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INTRODUCTION
1.1Pneumatic conveying system
A pneumatic conveying system is a process by which bulk materials of almost any type are transferred or injected using a gas flow as the conveying medium from one or more sources to one or more destinations. Air is the most commonly used gas, but may not be selected for use with reactive materials and/or where there is a threat of dust explosions. A well designed pneumatic conveying system is often a more practical and economical method of transporting materials from one point to another than alternative mechanical systems (belt conveyors, screw conveyors, vibrating conveyors, drag conveyors and other methodologies) because of three key reasons: 1. First, pneumatic systems are relatively economical to install and operate 2. Second, pneumatic systems are totally enclosed and if required can operate entirely without moving parts coming into contact with the conveyed material. Being enclosed these are relatively clean, more environmentally acceptable and simple to maintain 3. Third, they are flexible in terms of rerouting and expansion. A pneumatic system can convey a product at any place a pipe line can run.
Pneumatic tubes used for transporting physical objects have a long history. The basic principles of pneumatics were stated by the Greek Hero of Alexandria before 100 BC [2]._On the other hand, the concept of conveying materials in pipeline systems also goes back to pre-historical age with some evidence of that the Romans used lead pipes for water supply and sewage disposal and the Chinese used bamboo to convey natural gas [3]. Although there had been various applications of pneumatic conveying earlier in many civilisations, the first documented pipeline conveying of solid particles was recorded in 1847 [4]. In Peugeot plant in France, the pneumatic conveying principle was used for the exhaust of dust from number of grindstones with the help of an exhaust fan. In 1864, an experimental pneumatic railway was built at Crystal palace with the intention of using the principle of vacuum applied to a railway tunnel to move a carriage, which had been fitted with a sealing diaphragm [5]. Another application of vacuum pneumatic transport was reported in ship unloading plant in London in 1890. A number of applications of operational principles of pneumatic transport could be seen in last decade of the 19th century at some places in Europe [4, 6] and especially, in the grain transport and handling field [5]. During this time period, general break through events in the evolution of pneumatic conveying systems such as use of negative pressure systems, invention of auxiliary equipments like rotary feeders, screw feeders, valves, etc., could be emphasised. During early decades of 20th century, it was common practice to use pneumatic conveying to transport grain [6]. Ref. [7] presented a chronology of pneumatic pipeline highlighting the innovatory individuals and companies, especially during early and middle era of 20th century. During the First World War, the development of pneumatic conveying was influenced by the high demand for foods, labour scarceness and risks of explosion. Since the pneumatic conveying systems were seen as the answer for those situations, a huge evolution of pneumatic transport was achieved during that time period. In the post-war period, pneumatic conveying systems were used for more industrial related materials like coal and cement. Beginning of theoretical approaches, invention of blowers, introduction of batch conveying blow tanks, etc., were among the highlighted milestones of the evolution of pneumatic transport systems during this era. Nowadays, pneumatic transport is a popular technique in particulate material handling field. It has been reported that some plants have transport distance of more than 40 km [8], material flow rate of few hundreds tons per hour and solid loading ratio (the mass flow rate ratio between solid and air ) of more than 500.
The orientation of the pipe makes a considerable effect to the flow patterns and conveying regimes, because of the influence of gravity force. Consequently, the cross-sectional diagrams are totally different for the vertical pipe sections from those of horizontal sections, although the general appearance of the mass flow rate contours are similar to each other. Figure 1-9 shows a typical phase diagram of a vertical pipe section, together with various cross-sectional diagrams showing the representative state of possible flow patterns at different flow situations.
2.2 Limitations
A relatively high air volume and velocity is required: so power requirements are also high. Higher air velocities will have the following other disadvantages: 1. The wear caused by the product on the pipe is considerably higher therefore this process is NOT suitable for materials which are susceptible to degradation and/or are abrasive in nature. 2. The products can get deformed or crushed therefore this process is NOT recommended for friable products
pneumatic rigs were used to compare them with each other. To cover those models, in the first part of this section, the conveying line is virtually divided into different sections, such as; a) feeding devices and entry section b) horizontal pipes c) pipe bends d) vertical sections, etc, where distinguishably different flow behaviour could be expected and the available theoretical descriptions relevant to these sections are discussed. It starts from the beginning of the conveying line and proceeds along the pipeline upto the end of transport line, by considering different sections and components. After that, the models, which explain the whole conveying line as aglobal one, are reviewed. Finally, the available scale-up procedures based on mathematical descriptions are also discussed in details. In addition to the mathematical and stochastic models, numerical computational methods have also been extensively used to describe the flow phenomenon of gassolids flow during the last decade. Under this literature survey, computational fluid dynamics models were also discussed.
