A correlation for particle velocities in pneumatic conveying

George E. Klinzing, Omar M. Basha

PII: S0032-5910(17)30035-9
DOI: doi:10.1016/j.powtec.2017.01.020
Reference: PTEC 12262

To appear in: Powder Technology

Received date: 8 June 2016

Revised date: 20 December 2016
Accepted date: 6 January 2017

Please cite this article as: George E. Klinzing, Omar M. Basha, A corre-
lation for particle velocities in pneumatic conveying, Powder Technology (2017),
doi:10.1016/j.powtec.2017.01.020

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A Correlation for Particle Velocities in Pneumatic Conveying

George E. Klinzing

Omar M. Basha

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Department of Chemical and Petroleum Engineering, University of Pittsburgh, Pittsburgh, PA

15261, USA

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Abstract

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The particle velocity data to develop a correlation for predicting the particle velocity as a

function of experimental parameters and physical properties of the solids were obtained from
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electrostatic signals generated in pneumatic conveying of solids through a non-conductive

section of piping in our laboratory. The cross-correlation of two signals was used as the
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measurement technique. Three different data sets under a wide spectrum of conditions were
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employed in the analysis. Comparison of the correlations developed was made with a recent
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correlation developed using data obtained by the use of high speed video camera on single
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particles. In comparing these correlations a single unifying correlation was elusive. The data
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obtained for the cross-correlations included data that was taken on a system operating up to 40

bars of pressure. This particle velocity data remained unique in the analysis.

Keywords: Particle velocities, pneumatic conveying, experimental, electrostatic measurements,

correlation
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1. Past Studies on Particle Velocities under Various Conditions

In exploring particle motion and velocities in pneumatic conveying Tashiro [1] was the first

researcher to show the rotation of 6 mm particles in 30 mm diameter tubes in a dense phase plug

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using a high speed video camera. The system had 4 to 5 particle in the cross-section at a time.

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Having a rolling component to the shear definitely would require a modification of the models

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that consider sliding frictional shear generated only.

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Looking at the particle motion numerically, Zhou and Fan [2] probed the lift forces due to

particle rotation, finding their results to agree with previous simulation results and correlations
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by Van der Hoef et al. [3]. The lift force was found to be significant relative to the drag force.

Particle motion can be observed in the saltation layer in pneumatic conveying. In this case
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particle rotations in a saltation layer were measured by Von Pokorny and Horender [4]. They
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found little evidence that particle rotation speeds depend on either their size or height above the
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deposited sand bed. These results show a clear bias toward positive rotations, with the
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proportions of negative rotations being around 16% within the range of 450 to 850 rev/s. The
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negative rotations come from the “splash” process interacting with the deposited layer.

Other researchers who measured the particle motion and rotation in particulate systems were Wu

and Co-workers [5-7]. These results were mostly applied to circulating fluidized bed risers. They

used two techniques to measure particle rotations. One technique involved cross-correlation of

images to obtain particle rotation with full automation, and the other was a manual method which

identified characteristics of two particles.

Particle motion and rotation were also explored by Zhou et al. [8] in experiments on saltation in a

wind tunnel. They also explored the Magnus and Saffman forces arising from particle rotations.
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Klein et al. [9] reported a novel experimental technique that simultaneously measures, in three

dimensions, the trajectories, rotation, and translation of finite-size inertial particles together with

the turbulent flow. The flow field is examined by tracking the temporal evolution of small

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fluorescent tracer particles. The inertial particles consist of a super-absorbent polymer, with an

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index and density matched with water, thus making them invisible. Tracer particles are inserted

into the polymer at various locations to enable tracking of the particles. This can be interpreted

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as an indication of a wake induced by the particle.

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A novel experimental method was developed by Mordant et al. [10] to measure the Lagrangian
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velocity of tracer particles in a turbulent flow, based on ultrasonic Doppler tracking. This method

yields a direct access to the velocity of a single particle at a turbulent Reynolds number with two
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decades of time resolution.

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Tomography is now a highly developed technology that has been applied to observe particle
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flows. Dyakowski et al. [11, 12] were one of the first to apply this to dense phase pneumatic
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conveying. Tomography permits several time dependent phenomena to be explored such as flow

instabilities and the internal structure of the flow field [13].

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2. High-Speed Video Experiments to Determine Particle Velocities

Many of the studies using high-speed video cameras were employed to observe the structure of

turbulence of the flow, with the particles acting as tracers. It appears that most investigators were

looking at dilute phase flow, with the aim of either improving the unit performance of specific

equipment, or to fundamentally investigate the fluid mechanics.

