.351 0.063 2.202 0.847 4.676 5.66 110.246 38.256 123.673 9.26
F 2.000 8.040 2.555 5.111 0.063 2.581 0.991 2.853 4.05 23.975 13.478 27.219 3.34
G 2.690 10.730 2.914 5.828 0.063 2.940 1.126 0.400 0.65 0.000 0.000 0.000 0.00
H 0.000 10.730 2.914 5.828 0.063 2.940 1.126 0.400 0.65 0.000 0.000 0.000 0.00

For Empty Condition

Zone Depth (m) Ph(T/m2) Pv (T/m2) Ws (T/m2) Pn (T/m2) Pt (T/m2) d1 (m) TH(T/m2) V mat. A plate Wt TL(T/m2)
4.040 2.864 2.864 0.063 2.890 0.026 6.500 10.32 301.488 75.620 336.386 18.11
E 2.000 6.040 3.540 3.540 0.063 3.566 0.026 4.676 9.16 110.246 38.256 123.673 9.26
F 2.000 8.040 3.961 3.961 0.063 3.987 0.026 2.853 6.25 23.975 13.478 27.219 3.34
G 2.690 10.730 4.289 4.289 0.063 4.315 0.026 0.400 0.95 0.000 0.000 0.000 0.00
H 0.000 10.730 4.289 4.289 0.063 4.315 0.026 0.400 0.95 0.000 0.000 0.000 0.00

Silo Stiffner Plate Design

Thickness of Silo = 8 mm

For Silo height (10.73 m ) < Twice the nominal Diameter (13 m )
Horizantal Stiffner
Stiiffner Plate Thickness 100 mm x 10 mm Hence Ok
Provide Stiiffner @ 1400 mm < 1500 mm Hence Ok

Vertical Stiffner Not Exceding

Stiiffner Plate Thickness 100 mm x 10 mm Hence Ok
Provide Stiiffner @ 1702 mm < 3000 mm Hence Ok
( Spacing @ 30 Degree apart = 1702
 Project: - Prepared By : S. Dutta
Client: Sapoorji & Pallonji Ltd. Aprroved By : R.S. Ghosh
DESIGN OF STEEL BUNKER Date : 31/8/13

Meterial :Structural Steel Conforming to IS :2062 Grade Fe :410

Standard : IS:9178 (Part-1)-1979
IS:9178 (Part-2)- 1979
IS:800 -1984
Loads:
A) Horizontal Load due to Horizontal Pressure(Ph) of the stored material acting on wall .
B) Vertical Load due to Vertical Pressure(Pv) of the stored material acting on cross sectional area of the Bin .
C) Frictional Wall Load due to Frictional Wall Pressure (Pw) of the stored material acting on wall of the Bin .
Basis : Janssensen 's theory has been used for assessment of bin load considering constant value of
pressure ratio ( λ ) ,Angle of wall friction (∂ ) & Bulk Density of material ( W ) along the bin height .
Design Data :
1) Stored Material = Lime & Dolomite 5.00 m
2) Material Type = Granular
3) Length of the Bunker (L) = 5.00 m
4) Breadth of the Bunker (B) = 4.00 m
5) Height of the Bunker above waist level = 4.75 m 4.75 m
6) Depth of the Bunker below waist level = 4.16 m
7) Total height of the Bunker(H) = 8.91 m
8) Length of opening at bottom(l) = 0.50 m
9) Breadth of opening at bottom(b) = 0.60 m
10) Corrosion Allowence(Assumed)= = 0.00 mm
11) Angle of hopper w.r.t horizontal ( α ) = 61.59 Degree 4.16 m 1.074
12) Hydraulic Radius (R) = 1.11 m
13) Gross Volume of bunker = 127 m3
14) Net Volume of bunker = 107 m3 m
15) Bulk density of the material(W) = 1.10 T/m3 2.25 m 2.25 m v1 = 11.94
16) Weight of stored material = 139 T 0.50 v2 = 63.51
17) Angle of Internal friction (Ø) = 35.00 Degree / 0.61 Rad v3 = 31.55
Static Condition :
18) Angle of pressure co-efficient (k) = 0.27 { k = (1-sinΦ)/(1+sinΦ) }

Variation of pressure along depth Pi( Z ) = Pi ,max (1-e-z/z0)

During Filling:
19) Angle of wall friction (∂f) = 26.25 { ∂f = 0.75Φ }
20) Pressure Ratio (λf) = 0.5 { λf = Ph/Pv }
21) Coefficient of wall friction (μf) = 0.493 { μf = tan(∂f) }
22) Pw max = 1.22 T/m2 { = WR }
23) Ph max = 2.48 T/m2 { = WR/μf }
24) Pv max = 4.96 T/m2 { = WR/μf λf }
Zof = 4.51 m { = R/μf λf }
During emptying:
25) Angle of wall friction (∂e)= = 21.00 { ∂e = 0.60Φ }
26) Pressure Ratio (λe) = 1 { λe = Ph/Pv }
27) Coefficient of wall friction (μe) = 0.384 { μe = tan(∂e) }
28) Pw max = 1.22 T/m2 { = WR }
29) Ph max = 3.19 T/m2 { = WR/μe }
30) Pv max = 3.19 T/m2 { = WR/μf λe }
Zoe = 2.90 m { = R/μe λe }
DESIGN OF PRISMATIC PORTION :

Design of Hopper Plate Thickness :

During Emptying,
Ph at depth 4.75 m
PhZ = Phmax (1- e -Z/Zo) = 2.57 T/m2
Try 10 Thk Plate :

Provide Stiffeners span @ 675 mm c/c .

So maximum bending moment for 1m width of plate(M) = (2.57 x 0.675 ^2 )/8 = 0.146 T-m
Sectional Modulas (Zxx) of 1m width of plate= 100 x1^2/6
= 16.67 cm2
Bending stress,s b= (0.147x 1000 x100 ) /16.67 = 877 kg/cm2 < 1650 kg/cm2 Hence Ok

Design of Verical Stiffner :

Span of Vert. Stiffner Plate = 1250 mm
Load on Vert. stiffner Plate = ( 2.57 x 1.25 ) = 3.21 T/m
Max. Length of Stiffner plate = 4750 mm P= ( 1/2 x 3.21x4.75) = 7.62 T/m
So maximum bending moment (M) = (0.128 x3.21 x 4.75) = 4.63 T-m
Use as verical stiffner
Top Flange = 240 x 10 ( Width of top Falnge = ( 24 x10 ) = 240 mm
Web = 9 x 184 Provide = 240 mm
Bottom Flange = 140 x 16
Area = 6296 mm2 y= 101 mm Ixx= 4971 cm4
Zxx (Top) = 494.12 cm3 Zxx (Bottom) = 454.39 cm3
.
A1 = 2400 mm2 I1 = 2 cm4 I4 = 2194 cm4
A2 = 1656 mm2 I2 = 467 cm4 I5 = 0 cm4
A3 = 2240 mm2 I3 = 5 cm4 I6 = 2303 cm4

Bending stress,sb= (4.635x 1000 x100 ) /455 = 1020 kg/cm2 < 1650 kg/cm2 Hence Ok

Design of Horizantal Stiffner :

