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These phenomena are explored along with Materials for which the mean particle size is less
related topics such as: than, say, about 100 µm (termed a fine powder
in this paper) can also exhibit the following
· Steady flow phenomena in bins and hoppers additional flow problems:
· Air permeation systems
· Unsteady flow phenomena (e.g., settlement) · Flooding or uncontrolled flow which is often
· Fluidized handling of powders the result of a collapsing rathole in a funnel
flow bin
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Source: Royal, T. A. and Carson, J. W.: Fine Powder Flow Phenomena in Bins, Hoppers and Processing Vessels.
Presented at Bulk 2000: Bulk Material Handling Towards the Year 2000, London, 1991.
400 Business Park Drive Tyngsboro, MA 01879 • Tel: (978) 649-3300 • FAX: (978) 649-3399
Also: San Luis Obispo, CA • Toronto, Canada • Viña del Mar, Chile
www.jenike.com
· Limited discharge rate through a bin’s outlet solid, not a fluid. Thus when this fluidized
· Unsteady flow phenomena such as material reaches the outlet, it often flows
settlement as the powder is charged into a uncontrollably resulting in what is termed
bin flooding.
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· Particle entrainment in an air stream which Fine powders exhibit significant two-phase flow
can result in unusual segregation patterns effects due to the movement, however slight, of
depending on where particles drop out of interstitial gas as the powders compress or
suspension. expand during flow. The following is a
description of the three flow-rate dependent
As with larger particle materials, fine powders modes that can occur in a mass flow bin,
can exhibit significant levels of segregation as depending on the solids flow rate.
they discharge from a funnel flow bin. This is
the result of the segregation pattern, which 1. The first mode of flow is characterized by
develops as the bin is filled, combined with the the steady gravity flow of partially deaerated
first-in-last-out flow pattern of a funnel flow material controlled by a feeder. The limiting
bin. Unlike coarser particle material, however, steady-state condition occurs when
many fine powder segregation problems cannot compaction in the cylinder forces too much
be overcome by simply converting to a mass gas out through the material top surface.
flow pattern. This is particularly true of fine This causes a slight vacuum to form as the
powders that segregate by the fluidization material expands while flowing through the
mechanism. In fact, since materials discharge converging portion of the bin. The result is
from a mass flow bin in a first-in-first-out flow a gas counterflow through the bin outlet,
sequence, the effect of a vertical striation profile which forces the solids contact pressure to
can be much worse than experienced in a funnel drop to zero and limits the steady solids flow
flow bin. Fortunately there are ways that this rate.
can be minimized, e.g. by charging the material
into the bin in such a way that the larger and/or 2. The second mode occurs at flow rates
more dense particles are not driven down into somewhat greater than the limiting rate.
the bed of material. This mode of flow is characterized by an
erratic, partially fluidized powder
3. STEADY FLOW PHENOMENA IN discharging from the bin, which can be
MASS FLOW CONTAINERS controlled by some feeder arrangements. At
these flow rates, a steady rate from the bin
The maximum flow rate of a fine powder can best be achieved by the use of an air
through a bin outlet can be several orders of permeation system at an intermediate point
magnitude lower than that of a coarser particle in the bin to replace the lost gas.
material. The primary reason for this limitation
is the air pressure gradient that forms naturally 3. The third mode of flow occurs when the
at a bin outlet as air flows up into the hopper flow rate is too high to allow much, if any,
section. This pressure gradient acts upward, gas to escape from the material voids. In
counter to gravity, thus reducing the rate of this extreme, the material may be
material discharge. The magnitude of the completely fluidized and flood through the
pressure gradients is very low with coarser outlet unless the feeder can control fluidized
particle materials because they are more solids.
permeable. In other words, air can easily flow
through their voids without resulting in much of Testers are available to measure the
a pressure drop. permeability (3) and compressibility (4) of
powders and other bulk solids. From such tests
one can calculate critical, steady-state flow rates
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through various outlet sizes in mass flow bins.