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In the area of drug delivery, Coker and Fricker [14] used high-speed videos to follow the

performance of the powdered drug. The high speed camera permitted them to capture dry-

powder motion and the air flow rates in the device needed to tailor the patients of different age

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and size. Tsutahara et al. [15] explored shear flow through narrow gaps where atomization takes

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place and measured the atomization droplets with a high-speed camera. Coates et al. [16, 17]

employed a spinning capsule for dispersing 6.8 micron particles and studied the particle flow

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using high speed photography. They used a Phantom v 4.0 CMOS video camera at 1000 frames/s

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seeing 2700-2800 rpm for the particles. The ANSYS CFX5.7 program was used to model the

particle behavior.
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Mack et al. [18] studied a small 3-D sliced hopper experimentally and computationally with the
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discrete element method (DEM). A high-speed camera was used to examine the flow behaviors.
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Agreement was seen between the experiments and computations. The side lengths of the

polyhedra were between 1.32 and 2.08 cm. A Phantom V 710 camera was used in the study at
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1000 fps.

Zimmerman et al. [19] used a particle that was 18 mm in diameter and made it neutrally buoyant
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by adjusting the liquid density. They used two Phantom V12 cameras at 90 degrees of each other

and a frame rate of 600 frames/sec. The researchers painted the particles to follow them in a

stirred tank arrangement. The main results of this work focused on the strong intermittency both

for the translational and the angular accelerations, and the coupling between the rotational and

translational degrees of freedom.

Son and Kihm [20] carried out experiments using copper-vapor laser illumination synchronized

with a high-speed camera at 250 fps. They employed a Phantom Model V3.0 high speed camera

synchronized with the laser pulses. The capture rate ranged from 1 to 576 fps at the full
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resolution. The system used is a hydrodynamic wave generation system. Eddies were clearly

visible, and the velocity fields were constructed by temporal post-processing.

Corwin [21] employed optical and PIV techniques to measure the surface flow. They used a

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rapidly rotated bottom surface and fixed-wall vessel. A Phantom V 7 camera was used and

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positioned directly above the experimental cell. The capture speed was 8150 frames/sec, with an

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exposure of 30 micro seconds, and a resolution of 608 × 600 pixels for a period of 1000 frames.

Monodispersed 5 mm diameter particles were studied along with 1 mm particles.

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Brewster and Saeder [22] have employed a non-radioactive tagging material on particles. Two
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detector cells are place at a fixed distance apart along the length of the transport line. The

detectors consist of photomultiplier tubes which measure the light signal emitted by the tagged
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particles. Using radioactive tracers Tallon and Davies [23-25] were able to determine the slip
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velocity between the particles and the air through different piping arrangements in pneumatic
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conveying. Axial dispersion was assessed which were greater than those seen in turbulent fluid
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mixing.

An application of multiple-pulse particle image velocimetry to the study of particle motion in a

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two-phase flow through a cylindrical tube bank was employed. From these trajectories particle

velocities as well as points of impact and angles of incidence and rebound for particles that

collide with the cylinder surfaces are determined [26-32].

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3. Analysis of Particle Velocities from Cross-Correlation Experiments and Single Particle

Velocities with a Fast Video

The particle velocity in pneumatic conveying is a challenging parameter to measure. Often times,

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average velocities are measured using a variety of techniques from cross-correlation of various

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signals, to capture of particles in a section of pipe, to using quick action valves to trap the solids

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flow. The analysis varies from simple and routine to tedious depending on the capture technique

being employed. Recently, Santo et al. [33] have begun to measure individual particle velocities

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using a high speed camera. Depending on the flow situations different results and findings have
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been obtained. Klinzing and his students over the years have used the cross-correlation of signals

for a various of flow condition and particle characteristics, Myler [26-30], Rohatgi [31, 32],
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Plasynski [34]. An attempt has been made to correlate the cross-correlation data of various
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experiments into a single format. Table 1 has a listing of the various solids and their properties as
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well as operating conditions of these experimental studies.