Press on bunker wall = 2.57 T/m2

Effective Length for Horz. Stiffner = 625 mm
Max. Length of Stiffner plate = 1150 mm
Load on Hoz. Stiffner = (2.57 x 0.625) = 1.60 T/m
So maximum bending moment (M) = (1.61 x 1.15^ 2) /8 = 0.27 T-m

Use as verical stiffner

Top Flange = 240 x 10 ( Width of top Falnge = ( 24 x10 ) = 240 mm
Web = 8 x 100 Provide = 240 mm
Bottom Flange = 0 x 0
Area = 3200 mm2 y= 18.75 mm Ixx= 250 cm4
Zxx (Top) = 133.42 cm3 Zxx (Bottom) = 27.42 cm4
.
A1 = 2400 mm2 I1 = 2 cm4 I4 = 45 cm4
A2 = 800 mm 2 I2 = 67 cm 4 I5 = 136 cm4
A3 = 0 mm2 I3 = 0 cm4 I6 = 0 cm4

Bending stress,sb= (0.266x 1000 x100 ) /28 = 968 kg/cm2 < 1650 kg/cm2 Hence Ok

DESIGN OF HOPPER PORTION:

Design of Hopper Plate Thickness :

ZONE-D 2 @ 655 = 1310

ZONE-C 3 @ 600 = 1800

ZONE-B 1 @ 550 = 550

ZONE-A 1 @ 500 = 500

Normal pressure(Pn) & Tangential pressure (Pt) at any point on hopper

Pn= (Pvcos2α+Ph sin2α+Ws cosα) Total Depth = 8.91 m Phmax= 3.19 m
Pt= (Pv-Ph) sinα cosα +Ws sinα Hopper Angle = 1.07 Rad Zoe = 2.90 m
Thkness = 10 mm
 For Zone A For Zone B
Depth = 8.66 mm Depth = 8.135 mm
Ph = Phmax (1- e -Z/Zo) Ph = Phmax (1- e -Z/Zo)
= 3.026 T/m2 = 2.994 T/m2
Pv = 3.026 T/m2 Pv = 2.994 T/m2
Ws = 0.079 T/m2 Ws = 0.079 T/m2

Pn = 3.063 T/m2 Pn = 3.031 T/m2

Effective Length of Plate = 495 mm Effective Length of Plate = 625 mm

So , bending moment = 0.094 T/m2 So , bending moment = 0.148 T/m2
Zxx = 16.67 cm 2
Zxx = 16.67 cm2
Hence, Bending Stress = 562 kg/cm2 Hence, Bending Stress = 889 kg/cm2

For Zone C For Zone D

Depth = 7.56 mm Depth = 5.7325 mm
Ph = Phmax (1- e -Z/Zo) Ph = Phmax (1- e -Z/Zo)
= 2.952 T/m2 = 2.746 T/m2
Pv = 2.952 T/m2 Pv = 2.746 T/m2
Ws = 0.079 T/m 2
Ws = 0.079 T/m2

Pn = 2.989 T/m2 Pn = 2.783 T/m2

Effective Length of Plate = 682 mm Effective Length of Plate = 745 mm

So , bending moment = 0.174 T/m2 So , bending moment = 0.193 T/m2
Zxx = 16.67 cm2 Zxx = 16.67 cm2
Hence, Bending Stress = 1044 kg/cm 2
Hence, Bending Stress = 1158 kg/cm2

Ph=Pv
Zone Depth (m) Ws (T/m2) Pn (T/m2) Vert. Spc. Inc. Lenth
B.M Zxx fb(max)
(T/m2) (mm) (mm)
A 8.660 3.026 0.079 3.063 500 495 0.094 16.67 562
B 8.135 2.994 0.079 3.031 550 625 0.148 16.67 889
C 7.560 2.952 0.079 2.989 600 682 0.174 16.67 1044
D 5.733 2.746 0.079 2.783 655 745 0.193 16.67 1158

Design of Horizantal Stiffner :

Stffn.
Depth (Z) Ph (T/m2) Pv (T/m2) Ws (T/m2) Pn (T/m2) ln (mm) H= H'= b= M= R=
Mkd.
1 5.405 2.693 2.693 0.079 2.730 655 745 3.105 2.313 4.291 5.323 4.962
2 6.060 2.793 2.793 0.079 2.830 655 745 3.218 2.397 3.582 3.845 4.294
3 6.660 2.866 2.866 0.079 2.904 600 682 3.302 2.253 2.933 2.423 3.304
4 7.260 2.926 2.926 0.079 2.963 600 682 3.370 2.300 2.284 1.499 2.626
5 7.860 2.975 2.975 0.079 3.012 600 682 3.425 2.337 1.635 0.781 1.911
6 8.410 3.011 3.011 0.079 3.049 550 625 3.467 2.168 1.040 0.293 1.128
7 8.910 3.039 3.039 0.079 3.076 500 569 3.498 1.989 0.500 0.062 0.497
8

Stiffner Mkd. -1 & 2 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 148 mm

Plate a = 150 x 12 Ixx = 8627 cm4
y Plate b = 10 x 250
Plate c = 240 x 10
b
c A d Axd I1 I2 28.41
a 1800 6 10800 21600 36486197 0.50
2500 137 342500 13020833 323370 2620339.24
2400 267 640800 20000 33773600
6700 994100 13062433 70583167 86265940
272 57

Bending Moment = 5.32 T-m Zxx = 477 s bc = 1116 kg/cm2 Hence Ok

Shear Stress = 4.96 T A1 = 25 t v= 198 kg/cm2 Hence Ok
Aixal Force = 4.96 T A2 = 67 s t= 74 kg/cm2 Hence Ok

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

 = 1170 kg/cm2 Hence Safe

Stiffner Mkd. -3&4 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 88 mm

Plate a = 150 x 12 Ixx = 2825 cm4
y Plate b = 12 x 138
Plate c = 240 x 10
b
c A d Axd I1 I2 28.41
a 1800 6 10800 21600 12184395 0.50
1656 81 134136 2628072 87635 2620339.24
2400 155 372000 20000 10685473
5856 516936 2669672 22957502 28247514
160 57

Bending Moment = 2.42 T-m Zxx = 219 s bc = 1105 kg/cm2 Hence Ok

Shear Stress = 3.30 T A1 = 17 t v= 200 kg/cm 2 Hence Ok
Aixal Force = 3.30 T A2 = 59 s t= 56 kg/cm2 Hence Ok

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 1159 kg/cm2 Hence Safe

Stiffner Mkd. -5,6&7 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 74 mm

Plate a = 90 x 6 Ixx = 706 cm4
y Plate b = 6 x 84
Plate c = 240 x 10
b
c A d Axd I1 I2 28.41
a 540 3 1620 1620 2698945 0.50
504 48 24192 296352 332806 2620339.24
2400 95 228000 20000 1089177
3444 253812 317972 4120928 7059239
100 57

Bending Moment = 0.78 T-m Zxx = 85 s bc = 923 kg/cm2 Hence Ok

Shear Stress = 1.91 T A1 = 5 t v= 379 kg/cm2 Hence Ok
Aixal Force = 1.91 T A2 = 34 s t= 55 kg/cm2 Hence Ok

