SIMPLIFIED

PNEUMATIC
CONVEYING
DESIGN GUIDE

Aman Kapur
Class XII-A
Delhi Public School, Mathura Road,
New Delhi
 ABSTRACT

I discovered my passion for pneumatic conveying when I was just about seven or
eight years old. I used to see my mother vacuum the whole house and always
wondered how does it actually work and where does all the dust vanish once it got
into the storage compartment of the vacuum cleaning machine.

This interest evolved further during my visit to a local hospital to meet my

grandmother who was being treated for some illness. While settling bills I got the
opportunity to see a live tube conveying system and was fascinated by the way such
a complex technology was made to work in such a simple way. Bills, reports,
samples etc. from every department were being sent to the centralized bill
processing center and other departments at the click of a button.

My interest in the technology and my good luck helped me complete my internship at

New Logic Automation, a leading manufacturer of Pneumatic Conveying Systems in
India during the summer of 2016. I got an opportunity to learn about the design,
development, manufacturing, assembly, testing & installation of actual pneumatic
conveying systems for conveying sugar, flour, gram flour etc.

The design of Pneumatic Conveying Systems is a very complex exercise since it

involves a lot of variables including diverse material properties. I decided to work on
the same with an objective to come out with a Simplified Pneumatic Conveying
Design Guide.

I compiled this research paper under the mentorship of Mr. Sagar Mallah, Director,
New Logic Automation and shall always remain thankful to him for all his time &
guidance. This Simplified Pneumatic Conveying Design Guide has been compiled
with an objective to help any professional (having little or no knowledge about
Pneumatic Conveying) conclude on basic system design parameters.

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 PNEUMATIC CONVEYING DESIGN GUIDE

As per IS:8647-1977 Pneumatic Conveying is defined as the art of transporting dry

bulk materials through a pipeline by using either a negative or a positive pressure air
stream. The principal limiting factor in the use of pneumatic conveyors is usually the
material to be conveyed, Materials to be conveyed should be dry and relatively free-
flowing. Friable materials as a rule should not be conveyed pneumatically, except
when partial degradation of the material being conveyed is inconsequential to end
use of the material. Without booster stations, vacuum systems are practical up to
500 m in length and pressure systems up to 2 km or more.

The following are the main conveying systems:

a) Low Pressure System,

1) Positive pressure system,
2) Negative pressure system,
3) Combined negative-positive pressure system,

b) Medium Pressure System, and

c) High Pressure System,

Low Pressure System — Low pressure systems are ideal for in-plant use to convey
non-abrasive or mildly-abrasive dry pulverized materials. Air pressure used is
normally limited to 760 mmHg (1 atmosphere), and the air supply is provided by a
positive displacement lobe type of blower. Because of the low pressure, these
systems are restricted to a relatively short distance and small flow rate.

Positive pressure system is normally used for conveying material from one source
to several remotely located discharge points. A typical positive pressure system is
illustrated in Fig. 1

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Negative pressure system is normally used for conveying material from several
sources to one remotely located discharge point. A typical negative pressure system
is illustrated in Fig. 2.

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A combined negative-positive pressure system is generally used for conveying
materials from several sources to several discharge points. This type of system is
quite versatile and is commonly used for conveying materials from railway container
wagons and/or storage bins to different points of use. A typical negative-positive
pressure system is illustrated in Fig. 3.

Medium Pressure System - In medium pressure system, the material is first

compacted in a variable pitch screw before it is mixed with compressed air in the
mixing chamber of the screw type pump. This system thus requires a screw directly
coupled with motor in addition to a compressor for providing air at pressures ranging
between 760 to 2280 mmHg (1 to 3 atmospheres). Air pressure which can be used
in this system is limited because of the necessity of providing a seal between the
screw and the mixing chamber. This type of pump conveys continuously. A single
stage rotary compressor is generally connected directly with the screw type pump for
supplying the required compressed air.

High Pressure System - High pressure system uses dense stream conveying with
low ratio of air to material resulting in lowest particle degradation when handling
friable materials. Because of higher air pressure used, smaller pipelines can be used
in this system.

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High pressure conveying pumps are batch type units which use compressed air only
when conveying. These pumps are used for continuous, intermittent or batching
operations. In a continuous process operation, a surge hopper is provided above the
pump for collecting the material during the discharge cycle of the pump. A typical
high pressure system is illustrated in Fig. 4.

For high pressure conveying system a double stage compressor is normally used for
supplying compressed air at pressures ranging between 3040 to 5320 mmHg (4 to 7
atmospheres). Pumping being a batch operation, an air receiver is required for the
compressed air. The air receiver should be sized in such a way that full pressure in
the air receiver is recovered in the time the pump performs the filling and discharging
operation. The compressor delivers air continuously during the discharge cycle and
should be completed by the time the pump is filled again with material.