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Santo et al. [33] developed a unique technique to measure the individual particle velocities in

both the longitudinal and transverse directions to the flow using a high speed video camera and a
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Matlab algorithm for analysis of the data. Recently, Klinzing and his students [35] have

employed the analysis technique of Santo et al. [33] to measure individual particle velocities of

different polymer pellets including the polyolefin particles that have a high coefficient of

restitution. These polyolefin particles have yielded large energy losses in pneumatic conveying

due to the particle behaviors seen by high speed filming which include spinning, wall

interactions, and backwards motion of the particles in flow system. These behaviors have been

attributed to the higher energy losses in such conveying operations. The data obtained showed a

wide variation in the angle of restitution of the particles with the wall.
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The particle velocities determined by our studies were average particle velocities across the

cross-section of the pipe rather than individual particle velocities measured by the fast video

arrangement. The signals measured and cross-correlated came from electrostatic generation of

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the particle interacting with the pipe wall. As noted in Table 1, the humidity of the air flow, the

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inclination of the pipe and the pressure of the system were varied for glass beads, coal and

Plexiglas particles of different particle diameters. It will be noted that the experiments conducted

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at high pressure were unique in their behaviors. Figure 1 shows both the coil probes and the ring

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probes used in studies in our laboratory.
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We addressed all the data obtained for particle velocities under the various conditions of particle

properties and experimental test parameters listed in Table 1 and obtained a correlation which
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predicted the logarithm of the particle Reynolds number with a +/- 30% degree of correlation as
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seen in Figure 2. The correlation is represented using Equations (1) to (4). The average absolute

relative error (AARE) obtained using this correlation was 8.9%. Moreover, the correlation was
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also able to predict the particle velocities with an AARE of 24.47%, as shown in Figure 3.

௣ = 0.96 ∙  ஻∙ோ௘೒

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(1)

௧ ଴.ଷ
ି଴.ଷ ఘ೒
ඨఘ
 = 300  ଶ      


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(2)
100

 = 10ିହ  ln (3)

When we attempted to include the data of Plasynski [34] at higher pressures this correlation

failed and thus is not reported. Similarly we attempted to compare our results with those of

Santo et al. [33] again having considerable difficulties and large errors to blend the cross-
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correlation data and the single particle high speed video data. These attempts are not presented

in this discussion.

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4. Conclusions

Consolidating a large group of data from various experimenters in our laboratory we attempted

to determine a generalized correlation for the average particle velocities. A correlation was

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developed that gave a reasonable correlation for all the data expect that taken at high pressures.

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Further analysis is anticipated with the measurement of individual particle velocity using a fast

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video camera.

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5. Nomenclature
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A – Empirical Constant in Equation (1), defined in Equation (2)

B – Empirical Constant in Equation (1), defined in Equation (3)

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Ar – Archimedes Number
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d – Diameter of the particle

D – Diameter of the pipe

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g- Gravitational constant

Reg – Reynolds number based on the gas superficial velocity =

ߩ‫݁݌݅݌ܦ ݎ݅ܣܸ ݎ݅ܣ‬
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ߤ‫ݎ݅ܣ‬

Rep – Reynolds number based on particle diameter and velocity =

ߩ‫݈݁ܿ݅ݐݎܽ݌ܦ ݈݁ܿ݅ݐݎܽ݌ܸ ݎ݅ܣ‬
ߤ‫ݎ݅ܣ‬

Vg – Superficial velocity of the gas

Vp – Particle velocity

Vt - terminal velocity of the particle

Greek

ρp – Particle density
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ρg - Gas density

φ – Measure of the angle of inclination divided by 90o – dimensionless

η – Viscosity of the gas

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[4] M. Pokorny, S. Horender, Measurement of particle rotation in a saltation layer, Earth Surface
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International Mechanical Engineering Congress and Exposition, American Society of

Mechanical Engineers, 2008, pp. 49-53.
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mouthpiece length, Journal of pharmaceutical sciences, 93 (2004) 2863-2876.

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accelerations using an instrumented particle, Physica Scripta, 2013 (2013) 014063.
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particle image velocimetry, Experiments in fluids, 30 (2001) 537-550.
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[22] B.S. Brewster, J. Seader, Nonradioactive tagging method of measuring particle velocity in
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pneumatic transport, AIChE Journal, 26 (1980) 325-327.

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Measurement of Particulate Solids, 1998, pp. 10-17.

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Institute of Chemical Engineers, 1971-c2002., 1997, pp. 136-140.

[25] S.J. Tallon, C.E. Davies, The effect of pipeline location on acoustic measurement of gas–
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transport, Powder technology, 57 (1989) 51-57.
[27] C. Myler, A. Zaltash, G. Klinzing, Gas-solid transport in a 0.0508 m pipe at various
inclinations with and without electrostatics. I: Particle velocity and pressure drop, Journal of
powder and bulk solids technology, 10 (1986) 5-12.
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inclinations with and without electrostatics. II: Stability, Journal of powder and bulk solids
technology, 10 (1986) 13-17.
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[29] C.A. Myler, A. Zaltash, G. Klinzing, Gas-solid transport in a 0. 0508 m pipe at various
inclinations with and without electrostatics, Chemical/Petroleum Engineering Dept., Univ.
of Pittsburgh, Pittsburgh, PA 15261, 1985.
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DTIC Document, 1987.

