Designing of atomized slip pneumatic conveying

plant in ceramic industry by a simulator and

experimental tests

Saccani C., Bianchini A., Pellegrini M., Simoni M.

Department of Industrial Engineering (DIN) – University of Bologna

Manufacturing cycle main phases

The question: is it possible to

substitute conveyor belts by a
pneumatic conveying?

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 Atomized slip conveying

CONVEYOR BELT BENEFITS:

• Reliability and management simplicity
• No product damage
• Low atomized slip humidity variation

CONVEYOR BELT DRAWBACKS:

• Powder dispersion in working
environment
• Higher investment and management cost
• Higher occupation of productive lay-out
• Product contamination

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 Atomized slip conveying
PNEUMATIC CONVEYING BENEFITS:
• Remove any worker healthiness problem
• Lower investment and management cost
• Free from constraints the lay-out design

PNEUMATIC CONVEYING DRAWBACKS:

• Product damage at high velocity
(if higher than 7 m/s)
• Product damage at high velocity gradient
(if higher than 8 s-1)
• Higher risk of atomized slip humidity
variation

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 TPSim Win simulator
TPSIM WIN INPUT: TPSIM WIN OUTPUT:
• Pipeline geometry • Solid velocity
• Width of calculation steps • Air velocity
• Features of the plant • Total pressure loss
• Features of solid-gas mixture • Voidage ratio
Fundamental fluid dynamic characteristics of solid
particles are defined by 3 parameters:
- Hydraulic diameter
- Straight friction coefficient
- Bend friction coefficient

WE NEED TO KNOW THESE 3

PARAMETERS!

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 Lay-out of experimental plant

The lenght of transport is around 72 m and it is characterized by:

- Vertical section: 4 m
- Long horizontal section (high velocity): 22 m
- Number of blends: 11 (5 at 90° and 6 at 45°)
- 8 differential pressure transmitters
- 12 temperature transmitters 6
 Characterization of atomized slip
The characterization of atomized slip is an iterative process aimed at determining the
three characteristic parameters of solid particles: hydraulic diameter, straight friction
coefficient, bend friction coefficient

Transport test on the

experimental plant Iterative process proceed until computational and
experimental pressure diagram are sufficiently similar

Simulation of the
First attempt transport test by
values TPSim Win

Comparing
computational and
experimental results

Revision of the three

values

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 Industrial plant design: pipeline diameter
 Atomized slip mass flow rate: 30 t/h
 Overall length of the line: 54,5 m

Three different configurations were simulated by TPSim Win and compared:

• The configuration with d=240 mm generates the lowest pressure loss

• In the configuration with d=215 mm the system is more stable and flexible: the plant
can work with different values of solid loading ratio in a smaller range of pressure
drop
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 Industrial plant design: solid loading ratio
TPSim Win is a very useful tool also in the choice of solid loading ratio

Low solid loading ratio: m/mmax= 0,68

• ∆p = 205 mbar
• maximum speed of solid > 7 m/s
• solid velocity ≈ air velocity (risk of transport
blockage)

High solid loading ratio: m/mmax= 0,93

• ∆p = 355 mbar
• maximum speed of solid < 7 m/s
• solid velocity < air velocity

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 Conclusions

 Ability to characterize any kind of bulk solid material, thanks to the

experimental plant

 Abilty to design an industrial plant for pneumatic conveying of atomized

slip in dense phase, using TPSim Win simulator:
• Ensure product integrity
• Avoid excessive drying or humidifying of the material
• Minimize total pressure loss

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