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Factors for Design and Use

The material to be conveyed should be known by all its characteristics including bulk
density, particle size and shape, temperature, susceptibility to moisture,
corrosiveness, nature of material, abrasiveness and moisture.

Bulk Density - The mass per unit volume should be known under three conditions,
namely, in poured condition, stored in bin and when under influence of aeration. The
material may enter the system in the poured state, but when it is discharged, it may
be in the aerated state, which means that more bulk is involved at the discharge than
at the entrance. Volumetric capacity, as well as flowability is vitally affected by this
phenomenon.

Particle Size - The particle size of material to be conveyed may be classified as

below:
Very fine - All passing 150 micron sieve [see IS:460-1962 Test sieves (revised)"]
Fine - All passing 1.00 mm sieve
Granular - All passing 12.5 mm sieve
Lumpy and irregular - More than 12 mm in any direction
Irregular materials are those that are fibrous, stringy, etc

Moisture Content - The moisture content of material should be known. The

conveying rate of material reduces with increase in moisture. For satisfactory
operation, free moisture should normally not exceed 1 percent by mass.

Corrosiveness - The pH (a symbol denoting acidity on alkalinity) value of material

should be known. This information is necessary for selecting the material of
construction for conveying equipment and also the type of cloth to be used in dust
collector. A highly corrosive material may require special materials of construction.

Explosive or Combustible Nature of Material - Even though pneumatic conveying

is amongst the safest material handling techniques, however in handling explosive or
combustible materials, precautions in the system must be taken. Some of these
materials may require inert gas to be used as conveying medium.

Abrasiveness - Abrasiveness may be classified as follows:

Class Abrasiveness
1 Non-abrasive
2 Slightly abrasive
3 Medium abrasive
4 Highly abrasive

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Materials having hardness above that of ’highly abrasive’ materials are mostly too
abrasive to be handled in pneumatic conveyors.

Duty Requirement - In conjunction with conveying rates, the severity of operation

should also be determined. The construction of pneumatic conveyor can be linked to
the degree of design and construction of speed reducer. Severity of operation can be
classified as follows:

Class Hours of Operation per Week

1 160
2 80
3 40
4 20

With the above classification, the degree of sturdiness to which the conveyor must
be constructed, can be determined. It will also tell the appurtenances necessary to
meet the requirements of the operation.

Elevation and Environmental Condition

a) Elevation of the installation In relation to sea level should be known. Difference in
air density is very pronounced in the operation of pneumatic conveyors and should
always be considered.
b) Environmental condition, that is, whether system is exposed to hazardous dusts
and gases or corrosive elements should be known.

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Design Procedure - Based on the factors mentioned above, the Tables 1, 2 and 3
may be used for determining the type of conveying to be used.

TABLE 1: SYSTEM TYPE ACCORDING TO PARTICLE SIZE

Particle Size Type Of System
Low Pressure
Medium High
Negative
Negative Positive Pressure Pressure
- Positive
Lumpy or Irregular X X X - -
Granular X X X - X
Fine X X - - X
Very Fine X X X X X

Note: X indicates suitability

TABLE 2: SYSTEM TYPE ACCORDING TO MATERIAL CHARACTERISTICS

Material Type Of System
Characteristic Low Pressure
Medium High
Negative
Negative Positive Pressure Pressure
- Positive
Non - Abrasive X X X X X

Abrasive, Slightly X X X X X

Abrasive, Medium * * - X X

Abrasive, High - - - X X

Hygroscopic X X - - -

Deliquescent * * * * *

Combustible X X X X -

Explosive X X X - -

Acid X X X X X

Alkaline X X X X X

Toxic - - - - -

Fragile X X - - -

Corrosive * * * * X

Thermoplastic X X - - -
Note: X indicates suitability. The asterisk mark (*) indicates that a pilot plant study will
be necessary to establish the suitability of the material for pneumatic conveying.