may prevent the build-up of enough lift. Marcus et al. found that the discharge performance from a blow tank can be significantly influenced by the method of introducing air into the blow tank. With some products, by adding air to the top of the material, the highest rate was obtained. Other materials performed better when the air was introduced into the material via a nozzle located at the discharge pipe. Jones et al.compared the performance differences between top and bottom discharge blow tanks and found that there is no significant difference in the pressure,and thus the energy, required to convey a product through a pipeline at a given mass flow rate and loading condition in both configurations.
among the advantages of dense phase conveying. But, unfortunately, there are number of uncertainties, design difficulties and unforeseen pipe blockages, most of which arise from the fact that the precise mechanism by which the particles are conveyed has never been well understood. Among the vast number of literatures on dense phase conveying, few of them, which show a comparatively good agreement with the experimental data and are well documented, has been selected for this study. In this section, the models o horizontal dense phase conveying are considered and the vertical sections and the velocity concepts will be discussed in their respective sections The work done by Konrad et al. could be seen as one of the earliest and frequently cited publication by fellow reseachers. They developed a theoretical model to predict the pipeline pressure drop in horizontal dense phase plug conveying. They describe the flow mechanism with following phenomenal concepts. The material is conveyed only in the plugs and in the regions just in front and behind them. There is a layer of stationary material between the plugs. The flow pattern is similar to that of a gas-liquid system. 4. MODE OF CONVEYING Much confusion exists over how materials are conveyed through a pipeline and to the terminology given to the mode of flow. First it must be recognized that materials can either be conveyed in batches through a pipeline, or they can be conveyed on a continuous basis, 24 h a day if necessary. In batch conveying the material may be conveyed as a single plug if the batch size is relatively small. For continuous conveying, and batch conveying if the batch size is large, two modes of conveying are recognized. If the material is conveyed in suspension in the air through the pipeline it is referred to as dilute phase conveying. If the material is conveyed at low velocity in a non-suspension mode, through all or part of the pipeline, it is referred to as dense phase conveying.
sized, since these allow the air to pass readily through the interstices between the particles. Pelletized materials and seeds are ideal materials for this type of flow. 4.3Conveying air velocity For dilute phase conveying a relatively high conveying air velocity must be maintained .This is typically in the region of 12 m/s for a fine powder, to 16 m/s for a fine granular material, and beyond for larger particles and higher density materials. For dense phase conveying, air velocities can be down to 3 m/s, and lower in certain circumstances. This applies to both moving bed and plug type dense phase flows. These values of air velocity are all conveying line inlet air velocity values. Air is compressible and so as the material is conveyed along the length of a pipeline the pressure will decrease and the volumetric flow rate will increase.
5. MATERIAL VELOCITY
In dilute phase conveying, with particles in suspension in the air, the mechanism of conveying is one of drag force. The velocity of the particles, therefore, will be lower than that of the conveying air. It is a difficult and complex process to measure material velocity, and apart from research purposes, particle velocity is rarely measured. It is generally only the velocity of the air that is ever referred to in pneumatic conveying. 1. In a horizontal pipeline the velocity of the particles will typically be about 80% of that of the air. This is usually expressed in terms of a slip ratio, defined in terms of the velocity of the particles divided by the velocity of the air transporting the particles, and in this case it would be 0.8. 2. In vertically upward flow in a pipeline a typical value of the slip ratio will be about 0.7. These values relate to steady flow conditions in pipelines remote from the point at which the material is fed into the pipeline, bends in the pipeline and other possible flow disturbances. At the point at which the material is fed into the pipeline, the material will
For dilute phase conveying, maximum values of solids loading ratio that can be achieved are typically of the order of about 15. This value can be a little higher if the conveying distance is short, if the conveying line pressure drop is high, or if a low value of conveying air velocity can be employed. If the air pressure is low or if the pipeline is very long, then the value of solids loading ratio will be very much lower. For moving bed flows, solids loading ratios need to be a minimum of about 20 before conveying at a velocity lower than that required for dilute phase can be achieved. Solids loading ratios, however, of well over 100 are quite common. The data presented in this Design Guide on materials such as cement and fine fly ash, solids loading ratios in excess of 100 are reported, whether for horizontal or vertical flow. In conveying barytes vertically up the author has achieved a solids loading ratio of about 800 with a short pipeline. Conveying at very low velocity is necessary in order to achieve very high values of solids loading ratio in moving bed flow. This is because air flow rate is directly proportional to air velocity and air flow rate is on the bottom line. For plug type flow the use of solids loading ratio is not as appropriate, for the numbers do not have the same significance. Since the materials have to be very permeable, air permeates readily through the plugs. Maximum values of solids loading ratio, therefore, are only of the order of about 30, even with high values of conveying line pressure drop. If a material is conveyed at a solids loading ratio of 10, for example, it could be conveyed in dilute phase or dense phase. It would only be with the value of the conveying line inlet air velocity that the mode of flow could be determined.
