Pneumatic conveying system design involves utilizing air streams to effectively move powders, granules, pellets, or flakes through a pipeline, based on specific operational needs. This process is complex and requires advanced knowledge and specialized engineering skills, due to the variety of powders and granular materials involved and the diverse range of practical applications for this conveying method.
WHY EXPERT PNEUMATIC CONVEYING SYSTEM DESIGN IS SO IMPORTANT
When a pneumatic conveying system is improperly designed, it can cause significant operational problems that can have a serious impact on its performance and maintainability. Addressing these issues and diagnosing them can be time-consuming and difficult. Due to the central role that pneumatic conveying plays within a processing plant, these problems can also affect the overall performance of the plant. Rectifying these issues can be a complex and costly process, requiring detailed planning and skilled execution to minimize downtime. Poor design of a pneumatic conveying system can result in various types of operational problems.
BUILDUP AND PLUGGING
It is important to note that excessive powder or granular material can cause blockages and disruptions in a pneumatic conveying system, leading to higher energy consumption and decreased efficiency.
RESTRICTED THROUGHPUT
Possible issues with pipeline layout and obstructions within the pipe work may decrease pneumatic conveying capacity. Additionally, using excessive air speed for transportation within the pipeline may also have a negative impact on conveying capacity (although this may not be immediately apparent).
LINE OR ELBOW WEAR
Greater conveying speeds can lead to increased abrasion of elbows and sweeps along the pipework when handling hard powder or granular materials. This can result in more downtime and higher maintenance needs, potentially requiring more frequent replacement or sturdier construction in these areas.
PARTICLE ATTRITION
The particles of certain powder or granular materials may chip or shatter if excessive conveying speed is applied. This can lead to the formation of dust particles, known as fines, which continue to break apart due to the rough internal surfaces within the conveying system. As a result, the transported bulk material can suffer significant damage and the overall quality of the output can be seriously affected.
PROVEN APPROACH TO PNEUMATIC CONVEYING SYSTEM DESIGN
When planning a new pneumatic conveying system or improving an existing one, it is crucial to determine several key characteristics, such as minimum and optimal air flow rates, pipeline diameters, solids to air ratio, and pressure gradient. These factors are essential in creating an efficient and durable system that minimizes energy consumption, pipeline wear, and utilizes the best feeding, receiving, and air-particle separation mechanisms.
KNOW YOUR BULK MATERIAL PNEUMATIC CONVEYING CHARACTERISTICS
Properly understanding the conveying characteristics of bulk materials is crucial for avoiding design problems in pneumatic conveying systems. This understanding is dependent on the size, distribution, and density of the materials being transported, and allows for accurate determination of conveying mode, air flow, and type of air mover to be used. It is important to consider the potential for streamers, snakeskins, angel hair, and fluff in materials with low melting points, as these can cause issues such as blockages and uneven flow. Testing is essential in determining operating parameters such as minimum transport speed, which is influenced by material density, bulk density, and flow mode. This testing includes evaluating fluidization and permeability, air-retention and deaeration, and vertical and horizontal minimum transport.
UNDERSTAND THE PNEUMATIC CONVEYING SYSTEM REQUIREMENTS
When designing a solution, it is crucial to understand the various requirements of a pneumatic conveying system. These requirements must be carefully considered in order to create the best-fit solution.
MEETING YOUR NEEDS
In general, designing a pneumatic conveying system within a processing plant requires considering the specific capacity rate of the system and distance to be transported in order to meet the customer’s needs.
POWDER PROPERTIES
To determine the type of conveying mode to be used, it is essential to understand the conveying characteristics of the powder or granular material. Characteristics such as lift, drag, and particle collisions are the main factors in lean phase systems, while air particle interactions play a more significant role in dense phase systems, which are more complex than lean systems.
OPERATING CONDITIONS
To ensure acceptance, the merchant requires calculating and verifying multiple constraints and parameters. This includes determining air speeds and capacity rates, pressure drops and energy losses, as well as the ratio of solids to air within the system.
PIPELINE SIZE AND LAYOUT
Determine how the pneumatic conveying system will be integrated into the processing plant while minimizing its length. Ensure that wear and maintenance considerations are in line with the anticipated impact of air flow rates on the transported bulk materials. To determine the optimal pipeline layout and diameter, balance these factors: minimum acceleration zone lengths, types of elbows and sweeps, and components like diverters. Consider replacement times for both the pipeline and its components.
AIR MOVEMENT
Determining the necessary air flow rates for the pneumatic conveying system is crucial in selecting the appropriate fans, blowers, or compressors. This careful consideration will lead to optimal specifications for the system.
SPECIAL FEATURES
To minimize the detrimental effects of abrasive pipeline wear, particle attrition, dust and fines, material accumulation and build up, and streamers, snakeskins and angel hair, specialized components may be necessary. These components not only prevent or reduce these impacts, but also increase overall efficiency and longevity.
DELIVERING PNEUMATIC CONVEYING SYSTEM DESIGN RESULTS
With our expertise and adherence to industry standards, conducting a thorough analysis of our specific needs has resulted in exceptional design and prevention of significant issues in pneumatic conveying systems.