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 1134 kg/cm2 Hence Safe

Design of Verical Stiffner :

Pressure at Depth 5.078 m lev = 2.63 T/m
Spcaing Vert. Stiffner = 600 mm
Load on Stiffner = 1.58 T/m2
Span of Stiffner = 655 mm
Bending Moment = 0.08 T-m

Use as verical stiffner

Top Flange = 240 x 10 ( Width of top Falnge = ( 24 x10 ) = 240 mm
Web = 8 x 100 Provide = 240 mm
Bottom Flange = 0 x 0
Area = 3200 mm2 y= 19 mm Ixx= 2394 cm4
Zxx (Top) = 1276.85 cm3 Zxx (Bottom) = 262.37 cm3
.
A1 = 2400 mm2 I1 = 2 cm4 I4 = 2194 cm4
A2 = 800 mm 2 I2 = 67 cm4 I5 = 132 cm4
A3 = 0 mm2 I3 = 0 cm4 I6 = 0 cm4

Bending stress,sb= (0.085x 1000 x100 ) /263 = 32 kg/cm2 < 1650 kg/cm2 Hence Ok

DESIGN OF STIFFNER AT WAIST LEV.:

Bulk Density of Material = 1.1 T/m3 Length of Bunker = 5.0 m Depth of Waist = 4.75 m
Gross Volume of Bunker = 127 M3 Width of Bunker = 4.0 m Ph at waist lev. = 2.57 T/m2
Total Wt = 139 Hopper Slope = 61.6
Tensile Force on wall plate of hopper (T) = (140x cosec(61.6))/2x5+4)
= 8.79 T/m
Tcos a = 4.19 T/m H = 1/2 x 2.57 x 4.75 = 6.10 T/m
 Hence, 2/3 H = 4.07 T/m 1/3 H = 2.03 T/m

At waist lev Ph = 2.57 T/m2 Pv= Ph = 2.57 T/m2

Ws = 0.08 T/m 2
Pn = 2.61 T/m2
H= Pn cosec a = 2.96 H' = 2.97 x 0.655 / 2 = 0.97 T/m2

2/3 H + H'- Tcos a = 0.85 T/m Bending Moment = 1.70 T-m

Use as verical stiffner

Top Flange = 240 x 10 ( Width of top Falnge = ( 24 x10 ) = 240 mm
Web = 10 x 350 Provide = 240 mm
Bottom Flange = 200 x 12
Area = 8300 mm2 y= 185.3 mm Ixx= 19216 cm4
Zxx (Top) = 1037.10 cm3 Zxx (Bottom) = 1029.20 cm 3

.
A1 = 2400 mm2 I1 = 2 cm4 I4 = 7801 cm4
A2 = 3500 mm 2 I2 = 3573 cm4 I5 = 0 cm4
A3 = 2400 mm2 I3 = 3 cm4 I6 = 7838 cm4

Bending stress,sb= (1.696x 1000 x100 ) /1030 = 165 kg/cm2 < 1650 kg/cm2 Hence Ok

DESIGN OF STIFFNER AT TOP LEV.:

Force at Top Lev. = 2.03 T/m2

Bending Moment = 4.07 T-m

Use as verical stiffner

Top Flange = 120 x 10 ( Width of top Flange = ( 12 x10 ) = 120 mm
Web = 8 x 250 Provide = 120 mm
Bottom Flange = 120 x 10
Area = 4400 mm2 y= 135.0 mm Ixx= 5100 cm4
Zxx (Top) = 377.75 cm3 Zxx (Bottom) = 377.75 cm3
.
A1 = 1200 mm2 I1 = 1 cm4 I4 = 2028 cm4
A2 = 2000 mm2 I2 = 1042 cm4 I5 = 0 cm4
A3 = 1200 mm2 I3 = 1 cm4 I6 = 2028 cm4

Bending stress,sb= (4.066x 1000 x100 ) / 378 = 1076 kg/cm2 < 1650 kg/cm2 Hence Ok
Project: 1X33 MVA Ferro Alloys Furnace-RMHS Prepared By : S. Dutta
Client: Rohit Ferro Tech Ltd. Aprroved By : R.S. Ghosh
DESIGN OF STEEL BUNKER Date : 31/8/13

Meterial :Structural Steel Conforming To IS :2062 Grade Fe :410

Standard : IS:9178 (Part-1)-1979
IS:9178 (Part-2)- 1979
IS:800 -1984
Loads:
A) Horizontal Load due to Horizontal Pressure(Ph) of the stored material acting on wall .
B) Vertical Load due to Vertical Pressure(Pv) of the stored material acting on cross sectional area of the Bin .
C) Frictional Wall Load due to Frictional Wall Pressure (P w) of the stored material acting on wall of the Bin .
Basis : Janssensen 's theory has been used for assessment of bin load considering constant value of
pressure ratio ( λ ) ,Angle of wall friction (∂ ) & Bulk Density of material ( W ) along the bin height .
Design Data :
1) Stored Material = Lime & Dolomite 5.00 m
2) Material Type = Granular
3) Length of the Bunker (L) = 5.00 m
4) Breadth of the Bunker (B) = 4.00 m
5) Height of the Bunker above waist level = 4.75 m 4.75 m
6) Depth of the Bunker below waist level = 4.16 m
7) Total height of the Bunker(H) = 8.91 m
8) Length of opening at bottom(l) = 0.50 m
9) Breadth of opening at bottom(b) = 0.60 m
10) Corrosion Allowence(Assumed)= = 1.50 m
11) Angle of hopper w.r.t horizontal ( α ) = 61.59 Degree 4.16 m 1.074
12) Hydraulic Radius (R) = 1.11 m
13) Gross Volume of bunker = 126.55 m
14) Net Volume of bunker = 300.00 m m
15) Bulk density of the material(W) = 1.60 T/m3 2.25 m 2.25 m
16) Weight of stored material = 202.47 T 0.50
17) Angle of Internal friction (Ø) = 35.00 Degree / 0.61 Rad
Static Condition :
18) Angle of pressure co-efficient (k) = 0.27 { k = (1-sinΦ)/(1+sinΦ) }

Variation of pressure along depth P i( Z ) = Pi ,max (1-e-z/z0)

During Filling:
19) Angle of wall friction (∂f) = 26.25 { ∂f = 0.75Φ }
20) Pressure Ratio (λf) = 0.5 { λf = Ph/Pv }
21) Coefficient of wall friction (μf) = 0.493 { μf = tan(∂f) }
22) Pw max = 1.78 T/m2 { = WR }
23) Ph max = 3.61 T/m2 { = WR/μf }
24) Pv max = 7.21 T/m2 { = WR/μf λf }
Zof = 4.51 m { = R/μf λf }
During emptying:
25) Angle of wall friction (∂e)= = 21.00 { ∂e = 0.60Φ }
26) Pressure Ratio (λe) = 1 { λe = Ph/Pv }
27) Coefficient of wall friction (μe) = 0.384 { μe = tan(∂e) }
28) Pw max = 1.78 T/m2 { = WR }
29) Ph max = 4.63 T/m2 { = WR/μe }
30) Pv max = 4.63 T/m2 { = WR/μf λe }
Zoe = 2.90 m { = R/μe λe }
DESIGN OF PRISMATIC PORTION :

Design of Hopper Plate Thickness :

During Emptying,
Ph at depth 4.75 m
PhZ = Phmax (1- e -Z/Zo) = 3.74 T/m2
Try 10 Thk Plate :

Provide Stiffeners span @ 625 mm c/c .

