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GEAPS 510: Grain Facilities Planning and Design I

Next course offering: May 27-June 27, 2014
Registration opens: April 28, 2014

Course Description: This new course will cover key factors and information needed for making grain-facility planning, design and construction decisions. It will examine various grain-facility types and their purposes, storage-structure types and options, how to determine the storage and handling capacities that will be needed, and how to best select a suitable construction site. It will also cover flow diagrams and help students get a jump on real-world planning by asking them to lay out a simple facility.

Course Goals: The course will help participants identify various grain-facility types and components and then determine the most appropriate type for their specific purposes before construction, expansion or modernization projects get underway.

Target Audience: The course is intended for grain-company executives, company board members, regional and local facility managers and supervisors; insurance underwriters, equipment vendors, grain-company accountants and others involved with planning and designing a new grain facility or updating or expanding an existing facility.

Instructors:

Dr. Fred Fairchild, Professor, Kansas State University Department of Grain Science and Industry | Show Bio

Dr. Dirk Maier, Professor and Head, Kansas State University Department of Grain Science and Industry | Show Bio

Carlos Campabadal, Program Specialist and Instructor for Feed Mfg and Grain Storage, Coord for Spanish-Speaking Outreach Program, Kansas State University Dept of Grain Science and Industry | Show Bio

Bob Klare, Director of International Development, River Consulting LLC | Show Bio


The Course of Study

Week 1
Lecture 1 – Facility Types and Purposes
To determine what type of grain handling facility should be designed or built, it's first necessary to have a good handle on anticipated main purposes. How is the facility going to be used? What are its functions? Once understood, options can be narrowed among the various facility types, including on-farm storage, country elevators, regional and terminal elevators and port facilities. This introductory lecture will discuss the reasons why grain is stored, and then review the major types of storage facilities and what they're designed to accomplish.
Lecturer: Dr. Fred Fairchild

Lecture 2 – Matching Commercial Needs and Facility Capacity
How large does a facility need to be? What types of equipment will it require generally? This lecture will explore how facility capacity and the types of equipment selected need to match the facility's commercial needs. The discussion will cover factors such as types of grains received; receiving quantities, units and frequencies; sampling and binning; weighing points; drying requirements; short-term and long-term storage; and shipping quantities, units and frequencies. It will also prompt students to start thinking about the final course assignment: laying out a facility.
Lecturer: Dr. Fred Fairchild

Week 2
Lecture 3 – Types of Storage Structures
Lecture 3 will familiarize students with various types of bin construction, and advantages and limitations of each type. It will also discuss other major issues to consider before design and construction, including marketing objectives, the impact of grain physical properties on the storage system, safety features, pest control, inventory management, maintenance and repair, and life-cycle costs.
Lecturer: Dr. Dirk Maier

Lecture 4 – Grain Handling Equipment Options
Building on previous course material, Lecture 4 will examine some of the major grain-facility equipment options, investigate their potential advantages and disadvantages, point out some suggested "do's and don'ts," and discuss where, physically, the equipment might be best suited within a facility. The lecture will cover equipment including screw conveyors, bucket elevators, and drag conveyors (especially en masse conveyors).
Lecturer: Dr. Fred Fairchild

Week 3
Lecture 5 – Receiving, Weighing and Loading Systems
Before design and construction of a facility, it's critical to plan the receiving, weighing and loading systems to optimize the operation of the entire location. This lecture will discuss considerations relating to truck and rail receiving including sampling, unloading, and dust control as well as road and track layout; options and arrangements for truck scales, rail scales, and bulk weighers; particular requirements and specific considerations for both rail and barge loading, including important safety considerations; and how these aspects of a facility connect to the overall arrangement and design.
Lecturer: Bob Klare
                       
Lecture 6 – Storage and Handling Capacities
This lecture will guide the students through different scenarios for determining the appropriate storage and handling capacities needed for a new or renovated facility. How fast does the drag or screw conveyor need to operate? What volumes need to be handled for dust control? What capacities are needed in the receiving systems? The lecture will discuss how to determine required handling rates and the size and quantity of the bins needed, and what equipment would be best-suited to the facility's purpose.
Lecturer: Dr. Fred Fairchild

Week 4
Lecture 7 – Grain Cleaning and Facility Design
Lecture 7 will cover grain cleaning equipment and systems, which allow facility operators to improve grain quality by removing foreign material and fines. The lecture will describe a variety of equipment options and how they work. It will cover various types of cleaners, scalpers, de-stoners, screeners, aspirators and optical sorters, and then relate how they are connected to facility design in terms of plant location, discharge, field-control devices, access for maintenance as well as changing screens. Additionally, the lecture will discuss safety, operational, and structural considerations when installing grain cleaners.
Lecturer: Bob Klare

Lecture 8 – Determining Facility Requirements and Layout
Building on previous lectures, Lecture 8 guides students through the process of determining the requirements and capacities required for a grain handling and storage system type that will assigned to them in Lecture 10. Topics covered will include determining storage capacities, bin sizes and numbers of bins required; determining handling system requirements and capacities; determining sampling and weight requirements; determining special requirements, such as those pertaining to cleaning, drying and dust control; and how to create a flow diagram.
Lecturer: Dr. Fred Fairchild

Week 5
Lecture 9 – Site Selection
Lecture 9 familiarizes students with considerations and requirements for selecting an appropriate site for the type of facility to be built. Topics covered will include determining and assessing the feasibility of the usable area, what types of road and rail access are available and whether they'll be sufficient, what types of utilities are available, accessibility and easements, codes and regulations, assessing the local labor market and security considerations.
Lecturer: Dr. Fred Fairchild

Lecture 10 – Time to Design!
In this lecture, students will apply what they've learned from the previous lectures, and lay out a basic grain facility. They'll be given some hypothetical information about grain types and input and output volumes and then asked to design a facility to handle the needs. How many bins will be required? How large would they need to be? Where should they be located? How big should the dryer be? What's the best approach for shipping? The idea is to give students an opportunity to experience the actual process of planning a facility to meet commercial and operational realities.
Lecturer: Dr. Fred Fairchild