Design of Raw Meal Silo Based on BS EN 1991-4:2006 for Obajana Cement Line 3, Nigeria

A. SILO CONFIGURATION

1 Material = Cemento

0.15
2 Peso del material almcacenado = 20000 Ton
3 Espesor del pared del Silo = 400 mm
4 Grosor promedio de la losa de techo = 150 mm
5 Espesor del cono Invertido = 500 mm 0.4 dc
6 EL. of Flat Slab Botom above GL = 21.02 m
7 EL. of Top of Top Slab above GL = 70.00 m 22.50
8 Max. Level of Filling below Silo Top = 0.15 m
9 Height of av. Material Storage from Flat Slab = 45.98 m
10 Diámetro interno del silo de almacenamiento D = 22.5 m
11 Angulo de reposo fr = 36 0
12 Ángulo medio de fricción interna fm = 30 0
13 Relación de esbeltez (hc / dc) = 2.04

13.675
14 Tipo de silo = Slender silo
15 Temperature of Hot Material inside Ti = 120 C
o

16 Temperature of Outside Atmosphere T0 = -0.6 C

o

17 Densidad aparente del material almacenado l = 1.6 T/m3 0.500

18 Máximo ht de losa plana = 0.200 M
19 Zona Sismica III Z = 0.16
20 Cargas vivas en pisos operativos = 1 T/m2 FGL
21 Velocidad de viento básica = 41 m/sec
22 Resistencia caracteristica del hormigon para la pared del Silo = 25 N/mm2
23 El. of Top of Flat Slab above GL = 21.016 m
24 Ángulo de cono invertido a = 60 o
25 Espesor de la pared de RCC debajo del soporte de cono = 500 mm
26 Axial Force Imposed on Ftop = 20 Ton
27 Yield Stress of Reinfocement = 300 N/mm2
28 Resistencia caracteristica del hormigon para la Fundacion = 25 N/mm2
29 Maximum eccentricity of filling ef = 0 m
30 Maximum eccentricity of outlet e0 = 0 m

B. CALCULO DE CAPACIDAD
Volume above cone = 18284 M3
TOTAL = 18284 M3
Peso del material = 21940 T Considerando la densidad del Mate1.2 T/M3 from capacity consideration
Peso del material = 29254 T Considering density of material 1.6 T/M3
for structural design
C. DISEÑO DEL PARED DEL SILO
Parámetros de diseño para determinar las Fuerzas de Silo
(a) A = Área de sección transversal del silo = 397.608 M2
(b) D = Diamero Interno del silo = 22.50 m
(c) d = Max. Dia. of the Circle that can be inscribed in the Bin = 22.50 m
(d) h = Altura del Contenedor (altura total del silo ) = 48.78 m
(e) U = Perimetro del silo con diametro Interno = 70.69 m
(f) R = A/U = 5.63 m
(g) l = Densidad aparente del material almacenado = 1.60 T/M3
(h) Z = Maximum depth below the Equivalent Surface of the Solid = 45.98 m
(i) fim = Mean angle of internal friction = 30 O
(j) f (max) = Maximum angle of internal friction (af X fim) = 36.60 O
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 Design of Raw Meal Silo Based on BS EN 1991-4:2006 for Obajana Cement Line 3, Nigeria

(k) f (min) = Minimum angle of internal friction (fim / af)) = 24.59 O

(l) Km = Mean lateral pressure ratio = 0.54

(m) K (max) = Maximum lateral pressure ratio (Km X ak) = 0.648
(n) K (min) = Minimum lateral pressure ratio (Km / ak) = 0.450
(o) mm = Mean wall friction coefficient for solid sliding on the vertical wall = 0.51
(p) m (max) = Maximum wall friction coefficient (mm X am) = 0.546
(q) m (min) = Minimum wall friction coefficient (mm / am) = 0.477
(r) cop = Patch load solid reference factor = 0.5
Note: 1) For maximum normal pressure on vertical wall m (min), K (max) & f (min) shall be used
2) For maximum frictional traction on vertical wall m (max), K (max) & f (min) shall be used
3) For maximum vertical load on silo bottom m (min), K (min) & f (max) shall be used