So maximum bending moment for 1m width of plate(M) = (3.74 x 0.625 ^2 )/8 = 0.182 T-m
Sectional Modulas (Zxx) of 1m width of plate= 100 x1^2/6
= 16.67 cm2
Bending stress,s b= (0.183x 1000 x100 ) /16.67 = 1094 kg/cm2 < 1650 kg/cm2 Hence Ok

Design of Verical Stiffner :

Span of Vert. Stiffner Plate = 1250 mm
Load on Vert. stiffner Plate = ( 3.74 x 1.25 ) = 4.67 T/m
Max. Length of Stiffner plate = 4750 mm P= ( 1/2 x 4.67x4.75) = 11.09 T/m
So maximum bending moment (M) = (0.128 x4.67 x 4.75) = 6.74 T-m
Use as verical stiffner
Top Flange = 240 x 10 ( Width of top Falnge = ( 24 x10 ) = 240 mm
Web = 9 x 184 Provide = 240 mm
Bottom Flange = 140 x 16
Area = 6296 mm2 y= 101 mm Ixx= 4971 cm4
Zxx (Top) = 494.12 cm3 Zxx (Bottom) = 454.39 cm3
.
A1 = 2400 mm2 I1 = 2 cm4 I4 = 2194 cm4
A2 = 1656 mm2 I2 = 467 cm4 I5 = 0 cm4
A3 = 2240 mm2 I3 = 5 cm4 I6 = 2303 cm4

Bending stress,sb= (6.742x 1000 x100 ) /455 = 1484 kg/cm2 < 1650 kg/cm2 Hence Ok

Design of Horizantal Stiffner :

Press on bunker wall = 3.74 T/m2

Effective Length for Horz. Stiffner = 625
mm
Max. Length of Stiffner plate = 1150 mm
Load on Hoz. Stiffner = (3.74 x 0.625) = 2.33 T/m
So maximum bending moment (M) = (2.34 x 1.15^ 2) /8 = 0.39 T-m

Use as verical stiffner

Top Flange = 240 x 10 ( Width of top Falnge = ( 24 x10 ) = 240 mm
Web = 8 x 100 Provide = 240 mm
Bottom Flange = 0 x 0
Area = 3200 mm2 y= 18.75 mm Ixx= 250 cm4
Zxx (Top) = 133.42 cm3 Zxx (Bottom) = 27.42 cm4
.
A1 = 2400 mm2 I1 = 2 cm4 I4 = 45 cm4
A2 = 800 mm2 I2 = 67 cm4 I5 = 136 cm4
A3 = 0 mm2 I3 = 0 cm4 I6 = 0 cm4

Bending stress,sb= (0.386x 1000 x100 ) /28 = 1408 kg/cm2 < 1650 kg/cm2 Hence Ok

DESIGN OF HOPPER PORTION:

Design of Hopper Plate Thickness :

ZONE-D 2 @ 655 = 1310

ZONE-C 3 @ 600 = 1800

ZONE-B 1 @ 550 = 550

ZONE-A 1 @ 500 = 500

Normal pressure(Pn) & Tangential pressure (Pt) at any point on hopper

Pn= (Pvcos2α+Ph sin2α+Ws cosα) Total Depth = 8.91 m Phmax= 4.63 m
Pt= (Pv-Ph) sinα cosα +Ws sinα Hopper Angle = 1.07 Rad Zoe = 2.90 m
Thkness = 10 mm

For Zone A For Zone B

Depth = 8.66 mm Depth = 8.135 mm
Ph = Phmax (1- e -Z/Zo) Ph = Phmax (1- e -Z/Zo)
= 4.401 T/m2 = 4.355 T/m2
 Pv = 4.401 T/m2 Pv = 4.355 T/m2
Ws = 0.079 T/m2 Ws = 0.079 T/m2

Pn = 4.438 T/m2 Pn = 4.392 T/m2

Effective Length of Plate = 495 mm Effective Length of Plate = 625 mm

So , bending moment = 0.136 T/m2 So , bending moment = 0.215 T/m2
Zxx = 16.67 cm2 Zxx = 16.67 cm2
Hence, Bending Stress = 815 kg/cm2 Hence, Bending Stress = 1289 kg/cm2

For Zone C For Zone D

Depth = 7.56 mm Depth = 5.7325 mm
Ph = Phmax (1- e -Z/Zo) Ph = Phmax (1- e -Z/Zo)
= 4.293 T/m2 = 3.994 T/m2
Pv = 4.293 T/m2 Pv = 3.994 T/m2
Ws = 0.079 T/m2 Ws = 0.079 T/m2

Pn = 4.331 T/m2 Pn = 4.031 T/m2

Effective Length of Plate = 682 mm Effective Length of Plate = 745 mm

So , bending moment = 0.252 T/m2 So , bending moment = 0.280 T/m2
Zxx = 16.67 cm2 Zxx = 16.67 cm2
Hence, Bending Stress = 1512 kg/cm2 Hence, Bending Stress = 1677 kg/cm2

Ph=Pv
Zone Depth (m) Ws (T/m2) Pn (T/m2) Vert. Spc. Inc. Lenth
B.M Zxx fb(max)
(T/m2) (mm) (mm)
A 8.660 4.401 0.079 4.438 500 495 0.136 16.67 815
B 8.135 4.355 0.079 4.392 550 625 0.215 16.67 1289
C 7.560 4.293 0.079 4.331 600 682 0.252 16.67 1512
D 5.733 3.994 0.079 4.031 655 745 0.280 16.67 1677

Design of Horizantal Stiffner :

Stffn.
Depth (Z) Ph (T/m2) Pv (T/m2) Ws (T/m2) Pn (T/m2) ln (mm) H= H'= b= M= R=
Mkd.

1 5.405 3.917 3.917 0.079 3.954 655 745 4.497 3.350 4.291 7.710 7.187
2 6.060 4.062 4.062 0.079 4.099 655 745 4.662 3.473 3.582 5.570 6.220
3 6.660 4.169 4.169 0.079 4.206 600 682 4.784 3.264 2.933 3.510 4.787
4 7.260 4.256 4.256 0.079 4.293 600 682 4.883 3.332 2.284 2.172 3.805
5 7.860 4.327 4.327 0.079 4.364 600 682 4.963 3.386 1.635 1.132 2.768
6 8.410 4.380 4.380 0.079 4.417 550 625 5.023 3.142 1.040 0.425 1.634
7 8.910 4.420 4.420 0.079 4.458 500 569 5.069 2.882 0.500 0.090 0.721
8

Stiffner Mkd. -1 & 2 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 148 mm

Plate a = 150 x 12 Ixx = 8627 cm4
y Plate b = 10 x 250
Plate c = 240 x 10
b
c A d Axd I1 I2 28.41
a 1800 6 10800 21600 36486197 0.50
2500 137 342500 13020833 323370 2620339.24
2400 267 640800 20000 33773600
6700 994100 13062433 70583167 86265940
272 57

