Industries acknowledge the pivotal role of pneumatic conveyors in the efficient transfer of bulk materials. Specifically engineered, pneumatic conveying systems are tailored to transport a blend of air and solid bulk materials. Depending on the mode of transportation, these systems are primarily categorized into two types: dense phase systems (operating under pressure and vacuum) and dilute phase systems (operating similarly under pressure and vacuum).
The design of pneumatic conveyors is customized according to various factors, including product attributes, particle size, throughput capacity, the number of feeding points, and the number of destinations.
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The quintessential factor in pneumatic conveying systems lies in the volume of air employed for material transfer.
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Types of Pneumatic Conveying Systems
Dilute Phase Conveying Systems
The distinguishing characteristic of dilute phase conveying lies in its higher air velocities, which typically range from 15 m/s to 25 m/s, in contrast to dense phase conveying. In this system, the product remains in a state of suspension flow throughout the entire length of the pipeline.
The required air pressure or vacuum for dilute phase conveying is relatively low, generally falling between 100 mbar(g) and 1000 mbar(g) for pressure systems, and between -100 mbar(g) and -500 mbar(g) for vacuum systems. However, due to these higher velocities, there is a greater likelihood of material attrition or breakage, as particles experience increased impact on metal surfaces.
The solids loading ratio, which is calculated as the ratio of the mass transfer rate of solids to the mass transfer rate of air, is typically lower in dilute phase conveying, ranging generally from 1 to 10. To achieve the same throughput or capacity as dense phase conveying, dilute phase systems often require pipelines with a larger diameter.
The conveyable distance in dilute phase conveying is usually limited to 100-200 meters, depending on the material being transported. The simplicity of the system results in less automation and a reduced reliance on various valves.
Despite these limitations, the initial cost or CAPEX for dilute phase systems is lower due to the use of simpler components.
Dense Phase conveying system
The defining characteristic of dense phase pneumatic conveying systems lies in their relatively lower air velocities, typically ranging between 3 m/s and 12 m/s, compared to those of dilute or lean phase pneumatic conveying systems. Throughout the entire conveying length, the product maintains either a slug flow or a fluidized dense phase flow, depending on its specific properties.
These systems require higher air pressure or vacuum levels, usually within the range of 1000 mbar(g) to 5000 mbar(g) for pressure systems and (-)500 mbar(g) to (-)950 mbar(g) for vacuum systems. The reduced velocities minimize material attrition or breakage within the pipeline, as the impact on metal surfaces is decreased.
The solids loading ratio, which represents the ratio of the mass transfer rate of solids to the mass transfer rate of air, is generally higher in dense phase pneumatic conveying systems, ranging from 5 to 100. To achieve the same throughput or capacity as dilute phase conveying, dense phase systems typically utilize pipelines with smaller diameters.
Despite their complexity, dense phase pneumatic conveying systems can cover significant distances, typically up to a maximum of 200-400 meters, depending on the material being conveyed. However, this complexity necessitates a higher level of automation and a greater dependency on various valves.
The initial cost or CAPEX for dense phase pneumatic conveying systems is higher due to the incorporation of more sophisticated components.