1 Determination of Lateral pressure, Vertical pressure and Frictional traction for Symmetrical filling load condition

P hf (z) = Horizontal pressure at depth Z = Pho*Yj(z) (T/M2)

P wf (z) = Wall friction traction at depth Z = m*Pho*Yj(z) (T/M2)
P vf (z) = Vertical pressure at depth Z = (Pho / K)*Yj(z) (T/M2)
n zSk = The resulting characteristic value of the vertical force in the wall after filling at depth Z = m*Pho*(z-zo*Yj(z))
zo = (1 / (K*m))*(A / U) M
P ho = l*K*zo (T/M2)
Y j (z) = 1 - e(-Z / Zo)
zo = 18.21 M ( for maximum normal pressure calculation )
zo = 15.91 M ( for maximum frictional traction calculation )
zo = 26.2255 M ( for maximum vertical load calculation )
P ho = 18.8824 (T/M ) ( for maximum normal pressure calculation )
2

P ho = 16.49 (T/M2) ( for maximum frictional traction calculation )

P ho = 18.8824 (T/M2) ( for maximum vertical load calculation )

Z Z / Z0 Z / Z0 Z / Z0 1 -e(Z/Zo) 1 -e(Z/Zo) 1 -e(Z/Zo) Phf Pwf Pvf nzSk

(M) Normal Friction Vertical Normal Friction Vertical (T/M2) (T/M2) (T/M2) (T/M)
2.80 0.000 0.000 0.000 0.000 0.000 0.000 0.00 0.00 0.00 0.00
6.98 0.230 0.263 0.159 0.205 0.231 0.147 3.87 2.08 6.18 3.96
9.98 0.394 0.451 0.274 0.326 0.363 0.240 6.15 3.27 10.05 11.02
12.98 0.559 0.640 0.388 0.428 0.473 0.322 8.09 4.25 13.50 20.92
15.98 0.724 0.829 0.503 0.515 0.563 0.395 9.73 5.07 16.58 33.17
18.98 0.888 1.017 0.617 0.589 0.638 0.460 11.12 5.75 19.32 47.36
21.98 1.053 1.206 0.731 0.651 0.701 0.519 12.30 6.30 21.77 63.17
24.98 1.218 1.394 0.846 0.704 0.752 0.571 13.30 6.77 23.95 80.32
27.98 1.383 1.583 0.960 0.749 0.795 0.617 14.14 7.15 25.90 98.57
30.98 1.547 1.772 1.075 0.787 0.830 0.659 14.86 7.47 27.63 117.74
33.98 1.712 1.960 1.189 0.820 0.859 0.695 15.47 7.73 29.18 137.67
36.98 1.877 2.149 1.303 0.847 0.883 0.728 15.99 7.95 30.56 158.23
39.98 2.041 2.337 1.418 0.870 0.903 0.758 16.43 8.13 31.79 179.30
42.98 2.206 2.526 1.532 0.890 0.920 0.784 16.80 8.28 32.89 200.81
48.78 2.525 2.891 1.753 0.920 0.944 0.827 17.37 8.50 34.69 243.38

2 Determination of Lateral patch pressure in wall for filling patch load condition

Silo Type = Thick walled circular silo

Ppf = Filling outward patch pressure = Cpf*Phf

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 Design of Raw Meal Silo Based on BS EN 1991-4:2006 for Obajana Cement Line 3, Nigeria

Ppfi = Filling inward patch pressure = Ppf/7

Cpf = 0.21*Cop*(1+2E2)*(1-e(-1.5*((hc/dc)-1)))
E = 2*ef / dc = 0.00
ef = Maximum eccentricity of surface pole during filling = 0.0 M

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 Design of Raw Meal Silo Based on BS EN 1991-4:2006 for Obajana Cement Line 3, Nigeria

Phf = Local filling pressure

Cop = Patch load solid reference factor = 0.50
s = The length of the zone on which the patch load is applied = p*dc/16 = 4.418 M
Phf,u = Resulting symmetrical horizontal pressure for filling = Phf,u*(1+ζ*Cpf)
ζ = Maximun(0.5+0.01*(dc/t) or 1) = 1.06