Bending Moment = 7.71 T-m Zxx = 477 s bc = 1616 kg/cm2 Hence Ok

Shear Stress = 7.19 T A1= 25 t v= 287 kg/cm2 Hence Ok
Aixal Force = 7.19 T A2= 67 s t= 107 kg/cm2 Hence Ok

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 1694 kg/cm2 Hence Safe

Stiffner Mkd. -3&4 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 88 mm

Plate a = 150 x 12 Ixx = 2825 cm4
y Plate b = 12 x 138
Plate c = 240 x 10
b
c A d Axd I1 I2 28.41
a 1800 6 10800 21600 12184395 0.50
1656 81 134136 2628072 87635 2620339.24
2400 155 372000 20000 10685473
5856 516936 2669672 22957502 28247514
160 57

Bending Moment = 3.51 T-m Zxx = 219 s bc = 1601 kg/cm2 Hence Ok

Shear Stress = 4.79 T A1= 17 t v= 289 kg/cm2 Hence Ok
Aixal Force = 4.79 T A2= 59 s t= 82 kg/cm2 Hence Ok

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 1680 kg/cm2 Hence Safe

Stiffner Mkd. -5,6&7 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 74 mm

Plate a = 90 x 6 Ixx = 706 cm4
y Plate b = 6 x 84
Plate c = 240 x 10
b
c A d Axd I1 I2 28.41
a 540 3 1620 1620 2698945 0.50
504 48 24192 296352 332806 2620339.24
2400 95 228000 20000 1089177
3444 253812 317972 4120928 7059239
100 57

Bending Moment = 1.13 T-m Zxx = 85 s bc = 1338 kg/cm2 Hence Ok

Shear Stress = 2.77 T A1= 5 t v= 549 kg/cm2 Hence Ok
Aixal Force = 2.77 T A2= 34 s t= 80 kg/cm2 Hence Ok

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 1643 kg/cm2 Hence Safe

Project: 1X33 MVA Ferro Alloys Furnace-RMHS Prepared By : S. Dutta
Client: Rohit Ferro Tech Ltd. Aprroved By : R.S. Ghosh
DESIGN OF STEEL BUNKER Date : 31/8/13

Meterial :Structural Steel Conforming To IS :2062 Grade Fe :410

Standard : IS:9178 (Part-1)-1979
IS:9178 (Part-2)- 1979
IS:800 -1984
Loads:
A) Horizontal Load due to Horizontal Pressure(Ph) of the stored material acting on wall .
B) Vertical Load due to Vertical Pressure(Pv) of the stored material acting on cross sectional area of the Bin .
C) Frictional Wall Load due to Frictional Wall Pressure (P w) of the stored material acting on wall of the Bin .
Basis : Janssensen 's theory has been used for assessment of bin load considering constant value of
pressure ratio ( λ ) ,Angle of wall friction (∂ ) & Bulk Density of material ( W ) along the bin height .
Design Data :
1) Stored Material = Man 5.00 m
2) Material Type = Granular
3) Length of the Bunker (L) = 5.00 m
4) Breadth of the Bunker (B) = 4.00 m
5) Height of the Bunker above waist level = 4.75 m 4.75 m
6) Depth of the Bunker below waist level = 4.16 m
7) Total height of the Bunker(H) = 8.91 m
8) Length of opening at bottom(l) = 0.50 m
9) Breadth of opening at bottom(b) = 0.60 m
10) Corrosion Allowence(Assumed)= = 1.50 m
11) Angle of hopper w.r.t horizontal ( α ) = 61.59 Degree 4.16 m 1.074
12) Hydraulic Radius (R) = 1.11 m
13) Gross Volume of bunker = 126.55 m
14) Net Volume of bunker = 300.00 m m
15) Bulk density of the material(W) = 1.60 T/m3 2.25 m 2.25 m
16) Weight of stored material = 202.47 T 0.50
17) Angle of Internal friction (Ø) = 35.00 Degree / 0.61 Rad
Static Condition :
18) Angle of pressure co-efficient (k) = 0.27 { k = (1-sinΦ)/(1+sinΦ) }

Variation of pressure along depth P i( Z ) = Pi ,max (1-e-z/z0)

During Filling:
19) Angle of wall friction (∂f) = 26.25 { ∂f = 0.75Φ }
20) Pressure Ratio (λf) = 0.5 { λf = Ph/Pv }
21) Coefficient of wall friction (μf) = 0.493 { μf = tan(∂f) }
22) Pw max = 1.78 T/m2 { = WR }
23) Ph max = 3.61 T/m2 { = WR/μf }
24) Pv max = 7.21 T/m2 { = WR/μf λf }
Zof = 4.51 m { = R/μf λf }
During emptying:
25) Angle of wall friction (∂e)= = 21.00 { ∂e = 0.60Φ }
26) Pressure Ratio (λe) = 1 { λe = Ph/Pv }
27) Coefficient of wall friction (μe) = 0.384 { μe = tan(∂e) }
28) Pw max = 1.78 T/m2 { = WR }
29) Ph max = 4.63 T/m2 { = WR/μe }
30) Pv max = 4.63 T/m2 { = WR/μf λe }
Zoe = 2.90 m { = R/μe λe }
DESIGN OF PRISMATIC PORTION :

Design of Hopper Plate Thickness :

During Emptying,
Ph at depth 4.75 m
PhZ = Phmax (1- e -Z/Zo) = 3.74 T/m2
Try 10 Thk Plate :

Provide Stiffeners span @ 625 mm c/c .

So maximum bending moment for 1m width of plate(M) = (3.74 x 0.625 ^2 )/8 = 0.182 T-m
Sectional Modulas (Zxx) of 1m width of plate= 100 x1^2/6
= 16.67 cm2
Bending stress,sb= (0.183x 1000 x100 ) /16.67 = 1094 kg/cm2 < 1650 kg/cm2 Hence Ok

Design of Verical Stiffner :

Span of Vert. Stiffner Plate = 1250 mm
Load on Vert. stiffner Plate = ( 3.74 x 1.25 ) = 4.67 T/m
Max. Length of Stiffner plate = 4750 mm P= ( 1/2 x 4.67x4.75) = 11.09 T/m
So maximum bending moment (M) = (0.128 x4.67 x 4.75) = 6.74 T-m
Use as verical stiffner
Top Flange = 240 x 10 ( Width of top Falnge = ( 24 x10 ) = 240 mm
Web = 9 x 184 Provide = 240 mm
Bottom Flange = 140 x 16
Area = 6296 mm2 y= 101 mm Ixx= 4971 cm4
Zxx (Top) = 494.12 cm3 Zxx (Bottom) = 454.39 cm3
.
A1 = 2400 mm2 I1 = 2 cm4 I4 = 2194 cm4
A2 = 1656 mm2 I2 = 467 cm4 I5 = 0 cm4
A3 = 2240 mm2 I3 = 5 cm4 I6 = 2303 cm4

Bending stress,sb= (6.742x 1000 x100 ) /455 = 1484 kg/cm2 < 1650 kg/cm2 Hence Ok

Design of Horizantal Stiffner :

