FOOD, POWDER, PNEUMATICS

Modes of pneumatic conveying: which one is best?

By Peter Wypych General Manager, Bulk Materials Engineering Australia, Faculty of Engineering, University of Wollongong he pneumatic conveying of powders and granular bulk materials has been in existence for over 100 years. In more recent times, different modes of dense-phase have been developed to take advantage of the different behavioral properties of bulk materials and also to meet the increasingly demanding requirements of industry in the areas of system reliability, product quality control and energy efficiency. To the novice end-user, engineer, designer or consultant, it may be a daunting task to determine which mode is best for a particular product and application. Some information in the lit-

erature, such as the dense-phase classification diagram shown in Figure 1, may prove useful in shortlisting some of the options or possibilities. However, care should be taken in using such generalised diagrams. For example, it should be noted that Figure 1 was developed mainly for the powders and granules handled and conveyed in the (plastics) chemical industry. Also, most of the other bulk materials found in industry tend to have a relatively wide particle size distribution (that could span at least 2 of the dense-phase categories or zones shown in Figure 1). The main aim of this paper is to summarise and describe each popular mode of pneumatic conveying and clarify the link between bulk material properties and pneumatic conveying performance, as indicated in Figure 1. References to suitable feeding systems also are included.

Dilute-phase
Traditional pneumatic conveying is based on the simple concept of providing sufficient air to entrain, suspend and transport particles along the pipeline, as indicated in Figure 2. Several terms are employed to describe this mode of flow, such as dilute-phase, lean-phase or suspension-flow. Many different feeders can be employed for dilute-phase pneumatic conveying systems, such as venturis, rotary valves, screw pumps and blow tanks. The following different modes of dense-phase conveying, also referred to as non-suspension flow, have been developed to improve product quality and system reliability and also expand the future potential of pneumatic conveying.

Figure 1. Dense-Phase Classication Diagram [1] for Conventional Pipelines: Group A (uidised dense-phase, FDP); Group B (troublesome in dense-phase); Group C (cohesive powders, possible FDP); Group D (low-velocity slug-ow, LVSF).

52

Australian Bulk Handling Review: May/June 2011

FOOD, POWDER, PNEUMATICS

The Original...
Figure 2. Dilute phase (suspension ow).

For Handling Powders

Very heavy duty - long life

Fluidised dense-phase

luidised dense-phase, Figure 3, is considered often as the most reliable and efficient method of conveying certain powders or fine granular bulk solids over distances ranging from only a few metres up to 2 km. It takes advantage of the fluidisation and air retention properties of the bulk material [2]. Group A materials, as shown in Figure 1, are generally the best candidates for this mode of conveying (e.g. cement, fly ash, pulverized coal, soap powder, skim milk powder, lead dust, powdered limestone, flour). The suitability of a given material to this mode of conveying and the best types of feeder for these systems (e.g. blow tank), including optimal operating conditions and the method of air injection [3], usually are determined by test work and experience.

(A product of Clyde Materials Handling)

The seal is out of the powder flow, and automatically inflates only when the Dome is fully closed.

Valve Closed
Figure 3. Fluidised dense phase (FDP).

Low-velocity slug-flow (LVSF)

This mode of dense-phase pneumatic conveying [4], see Figure 4, has been developed to allow friable and/or granular products to be conveyed with extremely low levels of particle damage (e.g. sugar, wheat, barley, skim milk powder, poly pellets, peanuts, milled grain, semolina, muesli, powdered and granulated coffee, sand grinding media) and also system damage (e.g. bend wear). These bulk materials are usually located in the Group D category shown in Figure 1. However, it should be noted many other Group D materials, especially those with a wide particle size range such as crushed coal and iron ore, cannot be conveyed under LVSF conditions. Some typical LVSF results obtained on sugar, poly pellets, wheat and duralina have been presented previously [5,6]. Due to the extremely high levels of concentration that occur during transportation, the subsequent operating conditions depend quite strongly on the nature and physical properties of the material being conveyed. It is important for this reason that large-scale pneumatic conveying tests be carried out prior to the design or selection of suitable equipment. The main features of this technology that allow friable or easily damaged products to be transported in this manner are listed below. The average material transport velocity can be controlled and maintained easily between 0.25 and 4 m/s (depending on degradation/throughput requirements). Even products, such as granulated sugar, have been conveyed successfully without even scratching the crystal surface. Due to material characteristics (e.g. permeability) and the relatively low velocities that are used, the conveying cycle can be stopped and restarted at any time. Due to the high volumetric concentration of product inside the pipeline, reasonable conveying rates still can be obtained despite the relatively low velocities that are used for transport. There is very little inter-particle movement in the full-bore moving slugs and hence, segregation effects are also avoided (even around bends). This aspect was confirmed in two cases studies, where milled/mixed grains (with particles

