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Innovative Applications Of U.S. Pneumatic Conveying Systems In Agriculture

Learn more about the most common method used for transferring powders, granules, and other dry bulk materials. This informative article provides expert insight, answering frequently asked questions about pneumatic conveying in dry bulk material processing and handling plants. Improve your understanding and efficiency with this essential knowledge.

WHAT IS A PNEUMATIC CONVEYING SYSTEM?
A pneumatic conveying system is used to transfer powders, granules, and other dry bulk materials through a sealed pipeline. The transfer is powered by a combination of pressure differential and the flow of a gas, such as air or nitrogen. The system consists of a motive air source (also known as an air mover, such as a fan or blower), a feeder or similar device for introducing materials, a conveying line, a termination vessel (such as an air-material receiver), and a dust collection system.

Although the most commonly transferred materials are flour, cement, sand, and plastic pellets, pneumatic conveying systems can handle hundreds of different chemicals, food products, and minerals. These materials are typically on the dry side; materials in slurry or paste form are not typically suited for pneumatic conveying.

HOW DOES A PNEUMATIC CONVEYING SYSTEM WORK?
To perform tasks, energy is required. For example, to manipulate a bolt, you must supply energy in the form of torque. This mechanical torque is typically measured in foot pounds, with both components – feet and pounds – being necessary for the task at hand. Similarly, in a pneumatic conveying system, energy is required to move materials. However, this energy is created by a difference in air pressure (in pounds per square inch) and the amount of airflow (in cubic feet per minute).

The location of the air mover within the system determines whether pressure or vacuum is generated: if it is at the beginning, the air mover pushes air through the system, creating pressure, while if it is at the end, it pulls air through the system, creating a vacuum. By regulating the pressure or vacuum and airflow, the system can effectively transfer materials.

WHAT ARE THE ADVANTAGES OF A PNEUMATIC CONVEYING SYSTEM OVER A MECHANICAL CONVEYING SYSTEM?
The initial discussion will focus on mechanical conveying systems. These systems typically operate linearly with minimal directional changes and require a separate motor and drive for each change in direction. Additionally, an open mechanical conveying system can produce dust and needs regular maintenance due to a larger number of moving parts.

Furthermore, the system often occupies a significant amount of space in a plant. In contrast, pneumatic conveying systems use a small pipeline to transfer materials. The pipeline can be designed with bends to fit around existing equipment, providing more options for layout. Furthermore, the system has a small overall footprint and requires very few moving parts since it is completely enclosed.

WHAT ARE THE DISADVANTAGES OF A PNEUMATIC CONVEYING SYSTEM IN COMPARISON TO A MECHANICAL CONVEYING SYSTEM?
In comparison to a mechanical conveying system of the same size, a pneumatic conveying system typically requires significantly more horsepower to function. This is because the process of adjusting air pressure for pneumatic conveying consumes a significant amount of power and is inherently less efficient than the mechanical transfer found in a mechanical conveying system. A pneumatic conveying system may need up to 10 times the horsepower of a mechanical conveying system for applications with the same transfer rate and distance.

Additionally, a pneumatic conveying system requires a larger dust collection system compared to a mechanical conveying system due to the need to separate the conveyed material from the conveying air at the end of the system. Certain materials, such as those with large particle sizes and high bulk densities, or extremely sticky materials like titanium dioxide, are difficult to convey in a pneumatic system and can lead to complete pipeline blockage. In these cases, a carefully chosen mechanical conveying system may be a more suitable choice for easier transfer.

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