Press on bunker wall = 3.74 T/m2

Effective Length for Horz. Stiffner = 625
mm
Max. Length of Stiffner plate = 1150 mm
Load on Hoz. Stiffner = (3.74 x 0.625) = 2.33 T/m
So maximum bending moment (M) = (2.34 x 1.15^ 2) /8 = 0.39 T-m

Use as verical stiffner

Top Flange = 240 x 10 ( Width of top Falnge = ( 24 x10 ) = 240 mm
Web = 8 x 100 Provide = 240 mm
Bottom Flange = 0 x 0
Area = 3200 mm2 y= 18.75 mm Ixx= 250 cm4
Zxx (Top) = 133.42 cm3 Zxx (Bottom) = 27.42 cm4
.
A1 = 2400 mm2 I1 = 2 cm4 I4 = 45 cm4
A2 = 800 mm2 I2 = 67 cm4 I5 = 136 cm4
A3 = 0 mm2 I3 = 0 cm4 I6 = 0 cm4

Bending stress,sb= (0.386x 1000 x100 ) /28 = 1408 kg/cm2 < 1650 kg/cm2 Hence Ok

DESIGN OF HOPPER PORTION:

Design of Hopper Plate Thickness :

ZONE-D 2 @ 655 = 1310

ZONE-C 3 @ 600 = 1800

ZONE-B 1 @ 550 = 550

ZONE-A 1 @ 500 = 500

Normal pressure(Pn) & Tangential pressure (Pt) at any point on hopper

Pn= (Pvcos2α+Ph sin2α+Ws cosα) Total Depth = 8.91 m Phmax= 4.63 m
Pt= (Pv-Ph) sinα cosα +Ws sinα Hopper Angle = 1.07 Rad Zoe = 2.90 m
Thkness = 10 mm

For Zone A For Zone B

Depth = 8.66 mm Depth = 8.135 mm
Ph = Phmax (1- e -Z/Zo) Ph = Phmax (1- e -Z/Zo)
= 4.401 T/m2 = 4.355 T/m2
 Pv = 4.401 T/m2 Pv = 4.355 T/m2
Ws = 0.079 T/m2 Ws = 0.079 T/m2

Pn = 4.438 T/m2 Pn = 4.392 T/m2

Effective Length of Plate = 495 mm Effective Length of Plate = 625 mm

So , bending moment = 0.136 T/m2 So , bending moment = 0.215 T/m2
Zxx = 16.67 cm2 Zxx = 16.67 cm2
Hence, Bending Stress = 815 kg/cm2 Hence, Bending Stress = 1289 kg/cm2

For Zone C For Zone D

Depth = 7.56 mm Depth = 5.7325 mm
Ph = Phmax (1- e -Z/Zo) Ph = Phmax (1- e -Z/Zo)
= 4.293 T/m2 = 3.994 T/m2
Pv = 4.293 T/m2 Pv = 3.994 T/m2
Ws = 0.079 T/m2 Ws = 0.079 T/m2

Pn = 4.331 T/m2 Pn = 4.031 T/m2

Effective Length of Plate = 682 mm Effective Length of Plate = 745 mm

So , bending moment = 0.252 T/m2 So , bending moment = 0.280 T/m2
Zxx = 16.67 cm2 Zxx = 16.67 cm2
Hence, Bending Stress = 1512 kg/cm2 Hence, Bending Stress = 1677 kg/cm2

Ph=Pv
Zone Depth (m) Ws (T/m2) Pn (T/m2) Vert. Spc. Inc. Lenth
B.M Zxx fb(max)
(T/m2) (mm) (mm)
A 8.660 4.401 0.079 4.438 500 495 0.136 16.67 815
B 8.135 4.355 0.079 4.392 550 625 0.215 16.67 1289
C 7.560 4.293 0.079 4.331 600 682 0.252 16.67 1512
D 5.733 3.994 0.079 4.031 655 745 0.280 16.67 1677

Design of Horizantal Stiffner :

Stffn.
Depth (Z) Ph (T/m2) Pv (T/m2) Ws (T/m2) Pn (T/m2) ln (mm) H= H'= b= M= R=
Mkd.

1 5.405 3.917 3.917 0.079 3.954 655 745 4.497 3.350 4.291 7.710 7.187

2 6.060 4.062 4.062 0.079 4.099 655 745 4.662 3.473 3.582 5.570 6.220

3 6.660 4.169 4.169 0.079 4.206 600 682 4.784 3.264 2.933 3.510 4.787

4 7.260 4.256 4.256 0.079 4.293 600 682 4.883 3.332 2.284 2.172 3.805

5 7.860 4.327 4.327 0.079 4.364 600 682 4.963 3.386 1.635 1.132 2.768

6 8.410 4.380 4.380 0.079 4.417 550 625 5.023 3.142 1.040 0.425 1.634

7 8.910 4.420 4.420 0.079 4.458 500 569 5.069 2.882 0.500 0.090 0.721

Stiffner Mkd. -1 & 2 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 148 mm

Plate a = 150 x 12 Ixx = 8627 cm4
y Plate b = 10 x 250
Plate c = 240 x 10
b
c A d Axd I1 I2 28.41
a 1800 6 10800 21600 36486197 0.50
2500 137 342500 13020833 323370 2620339.24
2400 267 640800 20000 33773600
6700 994100 13062433 70583167 86265940
272 57

Bending Moment = 7.71 T-m Zxx = 477 s bc = 1616 kg/cm2 Hence Ok

Shear Stress = 7.19 T A1= 25 t v= 287 kg/cm2 Hence Ok
Aixal Force = 7.19 T A2= 67 s t= 107 kg/cm2 Hence Ok

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 1694 kg/cm2 Hence Safe

Stiffner Mkd. -3&4 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 88 mm

Plate a = 150 x 12 Ixx = 2825 cm4
y Plate b = 12 x 138
Plate c = 240 x 10
 b
c A d Axd I1 I2 28.41
a 1800 6 10800 21600 12184395 0.50
1656 81 134136 2628072 87635 2620339.24
2400 155 372000 20000 10685473
5856 516936 2669672 22957502 28247514
160 57

Bending Moment = 3.51 T-m Zxx = 219 s bc = 1601 kg/cm2 Hence Ok

Shear Stress = 4.79 T A1= 17 t v= 289 kg/cm2 Hence Ok
Aixal Force = 4.79 T A2= 59 s t= 82 kg/cm2 Hence Ok

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 1680 kg/cm2 Hence Safe

Stiffner Mkd. -5,6&7 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 74 mm

Plate a = 90 x 6 Ixx = 706 cm4
y Plate b = 6 x 84
Plate c = 240 x 10
b
c A d Axd I1 I2 28.41
a 540 3 1620 1620 2698945 0.50
504 48 24192 296352 332806 2620339.24
2400 95 228000 20000 1089177
3444 253812 317972 4120928 7059239
100 57

Bending Moment = 1.13 T-m Zxx = 85 s bc = 1338 kg/cm2 Hence Ok

Shear Stress = 2.77 T A1= 5 t v= 549 kg/cm2 Hence Ok
Aixal Force = 2.77 T A2= 34 s t= 80 kg/cm2 Hence Ok

