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Bulk material handling is an
engineering Engineering is the use of scientific principles to design and build machines, structures, and other items, including bridges, tunnels, roads, vehicles, and buildings. The discipline of engineering encompasses a broad range of more speciali ...
field that is centered on the design of equipment used for the handling of dry materials. Bulk materials are those dry materials which are powdery, granular or lumpy in nature, and are stored in heaps.http://practicalmaintenance.net/wp-content/uploads/Maintenance-of-Ash-Handling-Plants-and-Pneumatic-Conveying-Systems.pdf Examples of bulk materials are
minerals In geology and mineralogy, a mineral or mineral species is, broadly speaking, a solid chemical compound with a fairly well-defined chemical composition and a specific crystal structure that occurs naturally in pure form.John P. Rafferty, ed ...
, ores,
coal Coal is a combustible black or brownish-black sedimentary rock, formed as rock strata called coal seams. Coal is mostly carbon with variable amounts of other elements, chiefly hydrogen, sulfur, oxygen, and nitrogen. Coal is formed when ...
,
cereal A cereal is any grass cultivated for the edible components of its grain (botanically, a type of fruit called a caryopsis), composed of the endosperm, germ, and bran. Cereal grain crops are grown in greater quantities and provide more food ...
s,
woodchips Woodchips are small- to medium-sized pieces of wood formed by cutting or chipping larger pieces of wood such as trees, branches, logging residues, stumps, roots, and wood waste. Woodchips may be used as a biomass solid fuel and are raw materia ...
,
sand Sand is a granular material composed of finely divided mineral particles. Sand has various compositions but is defined by its grain size. Sand grains are smaller than gravel and coarser than silt. Sand can also refer to a textural class ...
,
gravel Gravel is a loose aggregation of rock fragments. Gravel occurs naturally throughout the world as a result of sedimentary and erosive geologic processes; it is also produced in large quantities commercially as crushed stone. Gravel is classifi ...
,
clay Clay is a type of fine-grained natural soil material containing clay minerals (hydrous aluminium phyllosilicates, e.g. kaolin, Al2 Si2 O5( OH)4). Clays develop plasticity when wet, due to a molecular film of water surrounding the clay pa ...
,
cement A cement is a binder, a chemical substance used for construction that sets, hardens, and adheres to other materials to bind them together. Cement is seldom used on its own, but rather to bind sand and gravel (aggregate) together. Cement mixe ...
,
ash Ash or ashes are the solid remnants of fires. Specifically, ''ash'' refers to all non-aqueous, non-gaseous residues that remain after something burns. In analytical chemistry, to analyse the mineral and metal content of chemical samples, ash ...
,
salt Salt is a mineral composed primarily of sodium chloride (NaCl), a chemical compound belonging to the larger class of salts; salt in the form of a natural crystalline mineral is known as rock salt or halite. Salt is present in vast quant ...
,
chemicals A chemical substance is a form of matter having constant chemical composition and characteristic properties. Some references add that chemical substance cannot be separated into its constituent elements by physical separation methods, i.e., wit ...
,
grain A grain is a small, hard, dry fruit ( caryopsis) – with or without an attached hull layer – harvested for human or animal consumption. A grain crop is a grain-producing plant. The two main types of commercial grain crops are cereals and legum ...
,
sugar Sugar is the generic name for sweet-tasting, soluble carbohydrates, many of which are used in food. Simple sugars, also called monosaccharides, include glucose, fructose, and galactose. Compound sugars, also called disaccharides or do ...
,
flour Flour is a powder made by grinding raw grains, roots, beans, nuts, or seeds. Flours are used to make many different foods. Cereal flour, particularly wheat flour, is the main ingredient of bread, which is a staple food for many cul ...
and
stone In geology, rock (or stone) is any naturally occurring solid mass or aggregate of minerals or mineraloid matter. It is categorized by the minerals included, its Chemical compound, chemical composition, and the way in which it is formed. Rocks ...
in loose bulk form. It can also relate to the handling of mixed
waste Waste (or wastes) are unwanted or unusable materials. Waste is any substance discarded after primary use, or is worthless, defective and of no use. A by-product, by contrast is a joint product of relatively minor economic value. A waste pr ...
s. Bulk material handling is an essential part of all industries that process bulk ingredients, including: food, beverage, confectionery, pet food, animal feed, tobacco, chemical, agricultural, polymer, plastic, rubber, ceramic, electronics, metals, minerals, paint, paper, textiles and more. Major characteristics of bulk materials, so far as their handling is concerned, are: lump size, bulk weight (density),
