ISBind:
Reread my first post for some of the deeper meaning btwn. the lines. You are not going to find these friction factors in some nice clean mech. engrg. handbook list or some computer program. In that industry, these are brute force calcs., not finesse calcs. If you really want to know what those avg./approx./max. friction factors or forces are, you’ll have to measure the force it takes to push that plate in and out empty; and then do the same test with the block of coal in place. Do this at each plant (for different oven design details, etc.), at different oven positions (for plate guidance system fit-up, clogging, etc.); do this as many times as you want and look at the averages and the max. force required, for some design criteria. Then, back calc. for some Coef. of Friction if you wish. With your OP and your latest post, you seem to expect this to be some nice M.E. text book problem. It is not, in the slightest. I wonder if the smarter thing to do wouldn’t be look at what’s working and not working very well, or needs continuous repair, and ask what can I do in the way of design to improve that performance. RE: motor HP, what are they using now, and how long is it lasting? Long life means maybe you can reduce the motor size a bit, for a few dollars saved; maybe downsize gearbox, chain, etc. But, you’ll more than use that savings the first time one of these parts fails. Calculating the motor HP the way you are trying to do is a really tough assignment. Refining what’s working may be the easier route, or at least knowing what works is a good starting point for a design improvement or new design.
