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Article history:
Received 23 January 2014
Received in revised form 28 March 2014
Accepted 28 March 2014
Available online 5 April 2014
Keywords:
Pneumatic conveying
Dense-phase
High pressure
Bend
Pressure drop
a b s t r a c t
In order to investigate the effect material property, bend geometry and location on pressure drop through
the bend, experiments of dense-phase pneumatic conveying are carried out at conveying facility with the
pressure up to 4.0 MPa. Petroleum coke and anthracite powders with different particle sizes are applied
to examine ow characteristics. The empirical correlations of pressure drop through the bend are
obtained using Barths additional pressure theory and multi-variable linear regression. Results show that
pressure drop through vertical downward bend is the least, followed by pressure drop through horizontal
bend, pressure drop through vertical upward bend is the largest. Powders with larger size need consume
more energy than that with smaller size at the same solid loading ratio and conveying velocity as gas
solid mixture ows across the same radius bend. Flow characteristics of petroleum coke and anthracite
are analyzed and compared. Pressure drop through the bend with the long radius is greater than that with
the short radius. While to unit length, pressure drop of long radius bend is less than that of short radius
bend. The empirical correlations of pressure drop through the bend are derived and predicted results
agree well with the experimental results. The ow characteristics of the bend offer the theoretical support for design, control and operation of dense-phase pneumatic conveying at high pressure.
2014 Elsevier Inc. All rights reserved.
1. Introduction
Pneumatic conveying is an important process in the chemical,
energy and pharmaceutical industry for transportation of granular
particles [14]. The aim of these transport systems is to transfer
particulate material between storage locations, or to feed different
kinds of reactors. One of the advantages of using pneumatic conveying system to transport bulk particulate material, compared
to other systems, is the exibility in routing the pipeline. This often
results in transport pipes with many bends, which considerably increase the difculty in predicting the performance of the system.
Bends and elbows play vital roles in giving pneumatic conveying
systems considerable exibility by allowing routing and distribution. Dense-phase pneumatic conveying at high pressure is one
of the key technologies in gasication. Because of low velocity,
high pressure and high solid concentration in transportation,
gassolid mixture across bend is very unsteady and complicated
[514]. Pressure drop through bend is seriously affected by bend
geometry, location, material property, etc.
12
Nomenclature
D
dp
e
Fr
G
g
L
R
P2
Dp
Dpg
Dps
Dpsa
Dpsf
Dpsh
Dpsh1
Dpsh2
Re
U
Greek letters
kg
resistance coefcient of gas phase
ks
resistance coefcient of additional solid phase
l
solid loading ratio
qg
gas density, kg/m3
qs
solid density, kg/m3
The impact velocity is distributed as a result of a distribution in particle velocity and in impact angle, though the variability in the latter
is shown to be the signicant component. Rinoshika [24] studies
the effect of the dune model and soft ns in horizontal pneumatic
conveying involving a 90 bend. At the upstream of bend and in
the bend, the particle velocity of using the dune model is evidently
higher than that of the conventional pneumatic conveying and
using soft ns. However, the effect of soft ns and dune model on
the particle velocity is maintained downstream of the bend. Hidayat and Rasmuson [25] investigate the effects of particle diameter,
particle density, particle volume fraction, gas velocity and bend radius ratio on relevant quantities in engineering applications in a Ubend. A small bend radius ratio will produce a faster dispersion of
particles, which benets drying, but on the other hand, will increase
the total pressure drop. Thus, optimizing gas velocity and bend radius ratio is important in reducing energy consumption. Lan and
Sommerfeld [26] apply Euler/Lagrange approach in connection
with the ke turbulence model accounting for full two-way coupling to simulate the pneumatic conveying. The structure of the
secondary ow developing in the bend is investigated and the inuence of the particles as well as inter-particle collisions on the secondary ow structure and intensity is addressed. A detailed
analysis of the segregation phenomena occurring in the bend and
the inuence of the particle phase on the ow structure can be performed by the calculations. Despite numerous studies, both experimental and numerical, have been conducted on different
pneumatic conveying systems to characterize the ow behaviors
of the solids in bend, most of those researches are mainly carried
out to dilute-phase pneumatic conveying at low pressure. Effect
of material property, bend geometry and location on the pressure
drop through the bend in dense-phase pneumatic conveying is
not fully understood at high pressure.
This paper presents a comprehensive study of effect of material
property, bend geometry and location on pressure drop through the
bend in dense-phase pneumatic conveying at high pressure. A series
of cases with powders of different particle sizes and material categories are performed at different gas velocities. Pressure drops through
horizontal bend, vertical upward bend and vertical downward bend
are examined and compared. Empirical correlations of pressure drop
through the bend are derived and analyzed. The ndings should be
useful not only for establishing a comprehensive understand about
the effect of material property, bend geometry and location but also
for designing and controlling pneumatic conveying systems.
