presentation

ENG1002 Design project - Client Brief Version 2.0 1

© University of Southern Queensland

Client Brief Version 2.0 (revisions/additions since V1.1 are shown in green)

1. Project Outline

Black Gold Pty Ltd seeks submissions from suitably qualified companies for the design of coal load out

facility for their new coal mine. The system is to include a conveyor that raises the coal from ground level to

the top of the load out bin, the load out bin and the chute and gate that controls the delivery of coal into

individual train carriages. Figure 1 shows the components and layout specified for the design. The facility

also has to pass over an existing road and must provide the minimum specified clearances.

Figure 1: Proposed coal load out equipment

1.1 The process

Coal direct from the Black Gold mine arrives at the load out bin via a feed conveyor and is transferred to the

lift conveyor and carried to the top of the circular load out bin. A short chute (1 metre in height) and gate at

the base of the load out bin controls the flow of coal into each train wagon. The load out bin is comprised of

a conical section A, a cylindrical section B and a truncated conical section C.

Several design requirements will be specified by Black Gold Pty Ltd for the total storage volume of the load

out bin, a range of mass flow rates at which the train wagons can be loaded and the types of equipment that

can be selected for the design.

Students please note –

read the IMPORTANT NOTES on the last page of this document and the comments regarding the completion of individual assignments in italics

Plan View

Side View

Elevation

Coal flow

Load out bin

supported in

square frame

of steel

road

Feed conveyor

6m

H

D = 5m

minimum

Load-

out bin

rail line

8m

Minimum

clearance 6m

Drawing not to scale

chute diameter d

1m high

h2

h 1

h 3

5m

Steel support

3m

Lift conveyor

length L

A

B

C

x = 3m

minimum

x D

Lift conveyor

variable

length X

conveyor

angle

theta 1 θ 1

h C

the density of coal is 810 kg/m 3

cone angle theta 1 θ1

10 to 30 degrees

theta 2 = 45 degrees

2 ENG1002 – Introduction to Engineering and Spatial Science Applications

2. Design Sections

The project has been divided into three design sections, plus a costing, to ensure that the requirements of the

project are clear. Each section of the design is to be defined by the set of design parameters, listed in bold.

Any company submitting a design proposal must use these variables names to identify the parameters.

Each design section requires a technical analysis which must be summarised in the design proposal.

The Design Sections are:

1. The dimensions of the load out bin and other equipment

 D - the diameter of the load out bin (in m)

 H - the total height of the load out bin and frame (in m)

 h1 to h3 - the heights of each section of the load out bin (in m)

 θ1 (theta 1) - cone and conveyor angle (in degrees)

 V - the volume of the load out bin (in m 3 )

 x – the distance from the load out bin to the road (in m) (X and L now listed in section 2)

 hC - the clearance over the road (in m)

 M - the maximum mass of coal in the load out bin (in tonnes)

2. The dimensions of the conveyor and related parameters (this section may be used for the Presentation assessment)

(the width of the conveyor belt is not variable – see table 2)

 X and L – the lengths which define the conveyor (in m) (now to be stated here)

 Sc – the maximum speed of the conveyor (in m/s)

 MFc - the maximum Mass Flow rate of the Conveyor (in kg/s)

 P – the power output required of the conveyor motor (in W)

 M-n - the Motor size selected to drive the conveyor

3. The gate and loading control and related parameters (this section may be used for the Presentation assessment)

 d - the diameter of the chute (in m)

 a - the cross-sectional area of the chute (in m 2 )

 MFw - the Mass Flow rate into the Wagons (in kg/s)

 TFILL – the time required to fill each wagon (in seconds)

 TWAGON – the time interval between each wagon (in seconds)

 S – the required speed of the train (in kph)

4. The budget and costs of the components of the system including the steel frame and support (students are now to ignore the requirements of the steel frame)

 SA - the surface area of the load out bin (in m 2 )

 Cb – the cost of the load out bin (to the nearest $)

 Cc – the cost of the conveyor excluding motor (to the nearest $)

 Cm – the cost of the conveyor motor (to the nearest $)

 C – the total cost of the conveyor (to the nearest $)

2.1 Design Goals

The design goals for the project are to:

G1. maximise the storage volume of the load out bin G2. maximise the rate at which coal can be loaded into the train wagons G3. stay within the allocated budget

ENG1002 Design project - Client Brief Version 2.0 3

© University of Southern Queensland

3. Specification of Requirements

3.1 Requirements

The following requirements must be met:

R1. The facility must be capable of loading at least 2000 tonne (metric) of coal per hour into the wagons.

The train wagons hold a maximum of 100 tonne each (moved to constraints)

R2. A minimum of 300 tonne of coal (enough to load 3 train wagons) must be stored in the load out bin, to allow for brief stoppages of the conveyor.

R3. The conveyor must be capable of delivering coal to the load out bin at 110% of the rate at which the wagons can be filled. This will allow the level of coal in the load out bin to be replenished

after brief stoppages of the conveyor, while still loading wagons.

3.2 Scope

The technical analysis and design work required for this project only requires the selection of

components from those provided and the specification of values for the parameters listed for each Design Section. In particular, aspects of the project that are outside the scope of the design include:

 all components or materials not specified in versions of this brief

3.3 Constraints (constraints have been numbered)

The following constraints apply:

C1. A maximum budget of $82,500 C2. The maximum height (H) for the design is not to exceed 18m.

C3. The load-out bin must be cylindrical in shape, with conical ends.

C4. The minimum height for the cylindrical section of the load out bin is to be 1m.

C5. The minimum diameter of the load-out bin is to be 5m.