With this information, an engineer can 35° along carbon steel walls in cylindrical
determine the need for changing the outlet size section
and/or installing an air permeation system to 20° along 304 2B surface finish stainless
increase the flow rate. Furthermore, one can steel walls in conical hopper section
determine the optimum number and location of
air permeation levels, and estimate the air flow · Minimum outlet diameter to prevent arching
requirements. in a mass flow bin: <75mm
The types of conditions which can occur are · Bulk density/consolidating pressure
best illustrated by means of an example. Using relationship:
a proprietary, two-phase flow computer program
(5) we have analyzed the bin shown in Fig. 1. ⎛ σ ⎞ β
For this analysis we have assumed that this mass γ = γ 0 ⎜ ⎟
flow bin is filled with a dry sludge powder ⎝ σ 0 ⎠
having the following flow properties:
where: σ0 = 0.62 kPa
· Wall friction angle: γ0 = 0.577 tonne/m3
€ β = 0.05
⎛ γ ⎞ −a
3050mm I.D. K = Ko ⎜⎜ ⎟⎟
⎝ γ o ⎠
3771mm
3.2 Effect of different levels of powder
20°
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Fig. 2: Interstitial air pressure vs. material level
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Flow rate: 7 tonne/hr to lower solids contact stresses at the outlet.
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This is because the material is compacted more
in the cylinder at high levels, the longer
cyl. height 6.1m
Z Global (meters)
half full, or quarter full of material. This is for A similar result is shown in Fig. 3 in which the
boundary conditions of atmospheric pressure at same 7 tonne per hour discharge rate is used
both the top of the bin as well as the outlet. with a full cylinder but now three different
Note that just above the outlet, an air pressure outlet diameters are shown: 457 mm, 304 mm,
gradient due to upward flow of air exists which and 203 mm. Note that as the outlet becomes
tends to reduce the average vertical solids smaller, the magnitude of the air pressure
contact stress in this region. The limit is when gradient near the outlet increases; therefore the
this solids contact stress goes to zero which solids contact stress decreases. In fact, a
indicates the formation of a free surface, i.e. an limiting rate will occur for the smallest opening
arch. size.
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Flow rate:12 tonne/hr
average vertical solids stress at outlet, kPa
0.4 2
average vertical 6
solids stress
0.3 0
no air permeation
Z Global (meters)
4
0.2 -2 gas in: 2.55 cu. m/hr
0.0 -6
0
-0.1 -8
critical rate
-2
7.5 tonne/hr.
-0.2 -10
0 10 20 30 40
-4
flow rate, tonne/hour -4 -2 0 2
Interstitial air pressure (kPa)
3.4 Effect of powder flow rate However, there is a limit to the amount of
vacuum that can be maintained in the standpipe.
The results of a number of runs are shown in
Fig. 4. Here we have assumed a full cylinder of The most effective way this flow rate limitation
material and a 305 mm diameter outlet. This could be overcome is through the introduction
figure vividly demonstrates the effect that flow of a small amount of air using an air permeation
rate has on both interstitial air pressure and system (7,8) as shown in Fig. 5. The location as
solids contact stress. Note that below 7.5 tonne well as the quantity of air must be closely
per hour, the bottom boundary condition of examined; otherwise too much or too little air
atmospheric gas pressure can be met. Above may be added which will cause either a flooding
this rate we have an unstable flow condition condition or will not be sufficient to achieve the
since the solids contact stress goes to zero. The desired flow rate. As shown in Fig. 5, the
only way that this boundary condition can be addition of 2.55 m3/hr or 3.4 m3/hr at the
satisfied is to have a vacuum condition existing transition results in stable flow.
at the outlet.
The other area of interest is when the flow rate
One way to correct this problem would be to is very high. In this case material does not have
increase the size of the outlet as shown in Fig. 3. time to deaerate in the bin and remains
However, there is a limit to how large the outlet fluidized. Handling fluidized materials is
can be and still be reasonable in terms of the discussed below.
size of a feeder, which might be used to control
the discharge rate, or the size of interfacing 4. UNSTEADY FLOW PHENOMENA
equipment.
4.1 Firing of an air blaster
Another way to correct this would be to use a
standpipe below the outlet but above the feeder. In addition to the steady flow phenomena
described above, fine powders can exhibit
various types of unsteady flow phenomena as
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well. For example, when an air blaster is fired powder behaves quite differently both in the
or a vibrator turned on, material flow is likely to amount of settlement as well as its duration.