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 1643 kg/cm2 Hence Safe

Project: 1X33 MVA Ferro Alloys Furnace-RMHS Prepared By : S. Dutta
Client: Rohit Ferro Tech Ltd. Aprroved By : R.S. Ghosh
DESIGN OF STEEL BUNKER Date : 31/8/13

Meterial :Structural Steel Conforming To IS :2062 Grade Fe :410

Standard : IS:9178 (Part-1)-1979
IS:9178 (Part-2)- 1979
IS:800 -1984
Loads:
A) Horizontal Load due to Horizontal Pressure(Ph) of the stored material acting on wall .
B) Vertical Load due to Vertical Pressure(Pv) of the stored material acting on cross sectional area of the Bin .
C) Frictional Wall Load due to Frictional Wall Pressure (P w) of the stored material acting on wall of the Bin .
Basis : Janssensen 's theory has been used for assessment of bin load considering constant value of
pressure ratio ( λ ) ,Angle of wall friction (∂ ) & Bulk Density of material ( W ) along the bin height .
Design Data :
1) Stored Material = Man 4.5 m
2) Material Type = Granular
3) Length of the Bunker (L) = 5 m
4) Breadth of the Bunker (B) = 4 m
5) Height of the Bunker above waist level = 4.75 m 4.75 m
6) Depth of the Bunker below waist level = 4.16 m
7) Total height of the Bunker(H) = 8.91 m
8) Length of opening at bottom(l) = 0.5 m
9) Breadth of opening at bottom(b) = 0.6 m
10) Corrosion Allowence(Assumed)= = 1.5 m
11) Angle of hopper w.r.t horizontal ( α ) = 61.59 Degree 4.16 m 1.074
12) Hydraulic Radius (R) = 1.11 m
13) Gross Volume of bunker = 126.5 m
14) Net Volume of bunker = 300 m m
15) Bulk density of the material(W) = 1.6 T/m3 2.25 m 2.2 m
16) Weight of stored material = 202 T 0.5
17) Angle of Internal friction (Ø) = 35 Degree / 0.61
Static Condition :
18) Angle of pressure co-efficient (k) = 0.27 { k = (1-sinΦ)/(1+sinΦ) }

Variation of pressure along depth

Pi( Z ) = Pi ,max (1-e-z/z0)

During Filling:
19) Angle of wall friction (∂f) = 26.25 { ∂f = 0.75Φ }
20) Pressure Ratio (λf) = 0.5 { λf = Ph/Pv }
21) Coefficient of wall friction (μf) = 0.493 { μf = tan(∂f) }
22) Pw max = 1.78 T/m2 { = WR }
23) Ph max = 3.61 T/m2 { = WR/μf }
24) Pv max = 7.21 T/m2 { = WR/μf λf }
Zof = 4.51 m { = R/μf λf }
During emptying:
25) Angle of wall friction (∂e)= = 21.00 { ∂e = 0.60Φ }
26) Pressure Ratio (λe) = 1 { λe = Ph/Pv }
27) Coefficient of wall friction (μe) = 0.384 { μe = tan(∂e) }
28) Pw max = 1.78 T/m2 { = WR }
29) Ph max = 4.63 T/m2 { = WR/μe }
30) Pv max = 4.63 T/m2 { = WR/μf λe }
Zoe = 2.90 m { = R/μe λe }
DESIGN OF PRISMATIC PORTION :

Design of Hopper Plate Thickness :

During Emptying,
Ph at depth 4.75 m
PhZ = Phmax (1- e -Z/Zo) = 3.74 T/m2
Try 10 Thk Plate :

Provide Stiffeners span @ 625 mm c/c .

So maximum bending moment for 1m width of plate(M) = (3.74 x 0.625 ^2 )/8 = 0.182 T-m
Sectional Modulas (Zxx) of 1m width of plate= 100 x1^2/6
= 16.67 cm2
Bending stress,sb= (0.183x 1000 x100 ) /16.67 = 1094 kg/cm2 < 1650 kg/cm2 Hence Ok

Design of Verical Stiffner :

Span of Vert. Stiffner Plate = 1250 mm
Load on Vert. stiffner Plate = ( 3.74 x 1.25 ) = 4.67 T/m
Max. Length of Stiffner plate = 4750 mm P= ( 1/2 x 4.67x4.75) = 11.09 T/m
So maximum bending moment (M) = (0.128 x4.67 x 4.75) = 6.74 T-m
Use as verical stiffner
Top Flange = 240 x 10 ( Width of top Falnge = ( 24 x10 ) = 240 mm
Web = 9 x 184 Provide = 240 mm
Bottom Flange = 140 x 16
Area = 6296 mm2 y= 101 mm Ixx= 4971 cm4
Zxx (Top) = 494.12 cm3 Zxx (Bottom) = 454.39 cm3
.
A1 = 2400 mm2 I1 = 2 cm4 I4 = 2194 cm4
A2 = 1656 mm2 I2 = 467 cm4 I5 = 0 cm4
A3 = 2240 mm2 I3 = 5 cm4 I6 = 2303 cm4

Bending stress,sb= (6.742x 1000 x100 ) /455 = 1484 kg/cm2 < 1650 kg/cm2 Hence Ok

Design of Horizantal Stiffner :

Press on bunker wall = 3.74 T/m2

Effective Length for Horz. Stiffner = 625
mm
Max. Length of Stiffner plate = 1150 mm
Load on Hoz. Stiffner = (3.74 x 0.625) = 2.33 T/m
So maximum bending moment (M) = (2.34 x 1.15^ 2) /8 = 0.39 T-m

Use as verical stiffner

Top Flange = 240 x 10 ( Width of top Falnge = ( 24 x10 ) = 240 mm
Web = 8 x 100 Provide = 240 mm
Bottom Flange = 0 x 0
Area = 3200 mm2 y= 18.75 mm Ixx= 250 cm4
Zxx (Top) = 133.42 cm3 Zxx (Bottom) = 27.42 cm4
.
A1 = 2400 mm2 I1 = 2 cm4 I4 = 45 cm4
A2 = 800 mm2 I2 = 67 cm4 I5 = 136 cm4
A3 = 0 mm2 I3 = 0 cm4 I6 = 0 cm4

Bending stress,sb= (0.386x 1000 x100 ) /28 = 1408 kg/cm2 < 1650 kg/cm2 Hence Ok

DESIGN OF HOPPER PORTION:

Design of Hopper Plate Thickness :

ZONE-D 2 @ 655 = 1310

ZONE-C 3 @ 600 = 1800

ZONE-B 1 @ 550 = 550

ZONE-A 1 @ 500 = 500

Normal pressure(Pn) & Tangential pressure (Pt) at any point on hopper

Pn= (Pvcos2α+Ph sin2α+Ws cosα) Total Depth = 8.91 m Phmax= 4.63 m
Pt= (Pv-Ph) sinα cosα +Ws sinα Angle = 1.07 Zoe = 2.90 m
Thkness = 10 mm

For Zone A For Zone B

Depth = 8.66 mm Depth = 8.135 mm
Ph = Phmax (1- e -Z/Zo) Ph = Phmax (1- e -Z/Zo)
= 4.401 T/m2 = 4.355 T/m2
 Pv = 4.401 T/m2 Pv = 4.355 T/m2
Ws = 0.079 T/m2 Ws = 0.079 T/m2