C6. The angle (theta 1) of the conveyor must be between 10 and 30 degrees

C7. The train wagons hold a maximum of 100 tonne each

3.4 Assumptions

The following simplifying assumptions have been made:

 All volume within the conical ends of the load-out bin is usable, but not the chute.  The thickness of the walls of the silos and load-out bin can be ignored in volume calculations.  The flow rate of coal is able to be controlled as required, but how this is achieved is beyond the

scope of this design.

 The variation in the mass of the coal due to variations in moisture content is to be ignored.

 The cost of electricity to run the equipment is not to be considered.  The opening where coal enters the load out bin is to be ignored

4 ENG1002 – Introduction to Engineering and Spatial Science Applications

4.0 Technical Information (students - all this information is new, except rho)

4.1 Load Out Bin, chute and gate control

Table 1: Technical Information relevant to the load out bin

Quantity variable value unit

Density of coal (same as in V1.1) ρ (rho) 810 kg/m 3

Cost of load-out bin (per m 2 of surface area) cB 100 $/m

2

Length of wagon (wagon to wagon) Lw 12 m

Useful length of opening on the wagon Lo 9 m

Width of opening on the wagon w 1.5 m

Coal is loaded into the train wagons as the train moves continually at a constant speed S (in kph) beneath the

chute. The gate on the chute is to be opened while the opening in the wagon is under the centre of the chute.

You are to assume-

- that the useful length of opening Lo takes into account the position of the wagon with respect to the chute,

such that no coal is lost over the end of the wagon.

- the gate opens and closes instantaneously and that the coal flow into the wagon starts and stops

instantaneously (ignore any delays including the time for coal to fall through the 1m deep chute)

- the width of the opening on the coal wagon (w) is 1.5 m

Figure 2: Proposed coal load – train loading side view

The mass flow rate into the wagon from the chute is given by:

√

where MFw is the mass flow rate of coal (in kg/s), a is the cross-sectional area of the chute (in m 2 ),

d is the diameter of the chute (in m) and g is gravitational acceleration constant (in m/s 2 ).

12m

LO

Load-

out bin

chute diameter d

Side View 2

Elevation

useful length of opening

Length of wagon Lw (wagon to wagon)

w

width of opening

motion of train

ENG1002 Design project - Client Brief Version 2.0 5

© University of Southern Queensland

4.2 Conveyor

Black Gold already operates and maintains other conveyor equipment, so to avoid a requirement to hold

additional spare parts, you are required to select conveyor components from those listed below.

Table 2: Technical Information relevant to the conveyor

Quantity variable value or equation unit

Load Factor (accounts for conveyor friction) LF 0.2 none

Conveyor belt width W 0.8 m

Conveyor cross sectional area (of coal on conveyor) Ac = π/12 * W 2 m

2

Cost of conveyor (per linear metre) cC 700 $/m

The output power required from the motor to drive the conveyor and raise the coal in height is given by:

( )

where P is power (in W), MFc is the mass flow rate of coal (in kg/s), Δh is the change in height (in m), g is gravitational acceleration constant (in m/s

2 ), theta1 is the angle of the conveyor (in radians) and LF is

the Load Factor (dimensionless).

Table 3: Conveyor motor options – (costs include motor control equipment)

Motor Size Output Power (kW) Cost ($)

M-5 50 5000

M-8 80 8000

M-10 100 10000

M-12 125 12500

6 ENG1002 – Introduction to Engineering and Spatial Science Applications

Important note to students

The sections listed above are to be used to subdivide the analysis and design process and

identify the sections you are to use for your Technical Analysis, Presentation and Design

Proposal assessments, as detailed in the requirements of each assessment.

IMPORTANT: This is a closed design problem where all information required to

complete the technical analysis, calculations and evaluation of possible solutions will be

available in the Client Brief, your text books or other provided assignment material. The

problem presented is a simplified version of a real design problem, so the fine details of the

components of the proposed system are ignored.

If you find yourself seeking information beyond that provided in the Client Brief,

your text books or other assignment material then you are probably over thinking the

problem. The three assessments using this problem are able to be completed using just the

engineering fundamentals you are studying, supported by other course material and tools

like the spreadsheet. There is no need to research commercial equipment.

For the Technical Analysis assessment all students must complete a technical analysis

and prepare a short technical report on Design Section 1 (only) of the project. Your

memorandum to a (pretend) colleague is to request a technical analysis and short

technical report on one of either section 2 or 3.

For the Presentation assessment each student will select design section 2 or 3 of the

project on which to complete a technical analysis and prepare a short oral presentation.

[This can be the same as the section your request of your colleague in your memo – that is

not important.] You are to present a summarised technical analysis of that section of the

design and how it depends-on / influences any other section of the design. The

presentation is to be prepared and delivered as if to other colleagues in your company who

are working with you on the larger project.

For the Design Proposal assessment students are expected to complete the technical

analysis for the whole project, model the design on a spreadsheet, evaluate some

alternatives within the design and select a specific design solution to recommend in their

report. The recommendation must clearly specify all of the parameters listed in the design

sections in bold, as they define each section of the design.

Students should note there is more than one correct answer to this problem, as several

possible solutions will meet the requirements of the design.

Furthermore - a technical analysis of a single design section ALONE is unlikely to

identify a set of design parameters that results in the final project design, as the

sections are somewhat dependent on each other. Hence when you complete a technical

analysis on a single section of the design you are not looking for a specific ‘answer’ to

that section.

Your analysis should show the relationships between the parameters (eg. D, H, etc)

within a section and possibly with those in other sections of the design. This analysis

will allow you to eliminate some of the alternative equipment suggested (when it is evident

it cannot do the job), or you may be able to reduce the range of values for some parameters

which offer a possible solution.