Z Cpf Phf Ppf Ppfi s Phf,u

(M) Normal (T/M ) 2
(T/M ) 2
(M) (T/M2)
2.80 0.083 0.00 0.000 0.000 4.418 0.000
6.98 0.083 3.87 0.322 0.046 4.418 4.214
9.98 0.083 6.15 0.511 0.073 4.418 6.695
12.98 0.083 8.09 0.672 0.096 4.418 8.799
15.98 0.083 9.73 0.808 0.115 4.418 10.583
18.98 0.083 11.12 0.923 0.132 4.418 12.097
21.98 0.083 12.30 1.021 0.146 4.418 13.381
24.98 0.083 13.30 1.104 0.158 4.418 14.469
27.98 0.083 14.14 1.175 0.168 4.418 15.392
30.98 0.083 14.86 1.235 0.176 4.418 16.176
33.98 0.083 15.47 1.285 0.184 4.418 16.840
36.98 0.083 15.99 1.328 0.190 4.418 17.403
39.98 0.083 16.43 1.365 0.195 4.418 17.881
42.98 0.083 16.80 1.396 0.199 4.418 18.286
48.78 0.083 17.37 1.443 0.206 4.418 18.903

3 Determinación de presión lateral, presión vertical y tracción friccional para condición de carga de descarga simétrica

P he (z) = Horizontal pressure at depth Z = Ch*Phf (T/M2)

P we (z) = Wall friction traction at depth Z = Cw*Pwf (T/M2)
n zSk = The resulting characteristic value of the vertical force in the wall during discharge at depth Z = Cw*m*Pho*(z-zo*Yj(
Ch = Discharge factor for horizontal pressure = 1.15 = C0
Cw = Discharge factor for wall frictional traction = 1.10
C0 = Discharge factor for all solids

Z Phe Pwe nzSk

(M) (T/M2) (T/M2) (T/M)
2.80 0.00 0.00 0.00
6.98 4.45 2.29 4.36
9.98 7.07 3.60 12.12
12.98 9.30 4.68 23.01
15.98 11.18 5.58 36.48
18.98 12.78 6.32 52.10
21.98 14.14 6.94 69.49
24.98 15.29 7.44 88.35
27.98 16.27 7.87 108.43
30.98 17.09 8.22 129.52
33.98 17.80 8.51 151.44
36.98 18.39 8.75 174.05
39.98 18.90 8.94 197.23
42.98 19.32 9.11 220.89
48.78 19.98 9.35 267.71

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 Design of Raw Meal Silo Based on BS EN 1991-4:2006 for Obajana Cement Line 3, Nigeria

4 Determination of Lateral patch pressure in wall for discharge patch load condition

Silo Type = Thick walled circular silo

Ppe = Discharge outward patch pressure = Cpe*Phe
Ppei = Discharge inward patch pressure = Ppe / 7
hc / d c = 2.04
Cpe = 0.42*Cop*(1+2*E2)*(1-exp(-1.5*((hc/dc)-1)))
E = 2*e / dc = 0.0
e = Max(ef,e0) = 0.0 M
Phe = Local discharge pressure
Cop = Patch load solid reference factor = 0.50
s = The length of the zone on which the patch load is applied = p*dc/16 = 4.418 M
Phe,u = Resulting symmetrical horizontal pressure for discharge = Phe,u*(1+ζ*Cpe)
ζ = Maximun(0.5+0.01*(dc/t) or 1) = 1.00

Z Cpe Phe Ppe Ppei s Phe,u

(M) Normal (T/M ) 2
(T/M )2
(M) (T/M2)
2.80 0.166 0.00 0.000 0.000 4.418 0.000
6.98 0.166 4.45 0.740 0.106 4.418 5.193
9.98 0.166 7.07 1.175 0.168 4.418 8.250
12.98 0.166 9.30 1.545 0.221 4.418 10.843
15.98 0.166 11.18 1.858 0.265 4.418 13.042
18.98 0.166 12.78 2.124 0.303 4.418 14.907
21.98 0.166 14.14 2.349 0.336 4.418 16.489
24.98 0.166 15.29 2.540 0.363 4.418 17.830
27.98 0.166 16.27 2.702 0.386 4.418 18.968
30.98 0.166 17.09 2.840 0.406 4.418 19.933
33.98 0.166 17.80 2.956 0.422 4.418 20.751
36.98 0.166 18.39 3.055 0.436 4.418 21.446
39.98 0.166 18.90 3.139 0.448 4.418 22.034
42.98 0.166 19.32 3.210 0.459 4.418 22.534
48.78 0.166 19.98 3.318 0.474 4.418 23.294