moisture content Water content or moisture content is the quantity of water contained in a material, such as soil (called soil moisture), rock, ceramics, crops, or wood. Water content is used in a wide range of scientific and technical areas, and is expressed as ...
, flowability (particle mobility),
angle of repose The angle of repose, or critical angle of repose, of a granular material is the steepest angle of descent or dip relative to the horizontal plane to which a material can be piled without slumping. At this angle, the material on the slope fac ...
, abrasiveness and
corrosivity Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...
, among others. Bulk material handling systems are typically composed of stationary machinery such as
conveyor belt A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt conveyor). A belt conveyor system is one of many types of conveyor systems. A belt conveyor system consists of two or more pulleys (sometimes referred t ...
s,
screw conveyor A screw conveyor or auger conveyor is a mechanism that uses a rotating helical screw blade, called a "''flighting''", usually within a tube, to move liquid or granular materials. They are used in many bulk handling industries. Screw conveyor ...
s, tubular drag conveyors, moving floors, toploaders,
stacker A stacker is a large machine used in bulk material handling. Its function is to pile bulk material such as limestone, ores and cereals on to a stockpile. A reclaimer can be used to recover the material. Gold dredges in Alaska had a stacke ...
s, reclaimers,
bucket elevator A bucket elevator, also called a grain leg, is a mechanism for hauling flowable bulk materials (most often grain or fertilizer) vertically. It consists of: # Buckets to contain the material; # A belt to carry the buckets and transmit the pull; ...
s, truck dumpers, railcar dumpers or wagon tipplers, shiploaders, hoppers and diverters and various mobile equipment such as loaders, mobile hopper loaders / unloaders, various shuttles, combined with storage facilities such as stockyards,
storage silo A silo (from the Greek σιρός – ''siros'', "pit for holding grain") is a structure for storing bulk materials. Silos are used in agriculture to store fermented feed known as silage, not to be confused with a grain bin, which is used ...
s or
stockpile A stockpile is a pile or storage location for bulk materials, forming part of the bulk material handling process. Stockpiles are used in many different areas, such as in a port, refinery or manufacturing facility. The stockpile is normally cre ...
s. Advanced bulk material handling systems feature integrated bulk storage (silos), conveying (mechanical or pneumatic), and discharge. The purpose of a bulk material handling facility may be to transport material from one of several locations (i.e. a source) to an ultimate destination or to process material such as ore in concentrating and
smelting Smelting is a process of applying heat to ore, to extract a base metal. It is a form of extractive metallurgy. It is used to extract many metals from their ores, including silver, iron, copper, and other base metals. Smelting uses heat and a c ...
or handling materials for manufacturing such as logs, wood chips and sawdust at sawmills and paper mills. Other industries using bulk materials handling include flour mills and coal-fired utility boilers. Providing storage and inventory control and possibly material blending is usually part of a bulk material handling system. In ports handling large quantities of bulk materials continuous ship unloaders are replacing
gantry crane A gantry crane is a crane built atop a gantry, which is a structure used to straddle an object or workspace. They can range from enormous "full" gantry cranes, capable of lifting some of the heaviest loads in the world, to small shop cranes, us ...
s.


Other materials handling classifications (non-bulk)

Non-bulk materials handling classifications include palletization and
containerization Containerization is a system of intermodal freight transport using intermodal containers (also called shipping containers and ISO containers). Containerization is also referred as "Container Stuffing" or "Container Loading", which is the p ...
.


See also

*
Bulk cargo Bulk cargo is commodity cargo that is transported unpackaged in large quantities. Description Bulk cargo refers to material in either liquid or granular, particulate form, as a mass of relatively small solids, such as petroleum/ crude oi ...
*
Bulk carrier A bulk carrier or bulker is a merchant ship specially designed to transport unpackaged bulk cargo — such as grains, coal, ore, steel coils, and cement — in its cargo holds. Since the first specialized bulk carrier was built in 1852, eco ...
* Caking * Double dump valve * Rotary car dumper *
Self-discharger SS Carl D. Bradley unloading hopper in 1958 A self-discharger (or self-unloader) is a ship that is able to discharge its cargo using its own gear. The most common discharge method for bulk cargo is to use an excavator that is fitted on a traver ...


References

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