Pn = 4.438 T/m2 Pn = 4.392 T/m2

Effective Length of Plate = 495 mm Effective Length of Plate = 625 mm

So , bending moment = 0.136 T/m2 So , bending moment = 0.215 T/m2
Zxx = 16.67 cm2 Zxx = 16.67 cm2
Hence, Bending Stress = 815 kg/cm2 Hence, Bending Stress = 1289 kg/cm2

For Zone C For Zone D

Depth = 7.56 mm Depth = 5.7325 mm
Ph = Phmax (1- e -Z/Zo) Ph = Phmax (1- e -Z/Zo)
= 4.293 T/m2 = 3.994 T/m2
Pv = 4.293 T/m2 Pv = 3.994 T/m2
Ws = 0.079 T/m2 Ws = 0.079 T/m2

Pn = 4.331 T/m2 Pn = 4.031 T/m2

Effective Length of Plate = 682 mm Effective Length of Plate = 745 mm

So , bending moment = 0.252 T/m2 So , bending moment = 0.280 T/m2
Zxx = 16.67 cm2 Zxx = 16.67 cm2
Hence, Bending Stress = 1512 kg/cm2 Hence, Bending Stress = 1677 kg/cm2

Ph=Pv
Zone Depth (m) Ws (T/m2) Pn (T/m2) Vert. Spc. Inc. Lenth
B.M Zxx fb(max)
(T/m2) (mm) (mm)
A 8.660 4.401 0.079 4.438 500 495 0.136 16.7 815
B 8.135 4.355 0.079 4.392 550 625 0.215 16.7 1289
C 7.560 4.293 0.079 4.331 600 682 0.252 16.7 1512
D 5.733 3.994 0.079 4.031 655 745 0.280 16.7 1677

Design of Horizantal Stiffner :

Stffn.
Depth (Z) Ph (T/m2) Pv (T/m2) Ws (T/m2) Pn (T/m2) ln (mm) H= H'= b= M= R=
Mkd.

1 5.405 3.917 3.917 0.079 3.954 655 745 4.497 3.350 4.291 7.708 7.186

2 6.060 4.062 4.062 0.079 4.099 655 745 4.662 3.473 3.581 5.567 6.218

3 6.660 4.169 4.169 0.079 4.206 600 682 4.784 3.264 2.931 3.506 4.784

4 7.260 4.256 4.256 0.079 4.293 600 682 4.883 3.332 2.281 2.167 3.800

5 7.860 4.327 4.327 0.079 4.364 600 682 4.963 3.386 1.631 1.127 2.762

6 8.410 4.380 4.380 0.079 4.417 550 625 5.023 3.142 1.036 0.421 1.627

7 8.910 4.420 4.420 0.079 4.458 500 569 5.069 2.882 0.494 0.088 0.712

Stiffner Mkd. -1 & 2 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 99.05 mm

Plate a = 200 x 16 Ixx = 6268 cm4
y Plate b = 10 x 190
Plate c = 240 x 10
b
c 3200 8 25600 68267 26530270
a 1900 111 210900 5715833 271173
2400 211 506400 20000 30076935
7500 742900 5804100 56878379 62682479

216 57.15 0.00 0 0.00

Bending Moment = 7.71 T-m Zxx = 360 s bc = 2141 kg/cm2

Shear Stress = 7.19 T A1= 19 t v= 378 kg/cm2
Aixal Force = 7.19 T A2= 75 s t= 96 kg/cm2

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 2241 kg/cm2

Stiffner Mkd. -3&4 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 82.90 mm

Plate a = 150 x 12 Ixx = 2211 cm4
y Plate b = 12 x 128
 Plate c = 240 x 10
b
c 1800 6 10800 21600 10645541
a 1536 76 116736 2097152 73209
2400 145 348000 20000 9254262
5736 475536 2138752 19973011 22111763

150 57.15 0.00 0 0.00

Bending Moment = 3.51 T-m Zxx = 178 s bc = 1970 kg/cm2

Shear Stress = 4.78 T A1= 15.36 t v= 311 kg/cm2
Aixal Force = 4.78 T A2= 57.36 s t= 83 kg/cm2

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 2044 kg/cm2

Stiffner Mkd. -5,6&7 Inclined width of Top Flange = 240

Hopper Plate Thickness = 10 mm y= 69.66 mm

Plate a = 90 x 8 Ixx = 532 cm4
y Plate b = 8 x 82
Plate c = 240 x 10
b
c 720 4 2880 3840 3103785
a 656 49 32144 367579 279917
2400 95 228000 20000 1541469
3776 263024 391419 4925171 5316590

100 57.15 0.00 0 0.00

Bending Moment = 1.13 T-m Zxx = 61 s bc = 1854 kg/cm2

Shear Stress = 2.76 T A1= 6.56 t v= 421 kg/cm2
Aixal Force = 2.76 T A2= 37.76 s t= 73 kg/cm2

So, Combined Stress(σe) = ((fbc^2)+(σt^2)+(fb*σt)+(3*τv2))^1/2

= 1994 kg/cm2
Project: 1X33 MVA Ferro Alloys Furnace-RMHS Prepared By : S. Dutta
Client: Rohit Ferro Tech Ltd. Aprroved By : R.S. Ghosh
DESIGN OF STEEL BUNKER Date : 31/8/13

Meterial :Structural Steel Conforming To IS :2062 Grade Fe :410

Standard : IS:9178 (Part-1)-1979
IS:9178 (Part-2)- 1979
IS:800 -1984
Loads:
A) Horizontal Load due to Horizontal Pressure(Ph) of the stored material acting on wall .
B) Vertical Load due to Vertical Pressure(Pv) of the stored material acting on cross sectional area of the Bin .
C) Frictional Wall Load due to Frictional Wall Pressure (P w) of the stored material acting on wall of the Bin .
Basis : Janssensen 's theory has been used for assessment of bin load considering constant value of
pressure ratio ( λ ) ,Angle of wall friction (∂ ) & Bulk Density of material ( W ) along the bin height .
Design Data :
1) Stored Material = Man 4.5 m
2) Material Type = Granular
3) Length of the Bunker (L) = 4.5 m
4) Breadth of the Bunker (B) = 4 m
5) Height of the Bunker above waist level = 3 m 3 m
6) Depth of the Bunker below waist level = 3.875 m
7) Total height of the Bunker(H) = 6.875 m
8) Length of opening at bottom(l) = 0.7 m
9) Breadth of opening at bottom(b) = 0.7 m
10) Corrosion Allowence(Assumed)= = 1.5 m
11) Angle of hopper w.r.t horizontal ( α ) = 63.88 Degree 3.875 m
12) Hydraulic Radius (R) = 1.06 m
13) Gross Volume of bunker = 81.7 m
14) Net Volume of bunker = 300 m 0.7 m
15) Bulk density of the material(W) = 2.5 T/m 3
1.9 m 1.9 m
16) Weight of stored material = 204 T
17) Angle of Internal friction (Ø) = 38 Degree / 0.66
Static Condition :
18) Angle of pressure co-efficient (k) = 0.24 { k = (1-sinΦ)/(1+sinΦ) }

Variation of pressure along depth

Pi( Z ) = Pi ,max (1-e-z/z0)