13
Anthracite and petroleum coke are transported in the experiments and material properties are shown in Table 1. The particle
sizes of the experimental materials are measured by a laser particle
analyzer (LS, Beckman Coulter Inc., USA). Four experimental materials all cover a wide range of particle size and their size distributions are shown in Fig. 2. Fig. 3 illustrates the SEM (scanning
electron microscope) micrographs of experimental materials. It
can be seen from Fig. 3 that four kinds of experimental materials
have poor sphericity and rough surfaces. Particle size distributions
of anthracite #2 and petroleum coke #2 are similar and their volume mean particle diameters are nearly the same. Thus, these two
kinds of materials are treated as particles with the same particle
size in the analysis of experimental results. Moisture contents of
materials are measured according to the National Standards of
the Peoples Republic of China. External moisture contents and total moisture contents of experimental materials are very small,
which means the inuence of moisture content on ow characteristics and resistance properties can be ignored. Real densities of
experimental materials are measured by mercury intrusion analysis and real density of anthracite is larger than petroleum coke for
the same particle size.
3. Results and discussion
3.1. Comparison of pressure drops through different location bends
In pneumatic conveying system, three different location 90
bends with 200 mm radius are investigated using petroleum coke
and anthracite. In the conveying process, the pressure in receiving
tank is maintained at 3.0 MPa and other operation parameters are
same except the conveying velocity. Supercial gas velocity, which
will be referred to simply as conveying velocity in the paper, can be
calculated at gas temperature and average pressure in conveying
pipeline. Figs. 4 and 5 show the pressure drops through horizontal
bend, vertical upward bend and vertical downward bend. With the
increase in conveying velocity, pressure drops through different
bends rise slowly at rst and then increase rapidly [15,22]. Forces
between gas and particles, between particles, and between particles and wall are the key factors responsible for the features of
gassolid two-phase ow in a bend. As gassolid two-phase ow
enters the bend, particlewall collision can lead to particleparticle
collision in regions close to a bend wall. It is because some particles, after colliding with the bend wall, will change their velocities
and directions, and collide with incoming particles, forming a
shielding layer. Strong particlewall interactions exist in the outer
wall of a bend, which can lead to strong particleparticle interactions. Particlewall and particleparticle interactions both contribute to pressure drop. Then gassolid two-phase mixture ows out
from the bend and particles are accelerated by the gas. Particle
velocity decreases considerably at a bend and the afterward acceleration causes additional pressure lose. The pressure drop through
the bend depends on not only the particle velocity but also on the
particle concentration. When the conveying velocity is low, solid
loading ratio decreases with the increase in conveying velocity because of constant mass ow rate. Pressure drop contributed by
those factors almost rises slowly as shown in Figs. 4 and 5. As
14
Table 1
Material properties.
Material
Petroleum coke #1
Petroleum coke #2
Anthracite #1
Anthracite #2
163.0
56.69
139.9
52.78
1.05
0.59
1.84
2.35
1.19
0.72
2.63
2.99
1103
1103
1490
1490
616
475
736
588
5
4
Anthracite, dp =139.9 m
Anthracite , dp =52.78 m
Volume (%)
Volume (%)
3
3
2
1
0
10
100
1000
10
100
(b) Anthracite
1000
ratio. The pressure drop through the pipe can be described using
Eq. (1)
DPg is the pressure drop due to the gas friction, DPsf is the pressure
drop due to solid friction and impact, DPsh is the pressure drop due
to raising and suspending the solids, DPsa is the pressure drop due
to accelerating the solids. To the three different location bends with
15
26
28
Horizontal bend
Vertical upward bend
Vertical downward bend
G=900kg/h
P2=3.0MPa
24
24
P (kpa)
P (kpa)
26
Horizontal bend
Vertical upward bend
Vertical downward bend
G=760kg/h
P2=3.0MPa
22
22
20
18
20
16
18
10
12
10
U (m/s)
U (m/s)
12
28
P (kpa)
26
24
30
Horizontal bend
Vertical upward bend
Vertical downward bend
G=830kg/h
P2=3.0MPa
27
P (kpa)
30
22
20
21
18
18
16
24
Horizontal bend
Vertical upward bend
Vertical downward bend
G=900kg/h
P2=3.0MPa
10
12
14
15
10
U (m/s)
U (m/s)
12
16
26
26
dp=56.69m, G=760kg/h
24
P2=3.0MPa
P (kpa)
P (kpa)
28
dp=163m, G=700kg/h
22
20
24
dp=139.90m, G=830kg/h
dp=52.78m, G=900kg/h
P2=3.0MPa
22
20
18
18
4
10
12
16
10
12
U (m/s)
U (m/s)
(b) Anthracite
14
Fig. 6. Effect of particle size on pressure drop through the horizontal bend.
