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3. 4.
Theory
Material, Pressure Drops, Terminology and key points, Pipeline
100825_Pneumatic Transport_10_Intro_Theory.ppt
General
What is a pneumatic conveying? Where can pneumatic transport be found? The pneumatic conveying consists in handling solid bulk material suspended in or forced by a gas stream through a dust proof piping We will find pneumatic transport systems where there is dry and solid bulk material
Raw mix (mill to silo, kiln feed) Pulverised coal (hopper to burner with dosing, burner) Cement (conveying to silo) Some additives: Ash, Dust, Gypsum
100825_Pneumatic Transport_10_Intro_Theory.ppt
100825_Pneumatic Transport_10_Intro_Theory.ppt
Theory - Contents
100825_Pneumatic Transport_10_Intro_Theory.ppt
1 = Talc 2 = Gypsum
3 = Calcite
4 = Fluorine 5 = Apatite 6 = Feldspar 7 = Quartz 8 = Corundum 9 = Diamond
100825_Pneumatic Transport_10_Intro_Theory.ppt
Pressure f(speed 2)
Abrasion f(speed 3.5)
100825_Pneumatic Transport_10_Intro_Theory.ppt
(H2O weight / Dry material weight) % Inherent moisture + air high in moisture (dry air required) => build-up
100825_Pneumatic Transport_10_Intro_Theory.ppt
Cohesion
Fine powder = high cohesion Fluidisation aptitude of the product Aptitude to get the same behaviour as a fluid when mixed with gas Note: in a two-phase mix (gas + solid), experience is crucial for a proper understanding of behaviour, loss of pressure, friction
All these criteria will impact the conveying system design: choice of material to air ratio, air-flow, conveying velocity
100825_Pneumatic Transport_10_Intro_Theory.ppt
Biphasic flow (air + solids) higher P drop than air alone see next slide
Q (loading ratio) = kg material / kg air [or kg mat. / m3 air] = basic data
Lean phase
100825_Pneumatic Transport_10_Intro_Theory.ppt
Dense phase
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A curve = P due to the air only (# proportional to v2) W curve = Wedging of the material
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Material (kg/h) /Air (m3/h) - or kg/kg Air flow QV = volume at ambient, site conditions (air compressor intake) Air (mass) flow = QV x 1.293
Loading ratio is inherent to the pipeline length and to the choice (capacity) of the conveying system technology
Refer to the previous table usually between 15 and 40 for common systems in cement industry
Next, required airflow to be calculated from this ratio & expected output Then, from a first pipeline sizing (refer to next slide), pressure Drop calculations, and finally optimization
Gas Velocity = actual air flow (at P bar, TC) / pipe cross-sectional area
For common products in cement industry, usually recommended 10 m/sec, Take care to calculate the actual airflow at P bar (P1 V1 at compressor intake, P2 V2 at the pick-up point, P1 V1 = P2 V2 ) & at the estimated temperature
Exit velocity usually recommended 30 m/sec, usually at ambient pressure condition and at conveying temperature)
The air will expand as it moves down the pipeline. In a pipeline with fixed diameter, this can result in a high velocity at the end of the circuit. The pipe diameter can be increased by step to keep the velocity within a proper range (next slide).
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Stepped Pipeline: from the graph (principle), it is useful in a long distance system (>150m?) to keep the gas velocity in an envelope
Most economical system = minimizing both air flow (wasted energy for the air, wear) and pressure drop. Length and of each section to be carefully designed, f( material and rate)
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Conveying Pipeline equivalent length E.L. (m) formula used to carry out pressure drop estimations - example: E.L. = LH + 2^LV + 5^NB = (220 m) LH = actual horizontal pipe length (150 m) LV = actual vertical pipe length (25 m)
ID 183mm L1 = 25m
ID 207mm L1 = 25m
ID 207mm L1 = 0m
ID 183mm L1 = 25m
ID 183mm L2 = 100m
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Conveying Pipeline Many types of bends can be used: Long radius bends
Recommended radius = 6 x pipe to avoid excessive P drop. With or without wear-back (thick wall)
DENSIT wear-cast 2000 type inside (corundum aggregate)
Conveying Pipeline
Do not forget expansion joints wherever it is required (air intake or conveying pipe)
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Power Estimation
Simplified formulae
PKW pump = 1,3 x Q material x p P QV 60 p Patm
0,78
p = bar
Q material = kg/h
PKW compressor =
x 1,72 x
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