A wide range of models to achieve 7 bar(g) pressure and temperatures o to 480 C.

Valve Open

Some Users: Sunstate Cement BHP Billiton Adelaide Brighton Cockburn Cement Qld Magnesia Zinifex Holcim (NZ)

An all stainless steel valve

A heavy duty diverter valve

The professionals in powder handling...

KOCKUMS BULK SYSTEMS PTY. LTD.

Head Office VIC - Tel: (03) 9457 8240

www.kockumsbulk.com.au

DomeValve7

Australian Bulk Handling Review: May/June 2011

53

FOOD, POWDER, PNEUMATICS

of different size and density) and muesli (with rolled oats, sugar, coconut, sultanas, and etcetera) were conveyed successfully in low-velocity slug-flow.

Single-slug conveying
This dense-phase mode involves the transportation of a limited batch of material per conveying cycle, Figure 7. A detailed description of this method of transport together with typical performance results has been presented by Wypych and Arnold [8]. It can be used to transport granular materials (e.g. crushed coal, sand, grains, diamond ore aggregate, petroleum coke, food products, bone char) over relatively short distances (e.g. up to 200 m). Note: the materials suited to LVSF also can be conveyed successfully in single-slug mode, but this would result in inefficient conveying performance. Single-slug conveying is no longer considered as the brute-force technology of pneumatic conveying. In fact, the following advantages now are realized. Average conveying velocities are relatively low (e.g. 3 to 6 m/s). In dilute-phase, the same material may need to be transported at 20 to 40 m/s, depending on the size and density of the particles. Consequently, system erosion (e.g. pipe, bends) is minimised. For a large range of materials, the only alternative is dilutephase producing high rates of erosion and product degradation. That is, the other modes of dense-phase are not possible.

Figure 4. Low velocity slug ow (LVSF).

Low-velocity plug-flow
At first glance, as indicated in Figure 5, this mode of flow [4] appears similar to LVSF. However, the main differences are that LVPF does not produce a stationary layer of material and also is suited to more cohesive or sticky powders, such as fullcream milk powder, drinking chocolate and cocoa powder. Usually, a plug-forming method or device is employed at the feeder (e.g. blow tank, rotary valve) to ensure stable plugs are generated along the pipeline. The advantages and features of this mode of dense-phase are similar to those listed previously for LVSF.

Figure 5. Low velocity plug ow (LVPF).

Figure 7. Single-slug conveying.

Bypass conveying
A relatively unique range of gritty bulk materials (e.g. alumina, poly powder, fine sand, coarse fly ash) are troublesome in any of the above modes of dense-phase and can cause severe plugging, pipe vibrations and/or pressure surges in conventional pipeline systems. These bulk materials usually are located in the Group B category shown in Figure 1. Although these materials usually display good fluidisation behavior, they also de-aerate quite quickly (especially compared with the powders suited to FDP) and generate high friction forces when allowed to build up inside the pipeline. Hence, it is usually necessary to employ dilute-phase for such materials and also purge the pipeline prior to any shutdown operation. However, by employing specially designed bypass technology, it is still possible to convey such materials in dense-phase. Various types of bypass technology are available [7], such as multi-point injection, external bypass and internal bypass, as shown in Figure 6. The main concepts involved with this technology are controlling the length of material build-up along the pipeline and preventing the conveying air from being forced through this material. Blow tanks are usually employed for such bypass conveying systems.