28
P (kpa)
26
24
parameters and material properties. But mass ow rates of petroleum coke and anthracite are about 760 kg/h and 900 kg/h, respectively. So if the two kinds of powders ow at the same solid loading
ratio and conveying velocity, pressure drop though the bend for
petroleum coke is larger than that for anthracite. Because petroleum coke particles adhered at the pipe wall form the shell around
the conveying pipe as shown in Fig. 8, friction coefcient greatly
increases. Then at the same solid loading ratio and conveying
velocity, pressure drop of petroleum coke is larger than that of
anthracite.
22
20
18
10
12
U (m/s)
Fig. 7. Effect of material category on pressure drop through the horizontal bend.
P/L (kpa)
27
24
R=300mm
R=200mm
R=120mm
G=860kg/h
P2=3.0MPa
21
18
15
6
10
12
14
U (m/s)
Fig. 8. Petroleum coke of the adhered pipe wall.
DP s k s l
pR qg U 2
2D
17
ks f U; l; R; dp
ks alb Fr c
m n
dp
R
D
D
p
where Fr U= gD, dp is the average particle size. The a, b, c, m
and n are the constants. According to the experimental data,
empirical correlation of solid friction coefcient using multi-variable linear regression can be given as follows.
The solid friction coefcients of bend with 200 mm radius for
petroleum coke are given as follows.
Solid friction coefcient of horizontal bend:
0:133
dp
D
DP DP g DP s
where Dpg is pressure drop due to gas friction and Dps is additional
pressure drop due to solids. The gas pressure drop component is
evaluated by assuming that only gas is owing in the bend. Dpg
can be calculated according to the equation below:
DPg kg
Lqg U 2
2D
When 300 > ReD=2R2 > 0:034, gas friction coefcient can be given
[27]:
0:25
0:029 0:304ReD=2R2
kg
2R=D
11
0:042
dp
D
12
0:038
dp
D
0:012
dp
D
13
R=120mm
R=200mm
R=300mm
G=860kg/h
P2=3.0MPa
60
40
8
10
12
14
U (m/s)
Fig. 10. Pressure drop per unit length through horizontal bend with different
radius.
14
120
P (kpa/m)
0:104
dp
D
10
1=2
0:121
dp
D
0:072 0:634
dp
R
D
D
15
18
27
Experimental value
Predicted value
Experimental value
Predicted value
Predicted P (kpa)
Predicted P (kpa)
28
24
%
+5
%
-5
20
16
16
20
24
24
+5
21
-5
18
18
28
21
24
Experimental P (kpa)
Experimental P (kpa)
27
27
Predicted P (kpa)
Experimental value
Predicted value
24
%
+5
21
-5
18
15
15
18
21
24
27
Experimental P (kpa)
30
Experimental value
Predicted value
Predicted P (kpa)
Experimental value
Predicted value
24
+5
21
-5
18
15
15
18
21
24
+5
24
-5
18
18
27
24
Experimental P (kpa)
Experimental P (kpa)
27
Predicted P (kpa)
Predicted P (kpa)
27
24
21
Experimental value
Predicted value
+5
-5
18
15
15
18
21
24
27
Experimental P (kpa)
30
Predicted P (kpa)
30
Experimental value
Predicted value
24
+7
-8
18
12
12
18
24
30
Experimental P (kpa)
Fig. 13. Comparison of predicted and experimental pressure drop through different
radius bends for coarse anthracite.
4. Conclusions
The inuence of material property, bend geometry and location
on pressure drop through the bend in dense-phase pneumatic conveying at high pressure is investigated. According to Barths additional pressure theory, the empirical formulas are achieved using
the dimensional analysis and multi-variable linear regression.
With the increase in conveying velocity, pressure drops through
the bends rise slowly at rst and then increase rapidly. Pressure
drop through the vertical downward bend is the lowest, followed
by pressure drop through the horizontal bend, pressure drop
through the vertical upward bend is the largest at the similar solid
loading ratio and operation parameters. Pressure drop through the
horizontal bend with larger size particles is greater than that with
smaller size particles for the same kind of material. At the same solid loading ratio and conveying velocity, pressure drop of petroleum coke is larger than that of anthracite. The short radius bend
give an overall pressure drop less than the long radius bend. While
pressure drop per unit length decreases with the increase in bend
radius. Pressure drops through different bends are analyzed and
empirical correlations are derived. The predicted results agree well
with the experimental results and the relative errors between the
experimental results and predicted values are mostly less than 8%.
Acknowledgment
Supported by the Special Funds of National Key Basic Research
and Development Program of China (2010CB227002).
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