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 TABLE 3 SYSTEM TYPE ACCORDING TO MATERIAL
Material Type Of System
Low Pressure Medium High
Negative Positive Negative Pressure Pressure
-Positive
Alum X X - - -
Alumina, Floury X - X X -
Alumina, Sandy X - - X -
Aluminium Hydrate X - - X X
Aluminium Oxide - X - - -
Arsenic Oxide X - - - -
Asbestos Dust X - - - -
Barites - - - X -
Bauxite X - - X -
Best Pulp, Dried X - - - -
Bentonite X X X X X
Borax X X - X X
Calcium Carbonate X X X X -
Calcium Phosphate - - - X -
Carbon, Activated X X X X -
Carbon Black, Pelletized * * - - -
Catalysts, Petroleum X - - X -
Cellulose Acetate X X - - -
Cement, Portland - - - X X
Cement, Raw Materials - - - X -
Cereals X X - - -
Cerelose X X - - -
Caly, Kaolin X X - X -
Coal, Pulverized - - - X X
Cofee Beans X X - - X
Coke, Fines and Flour X X - - -
Corn Grits X X - - -
Cottonseed Meal X X - - -
Detergent Powders X X - X -
Diatomaceous Earth X X X X -
Dolomite - - - X X
Feed Ingredients X X - - -
Feeds, Soft X X - - -
Feldspar X - - X -
Fertilizers * * - * *
Flaxseed X X - - -
flint - - - X X
Flour, Wheat X X - - -
Fluorspar - - - X -
Fly Ash - - - X -
Fuller’s Earth X X - X -
Gluten Meal X X - - -
Grain, Whole X X - - -
Grain, Ground X X - - -
Graphite X X - - -
Gypsum X X - X -
Lime, Hydrated X X X X X

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Lime, Pebble X X - - -
Limestone, Pulverized - - - X -
Magnesium Oxide X X - X -
Malt, Brewers X X - - -
Milk, Dried X X - - -
Ores, Pulverized - - - X X
Petroleum Coke X X - - -
Phosphate Rock,
Pulverized - - - X X
Polyethylene X X X - -
Pyrites - - - X X
Resins X X X - -
Rice X X - - -
Rubber Pellets X X - - -
Salt X X - - -
Salt Cake X X - - -
Sawdust X X X - -
Seeds X X - - -
Semolins (Suji) X X - - -
Silica, Pulverized - - X - -
Soap Ingredients X X - * -
Soda Ash, Lights X X X - -
Soda Ash, Dense * * - - -
Sodium Carbonate X X - - -
Sodium Phosphates X X - X -
Sodium Sulphate X X - - -
Strach X X X X -
Sugar, Granulated X X - - X
Talc X X X X -
Titanium Dioxide * * - - -
Wood Chips - X - - -
Wood Flour X X - - -
Zinc Oxide X X - X -

Note: X indicates suitability. The asterisk mark (*) indicates that a pilot plant study will
be necessary to establish the suitability of the material for pneumatic conveying.

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Estimation of Pneumatic Conveying design parameters using Nomographs (for
preliminary design). This method provides conservative approximations for
conveyor size & power for a given product bulk density.

Step 1: Preliminary calculations are started with determination of equivalent length

of the system under consideration. The equivalent length is the sum of vertical and
horizontal distances along with allowance for all the pipe fittings used.

Allowance for most common pipe fittings are as under:

Long radius 90O elbow pipe: Equivalent length = 25ft ~7.6m
45O elbow pipe: Equivalent length = 15ft~4.6m

Step 2: Next find the air velocity needed to convey the solids. This can be found
using table for air velocity for various bulk densities, as under:

Bulk Density Air Velocity

3 3
lb/ft Kg/m Ft/min. m/min.
10 160 2900 884
15 240 3590 1094
20 320 4120 1256
25 400 4600 1402
30 480 5050 1539
35 560 5500 1676
40 640 5840 1780
45 720 6175 1882
50 800 6500 1981
55 880 6800 2072
60 960 7150 2179
65 1040 7450 2270
70 1120 7700 2347
75 1200 8000 2438
80 1280 8250 2515
85 1360 8500 2591
90 1440 8700 2652
95 1520 9000 2743
100 1600 9200 2804
105 1680 9450 2880
110 1760 9700 2957
115 1840 9900 3118
120 1920 10500 3200

Table: Air velocities needed to carry solids of various bulk densities.

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Step 3: Assume a pipe diameter and draw a straight line on Nomograph 1 between
the air velocity and the pipe-diameter scales. The same line when extended shall
intersect the air volume scale at some point.

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Step 4: Once we know the air volume we can now go to Nomograph 2 and draw a
straight line between air volume and system capacity under consideration. This line
shall cut & give corresponding value of solids ratio. Incase value of solids ratio
exceeds 15 repeat step 3 with a large diameter pipe.

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Step 5: Next go to Nomograph 3 and draw a line joining known value points of pipe
diameter & air volume. This shall give us value of design factor, or P100 ie the
pressure drop per 100ft (30.5m) (Point of intersection of center scale).

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Step 6: Go to Nomograph 4 and draw a line connecting known values of equipment
length of system & design factor. This line may be extended to intersect the pivot line
in the centre. Once we join this point on pivot line with point on solids ratio line, the
intersecting point gives value of system pressure loss. Incase system pressure loss
exceeds 10 PSI (70 kPa), repeat step 3, 4, 5 & 6 assuming a large pipe diameter.