Extrusion flow
Occasionally, it may be beneficial to maintain the total conveying pipeline full of material and produce an extrusion mode of flow, Figure 8. Usually, specially designed blow tank feeders are employed for this purpose. Some successful applications of this technology include the extrusion flow of: Meat lumps for canned dog food, where the product basically is conveyed in the form of a long sausage along the pipeline; Chopped fish chunks and gravy, as well as whole fish pieces and gravy, for canned cat food; Artificially formed meat lumps and gravy for canned pet food. Other possible applications include the transportation of softened grains, vegetables, etcetera for food processing and canning operations. It is important to emphasise that: The dilute-phase option would cause excessive damage to such products; These types of material are not suited to most of the other dense-phase options. The single-slug mode of conveying could be used for such materials, but would be relatively inefficient in terms of conveying capacity and maintaining a constant product velocity along the pipeline (especially if the length and/or diameter of pipeline are significant).  Mechanical pumps can be used for these applications but may cause excessive damage to the particles a properly designed blow tank feeder is preferred.

Air-assisted gravity conveying

Air-assisted gravity conveying [9] is a dense-phase mode of pneumatic conveying. In fact, it is actually one of the most efficient modes of dense-phase due to its relatively high solids loadings, low conveying velocities and low specific air power requirements. For example, a Roots-type blower or even a centrifugal fan is only required, as opposed to a compressor that quite often is selected for the other modes of dense-phase. The coarse end of Group A and the

Figure 6. (At top) internal bypass and (below) external bypass.

54

Australian Bulk Handling Review: May/June 2011

FOOD, POWDER, PNEUMATICS

Figure 8. Extrusion ow.

fine end of Group B materials should be good candidates for this mode of pneumatic conveying. Conveying capacities as high as 1000 tonnes per hour over 300 m have been achieved with this mode of dense-phase.

Conclusions
Dilute-phase systems are quite common in industry but in many instances can produce a wide range of unique problems, such as wear, product damage, segregation and relatively high power consumption. Different modes of dense-phase (non-suspension flow) have been developed mainly to eliminate/minimise these problems and hence, expand the future potential of pneumatic conveying. Due to the product being the dominant phase in densephase conveying, test work and experience usually are necessary to confirm dense-phase suitability, accurate operating conditions and product quality. The dense-phase classification diagram is useful in providing an initial indicator of dense-phase suitability.

References
1. G. Dixon, Plastics Pneumatic Conveying and Bulk Storage, Chapter 2. Applied Science Publishers, London, 1981. 2. N.J. Mainwaring and A.R. Reed, Bulk Solids Handling, Vol. 7, No. 3, 1987, pp. 415-425. 3. O.C. Kennedy, P.W. Wypych and P.C. Arnold, The effect of

blow tank air injection on pneumatic conveying performance, Pneumatech 3, Jersey, Channel Islands, U.K., 1987. 4. P.W. Wypych and G. Hauser, Design considerations for lowvelocity conveying systems & pipelines. Pneumatech 4, Glasgow, Scotland, 1990. 5. P.W. Wypych, P.C. Arnold and W.R. Armitage, Developing new methods for the pneumatic transport of bulk solids through pipelines, Chemeca, Sydney, 1988. 6. R. Pan, B. Mi and P.W. Wypych, Pneumatic conveying characteristics of fine & granular bulk solids, KONA Powder and Particle, No. 12, 1994, pp. 77-85. 7. J. Klintworth and R.D. Marcus, A review of low-velocity pneumatic conveying systems, Bulk Solids Handling, Vol. 5, No. 4, 1985, pp. 747-753. 8. P.W. Wypych and P.C. Arnold, Plug-phase pneumatic transportation of bulk solids and the importance of blow tank air injection, Powder Handling and Processing, Vol. 1, No. 3, 1989, pp. 271-275. 9. S.J. Ashenden, A.N. Pittman and M.S.A. Bradley, An economic assessment of air assisted gravity conveying as an alternative to pneumatic conveying. 5th Int. Conf. on Bulk Materials Storage, Handling and Transportation, Newcastle, Australia, 1995.
Contact: Peter Wypych, email wypych@uow.edu.au