5 Discharge loads for silos with large outlet eccentricities

e0 = 0.0 M
ef = 0.0 M
This procedures is not applicable

6 Pressure due to reduction in ambient atmospheric temperature

Temperature DIFFERENTIAL calculation

(Ref. Annex D of BS EN 1991-1-5-: 2003

Material temperature inside silo (Tin) oC= 120

Minimum temperature of outside environment (Tout) C= 0
-0.6
Thickness of silo wall (hi) m= 0.4
The thermal conductivity of concrete (λi) (W/(mK))= 1.71
The thermal resistance Rin (m2K/W)= 0.17
Thermal resistance Rout (m2K/W)= 0.04
Total thermal resistance (m2K/W)

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 Design of Raw Meal Silo Based on BS EN 1991-4:2006 for Obajana Cement Line 3, Nigeria

Rtot=Rin+∑(hi/λi)+Rout = 0.4439

Temperature differential [(Tin-Tout)/Rtot]*∑(h/λi) 0C= 63.549

Temperature DIFFERENTIAL calculation

(Ref. clause 6.10 of Reynolds handbook, 10th edition)
h = thickness of wall (m) = 0.4
Inside material/hot liquid/flue gas (TG) temperature (0C) = 120
External air temperature/temperature (TA)at other face of wall (0C) = -0.6
Thermal conductivity (kc) of RCC wall(watt/sqm/ C) = 0
1.71
ai = Resistance at the internal face (watt/sqm/ 0C) 0.17
aa = Resistance due to cavity (watt/sqm/0C) 0
ao = Resistance at the external face (watt/sqm/ 0C) 0.04
Co-efficient of linear expansion of concrete (Єc) (/0C) = 0.00001
Modulus of elasticity of concrete (Ec) (N/mm2) = 21000
Moment of inertia (Ic) of concrete section (m4) 0.0053333
Resistance to the transmission of heat (k) through wall (watt/sqm/ C) = 0
2.25
h
k= ( kc
+ ai+aa+ao )
The change in temperature (T0C) through concrete wall = 63.5
T = (TG-TA)*k*hc/kc

a) Tension due to Temperature

PhT = Normal pressure = CT*aw*DT*Ew/((r / t)+(1-v)*(Ew/EsU))
Ti = 120 oC To = 15 o
C
t = Thickness of silo wall = 0.400 m
CT = Temperature load multiplier = 3.0
aw = Coefficient of thermal expansion of the silo wall = 0.0000011 per degree centigrade
DT = Temperature differential = 63.5 oC
r = Silo radius (dc / 2) = 11.45 M
Ew = Elastic modulus of the silo wall = 5500*SQRT(fck) = 27500.0 N/mm2
v = Poisson's ration = 0.3
EsU = Inloading effective elastic modulus at depth Z = χ*Pvft = 15542.9 T/M2
Pvft = Vertical stress at the base of the vertical walled section = 34.69 T/M2

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 Design of Raw Meal Silo Based on BS EN 1991-4:2006 for Obajana Cement Line 3, Nigeria

χ = Modulus contiguity coefficient = 7*l3/2 = 448.00

PhT = 3.78 (T/M2)