be unsteady for some brief period, as previously The reason for this has to do with the inability
nonflowing material starts to flow. A similar of air and other gases to flow freely through the
phenomenon occurs with coarser bulk solids as voids of fine powders. Therefore, when a fine
well. The effects of this energy input, however, powder is compressed (such as when it is being
are often quite different with a fine powder, filled into a container), not only do the void
especially when an air blaster is fired into a bin. spaces shrink, but the gas pressure within the
With both a fine powder and a coarse bulk solid, voids increases. Thus, during filling, an upward
a solids stress wave propagates through the gas pressure gradient continually exists which
material. If the material is very compressible tends to support the fine powder and limit its
and/or frictional, the effect of the stress wave is compaction. At the end of the filling cycle, this
dissipated quickly. upward gas pressure gradient is still present and
gradually dissipates over time as the gas escapes
Another effect is an air pressure gradient through the top surface. Thus, the settlement of
imposed on the bulk solid because of the a fine powder takes place much more slowly
introduction of excess air. For a fine powder than that of a coarse bulk solid and, in general,
this pressure gradient can be several orders of the amount of settlement is much greater. In
magnitude higher than for a coarse bulk solid. fact, it is not unusual to find a fine powder
The magnitude of the air pressure gradient experience 300 mm or more of settlement which
imposed is approximately proportional to the occurs over several days or longer after the
square of the distance from the blaster. As a filling cycle has ended.
result, an air blaster is often more effective in
breaking arches that occur near its nozzle, but As an example of this phenomenon consider the
less effective in breaking arches that occur some bin shown in Figure 1 for storage of dry sludge
distance away. Detailed computer calculations powder having the same flow properties as
based on the flow properties of the material are previously given. The question is how fast the
necessary for determination of number, size, and bin can be filled and how soon it can be used
location of air blasters in a particular bin. (5) after filling without encountering flooding due
to the material being somewhat fluidized in the
4.2 Settlement bin. Figure 6 gives the results of calculations
for a fill rate of 91 tonne/hr. and 455 tonne/hr.
Another interesting unsteady phenomenon with As can be seen, the air pressure in the voids of
fine powders is that of settlement. (9) Nearly all the solids increases during filling and then
bulk solids settle as they are filled into a dissipates over time as the air escapes through
container because of the vertical compression of the top surface and settlement occurs. The
the material lower in the container as new pressure after filling is sufficient in both cases to
material is added on top of it. With coarse bulk cause problems with feeders not designed to
solids, the amount of settlement is usually quite handle material in a fluidized state. However, in
small, and as soon as filling is stopped, there is both cases this pressure is completely dissipated
little if any additional settlement. A fine after about 40 minutes.
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Fig. 6A: Settlement of material vs time
6500
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4. It is not always clear how much of the bin 3. Ensure that the design of the feeder is
volume needs to be fluidized. It is generally compatible with that of the bin so that the
best to fluidize the entire contents of the bin, full area of the outlet is live.
but this may be neither practical nor
necessary if the bin is relatively large. If 4. Whenever a pneumatic conveying line
only a portion of a bin is fluidized, one must terminates at a bin, arrange the interface
be concerned about the potential for a such that the material enters the bin
rathole forming in the deaerated material tangential to the cylinder wall. While this
outside of the fluidized volume. In addition, may result in some side-to-side segregation
void space must be provided for the material of particles, it will minimize any top-to-
to expand. bottom striations, which are difficult to
overcome.
5. Another concern is how long to leave on the
fluidizing air. This question is important not 5. Based on the permeability and
only during discharge, but more importantly, compressibility of the powder, calculate the
when there is no discharge taking place. critical, steady-state flow rate through the
Fine powders, which are cohesive when bin outlet. If possible, operate the feeder
deaerated, become very difficult to such that the discharge rate from the bin is
refluidize after they deaerate. If this is the always less than this critical rate.
case, intermittent fluidization during periods
of no discharge may be necessary. 6. If a higher discharge rate is needed, enlarge
the size of the outlet and feeder, lower the
6. SOLUTIONS TO FINE POWDER FLOW level of material in the bin, and/or use an air
PROBLEMS permeation system.
Fine powder flow problems can usually be 7. Place a standpipe between the outlet of a bin
minimized if not eliminated by using one or and the feeder to create a vacuum condition
more of the following techniques: at the outlet. This will result in somewhat
higher rates of material discharge.
1. Use bins designed for mass flow rather than
funnel flow. This will automatically 8. Beware of the settlement time of powders
eliminate problems of ratholing, limited live when placed in a bin. If sufficient time is
capacity, and the first-in-last-out flow not allowed for settlement, problems of
pattern, which often causes degradation of flooding through the outlet can occur
the powder being handled. In addition, mass because of entrapped gas.
flow designs minimize particle segregation
problems provided the segregation pattern 9. Use fluidized handling of powders if the
within the bin is of a side-to-side as opposed material characteristics and operational
to a top-to-bottom type. requirements allow it.
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(2) CARSON, J. W., T. A. ROYAL and D. J.
GOODWILL Understanding and
eliminating particle segregation problems.
Bulk Solids Handling, 1986, 6, 139-144.
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