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[31] G. Klinzing, N. Rohatgi, C. Myler, S. Dhodapkar, A. Zaltash, M. Mathur, Pneumatic
transport of solids in an inclined geometry, The Canadian Journal of Chemical Engineering,

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67 (1989) 237-244.

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[32] G. Klinzing, N. Rohatgi, A. Zaltash, C. Myler, Pneumatic transport—a review (generalized
phase diagram approach to pneumatic transport), Powder technology, 51 (1987) 135-149.
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[34] S.I. Plasynski, G.E. Klinzing, M.P. Mathur, High-pressure vertical pneumatic transport
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[35] G.E. Klinzing, Undergraduate student reports by Capelli, J. and Amy, B., University of
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Field Probes

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Coil Probes-antennae

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Figure 1- Probes used to cross-correlate the electrostatic signals generated in pneumatic flow
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3.5
+30%

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3
Predicted log(Rep)

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2.5

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2 -30%

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1.5

1
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0.5
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0 0.5 1.5 1 2 2.5 3 3.5 4

Experimental log(Rep)
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Myler et al. (1985) [29] - Glass, φ = 0

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Myler et al. (1985) [29] - Plexiglass, φ = 0

Myler et al. (1985) [29] - Glass, , φ = 45
Myler et al. (1985) [29] - Glass, φ = 90
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Myler et al. (1986) [28] - Glass & Plexiglass, φ = 0 - 90 , (Electrostatic)

Klinzing et al. (1989) [31] - Coal, φ = 0 - 90
Plasynski et al. (1994) [28] - Coal & Glass, φ = 0
Figure 2- Plot of Predicted vs Experimental log(Rep) of Cross-Correlation Data
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18

16
Predicted Particle Velocity (m/s) +30%
14

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12

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10
-30%

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0
0 2 4 6 8 10 12 14 16 18
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Experimental Particle Velocity (m/s)

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Myler et al. (1985) [29] - Glass, φ = 0

Myler et al. (1985) [29] - Plexiglass, φ = 0
Myler et al. (1985) [29] - Glass, φ = 45
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Myler et al. (1985) [29] - Glass, φ = 90

Myler et al. (1986) [28] - Glass & Plexiglass, φ = 0 - 90 , (Electrostatic)
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Figure 3- Plot of Predicted vs Experimental Particle Velocity of Cross-Correlation Data

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3.5
+30%
3

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Predicted log(Rep)

2.5

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2 -30%

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1.5

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0.5

0
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0 0.5 1 1.5 2 2.5 3 3.5 4

Experimental log(Rep)
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Myler et al. (1985) [29] - Glass, Angle of Inclination = 0

Myler et al. (1985) [29] - Plexiglass, Angle of Inclination = 0
Myler et al. (1985) [29] - Glass, Angle of Inclination = 45
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Myler et al. (1985) [29] - Glass, Angle of Inclination = 90

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Myler et al. (1986) [28] - Glass and Plexiglass, Angles of Inclination = 0 - 90 , With Electrostatic
Klinzing et al. (1989) [31] - Coal, Angles of Inclination = 0 - 90
Plasynski et al. (1994) [28] - Coal and Glass, Angle of Inclination = 0
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Graphical abstract
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Highlights

1. The particle velocity data by cross-correlation were analyzed.

2. A correlation was developed that was for a wide variety of conditions.
3. This logarithmic correlation showed +/- 30% for the data considered.

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4. High pressure data was found not to follow the correlation developed.

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Table 1- Experimental Conditions for Cross-Correlation Studies

Pipe
Particle Size Pressure
Researcher Material Inclination Diameter Humidity

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(microns) (atm)
(m)
Glass
79, 125, 450 Vertical 0.0508 High and low Ambient
Myler [26- beads

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30] Horizontal
Plexiglas 128 0.0508 High and low Ambient
45 degree

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Vertical
Rohatgi Horizontal
Coal 55, 61, 124 0.0095 High Ambient
[31, 32] 30 degree

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60 degree
Coal 89 Vertical 0.026 Low
Ambient,
Plasynski (Ambient)
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[34] Glass beads 545 Vertical 0.51 (High Low
41.8
Pressure)
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