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Step 7: Incase system pressure loss is ≤ 70 kPa, go to Nomograph 5 and draw a
straight line connecting corresponding values of system pressure and air volume.

Step 8: The point of intersection of the system pressure loss & air volume shall give
value of horsepower required.

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In short the various Nomographs provide the following critical information for
system design:

Nomograph 1.

Velocity - Pipe Diameter - Air Volume

(m/min) (mm) (m3/min)

Nomograph 2
Air Volume - Solids Ratio - System Capacity
(m3/min) (kg/hr)

Nomograph 3
Pipe Diameter - Design Factor - Air Volume
(mm) (m3/min)

Nomograph 4
Equivalent length - Design Factor & System Pressure Loss - Solids Ratio
(m) (kPa)

Nomograph 5
System Pressure Loss - Horsepower - Air Volume
(kPa) (Metric) (m3/min)

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Working Example:

Masala Conveying
Bulk Density: 450 kg/m3
System Capacity: 1200 kg/hr
Length of pipe (Horizontal + Vertical): 150 m
No of Bends: 12 Nos.

Calculations as per Nomographs:

1 Equivalent length of pipe = 150 m + ( . ) = 241.2 m

2 Air velocity needed to convey the solids from the table for bulk density of 450
kg/m3 = 1487 m/min = 24.8 m/sec
3 From Nomograph 1, assuming pipe diameter = 3” (76.2mm) air volume = 245
cfm = 416.43 m3/hr = 6.94 m3/min
4 From Nomograph 2, corresponding value of solids ratio = 2.7
5 From Nomograph 3, Design factor = 60
6 From Nomograph 4, System Pressure loss = 7 PSI ≈ 48 kPa
7 Horse Power from Nomograph 5 ≈ 11 HP

Calculations as per conventional formulas:

System capacity = 1200 kg/hr

Consider material to air ratio: 2.5:1
Consider conveying velocity of 25 m/sec
Quantity of air required = 1200/2.5 = 480 kg/hr
M3/hr = 83.14 X ( )X( ) = 411.6 m3/hr
.
Q = A x V i.e. =( ) x 25
d= 0.076 m = 76mm = 3” Pipe Diameter
System Pressure Loss, considering 1 PSI/100 ft = = 7.91 PSI = 8 PSI
Roots Blower required 411.6 m3/hr @ 7.91 PSI
Select Model Expo 1 (From Everest Blowers Standard Product Catalogue)
Q (FAD At Inlet Of Blower) = 411.6 m3/hr (242.158 CFM)
P (Differential Pressure across the blower) = 7.91 PSI
N (Blower Operating Speed) = 3420 rpm
BHP (Power Consumption) = 12.43 BHP
Recommended Motor = 15 HP/2 Pole

Calculations from Nomographs & conventional formulas yield similar results,

hence preliminary design calculations using nomographs may be considered
for design data & power consumption approximations.

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 Bibliography

1. Pneumatic Conveying Systems – Design, Selection and Troubleshooting with

Particular Reference to Pulverized Fuel Ash – David Mills & V.K. Agarwal
2. Pneumatic Conveying Of Solids – A theoretical and practical approach – R.D.
Marcus, L.S. Leung, G.E. Klinzing and F. Rizk
3. Pneumatic Conveying Design Guide – David Mills
4. Pneumatic Conveying – A concise treatment of the principles, methods and
applications of pneumatic conveyance of materials, with special reference to
the conveying and elevating of heavy solid materials for engineers, works
managers and students – Ernest George Phillips
5. IS : 8647 – 1977 (Reaffirmed 2006) – Design Criteria For Pneumatic
Conveying Systems
6. Flow assessment of powders in pneumatic conveying : a bench top
assessment – M.K. Desai – University of Wollogong
7. Pneumatic Conveying Systems – A. Bhatia – Continuing Education and
Development, Inc.
8. The Heart Of Pneumatic Conveying Systems – Positive Displacement Blower
Calculations – Roger E. Blanton
9. A View From India – Pneumatic Conveying Of Bulk Materials – G.D. Nigudkar
10. Material Conveying with Pneumatic and Vacuum Systems – Hank Van Ormer
11. Physical Properties and Conveying Characteristics of Corn and Barley Seeds
using suction type Pneumatic Conveying Systems – H. Ghafori, A. Hemmat,
A.M. Borghaee and S. Minaei
12. Design and Development of a Dense-Phase Suction Pneumatic System for
Conveying Granular Materials in Agriculture – Hasan Ghafori, Abbas
Hemmat, Ali Mohammad Borghaee, Saeid Minaei
13. Pneumatic Conveying Of Bulk Solids – P.W. Wypych – University Of
Wollongong
14. Perry’s Chemical Engineers’ Handbook – Robert H. Perry, Don W. Green,
James O. Moloney

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