7 Design against Hoop Tension due to Load P h

Dead Load Factor Kd = 1.20 live Load Factor Kl = 1.4

Lateral Pressure ( Ph)
Height Symmetrical filling Unsymmetrical filling (Phf,u) Symmetrical Unsymmetrical Pvft Esu Temperature
from top (Phf) discharge. (Phe) discharge. (Phe,u) pressure (PhT)
Design Factored Design Factored Design Factored Design Factored Design
(M) T/M 2
T/M2
T/M 2
T/M2
T/M 2
T/M2
T/M 2
T/M2
T/M 2
T/M 2
T/M2
2.80 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
6.98 3.87 5.42 4.21 5.90 4.45 6.23 5.19 7.27 6.18 2769.6 0.80
9.98 6.15 8.61 6.69 9.37 7.07 9.90 8.25 11.55 10.05 4502.2 1.26
12.98 8.09 11.32 8.80 12.32 9.30 13.02 10.84 15.18 13.50 6047.5 1.66
15.98 9.73 13.62 10.58 14.82 11.18 15.66 13.04 18.26 16.58 7425.8 2.00
18.98 11.12 15.56 12.10 16.94 12.78 17.90 14.91 20.87 19.32 8655.1 2.30
21.98 12.30 17.21 13.38 18.73 14.14 19.80 16.49 23.08 21.77 9751.5 2.55
24.98 13.30 18.61 14.47 20.26 15.29 21.41 17.83 24.96 23.95 10729.4 2.77
27.98 14.14 19.80 15.39 21.55 16.27 22.77 18.97 26.56 25.90 11601.6 2.96
30.98 14.86 20.81 16.18 22.65 17.09 23.93 19.93 27.91 27.63 12379.5 3.13
33.98 15.47 21.66 16.84 23.58 17.80 24.91 20.75 29.05 29.18 13073.4 3.28
36.98 15.99 22.39 17.40 24.36 18.39 25.75 21.45 30.02 30.56 13692.2 3.41
39.98 16.43 23.00 17.88 25.03 18.90 26.45 22.03 30.85 31.79 14244.1 3.52
42.98 16.80 23.52 18.29 25.60 19.32 27.05 22.53 31.55 32.89 14736.4 3.62
48.78 17.37 24.32 18.90 26.46 19.98 27.97 23.29 32.61 34.69 15542.9 3.78

Maximum Hoop Hoop Tension due to Temperature Steel Reqd. Steel Reqd.
Height Tension (T = PhT*D/2) from Filling & from
from top (T = Discharge Temperature
Ph*D/2)
(M) T/M of Height T/M of Height mm2/m mm2/m
2.80 0.00 0.00 0.00 0.00
6.98 83.25 12.77 3191.06 489.70
9.98 132.25 20.26 5069.56 776.82
12.98 173.81 26.65 6662.76 1021.45
15.98 209.06 32.12 8014.00 1231.09
18.98 238.96 36.83 9160.02 1411.65
21.98 264.31 40.90 10131.99 1567.83
24.98 285.82 44.44 10956.34 1703.42
27.98 304.06 47.52 11655.50 1821.52
30.98 319.53 50.21 12248.47 1924.67
33.98 332.64 52.56 12751.38 2014.98
36.98 343.77 54.63 13177.92 2094.23
39.98 353.21 56.45 13539.68 2163.89
42.98 361.21 58.05 13846.49 2225.23
48.78 373.41 60.63 14314.08 2324.15

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Level (m) Rebars(OF) for hoop

Height Rebars(IF) for hoop tension
tension
from top Check
f s reqd. s prov. f s reqd. s prov. Check
(M) mm mm (c/c) mm (c/c) mm mm (c/c) mm (c/c)
2.80 22 200 22 150
63.016 6.98 22 238 120 OK 22 182 120 OK
9.98 25 194 120 OK 25 148 120 OK
57.016 12.98 25 147 130 OK 25 113 65 OK
15.98 25 123 130 Revise 25 94 65 OK
51.016 18.98 25 107 110 Revise 25 82 55 OK
21.98 25 97 110 Revise 25 74 55 OK
45.016 24.98 25 90 100 Revise 25 68 50 OK
27.98 25 84 100 Revise 25 64 50 OK
39.016 30.98 25 80 100 Revise 25 61 50 OK
33.98 25 77 100 Revise 25 59 50 OK
33.016 36.98 25 74 90 Revise 25 57 45 OK
39.98 25 73 90 Revise 25 55 45 OK
27.016 42.98 25 71 90 Revise 25 54 45 OK
21.016 48.78 25 69 90 Revise 25 52 45 OK

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2.80
45.98
21.016

from capacity consideration

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m*Pho*(z-zo*Yj(z)) T/M

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Cw*m*Pho*(z-zo*Yj(z))
(T/M)

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Temperature
pressure (PhT)
Factored
T/M2

1.12
1.77
2.33
2.80
3.22
3.57
3.88
4.15
4.39
4.59
4.77
4.93
5.07
5.30

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