6. RECENT DEVELOPMENTS
Although pneumatic conveying systems have numerous advantages over alternative mechanical conveying systems for the transport of materials, they do have drawbacks, particularly for materials that can only be conveyed in dilute phase. Particle degradation and erosive wear of pipeline bends are particular examples. Due to the high conveyin air velocity required, energy requirements are also high. In recent years there have been many developments of pneumatic conveying systems aimed at increasing their capability for conveying a wider range of materials in dense phase, and hence at low velocity. This has generally been achieved by conditioning the material at the feed point into the pipeline, or by providing a parallel line along the length of the pipeline to artificially create either permeability or air retention in the material.
Logic diagrams are presented for pneumatic conveying system design based on both mathematical models and test data. They are presented for the purpose of checking the capability of an existing system, as well as for the design of a new system. Some of the available equations and bench scale test correlations are evaluated and the more useful relationships are included to show how they can be used in conjunction with the logic diagrams.
7. SYSTEM OPERATION
This group of chapters is concerned with the operation of pneumatic conveying systems. Pipeline blockages, do unfortunately occur, but mainly due to poor design and maintenance and so this topic is given particular consideration. Means of improving the performance of an existing system are considered, which may be to reduce power requirements or to increase material flow rate. Many problems relate to the properties of the conveyed material, and not least of these are abrasive and friable materials an so one chapter is devoted to erosive wear and another to particle degradation. Moisture and condensation is similarly considered, as well as the issues relating to health and safety. Due to the complexities of system design, a lack of reliable design data, and a poor understanding of compressible flow, many pneumatic conveying systems pose numerous problems on commissioning. Pipeline blockage and conveying systems not capable of achieving the desired material flow rate are common problems. A detailed analysis of all possible causes is given and a checklist is provided for quick reference.
Potential users are often reluctant to install a pneumatic conveying system because they anticipate operating problems. Pneumatic conveyors can experience problems but the situation has been improved by the introduction of new types of conveyor and by the modification of existing systems, based on a better understanding of the mechanisms of conveying. This often results in a choice of solutions to a particular problem. The most common problems affecting pneumatic conveyors are examined, such as static electricity and material deposition. Some practical solutions to these problems are presented.
One of the most easiest method of convey the material from one place to other place is by using the horizontal pipe. This is the simplest method because of less pressure drop.
contingencies. An unnecessarily high conveying air velocity should not be employed as this will have an adverse effect on system performance, in terms of air pressure needed, and hence power requirements. For guidance purposes an approximate value of the pick-up or conveying line inlet air velocity to be employed for pneumatic conveying and so this incorporates the 20 per cent margin. For convenience, materials here are classified as being either floury or sandy. Floury materials are those that are very fine and have good air retention properties and will convey in dense phase in a moving bed type of flow. Sandy materials are typically fine granular materials that have neither air retention nor permeability and so will only convey in dilute phase suspension flow in a conventional pneumatic conveying system. These curves simply represent average materials .
9.CONTROLLING SYSTEM
9.1 Air supply control
With some machines it may not be possible to obtain independent control of flow rate and pressure, and with others it may prove difficult to achieve the potential energy saving. If a general high pressure air supply service is available, choked flow nozzles can be used most effectively to control the air flow rate at a given pressure, but the energy saving will depend upon the air supply system employed. The use of choked flow nozzles . With some pneumatic conveying systems operating with their own self-contained air supply, others using a general service . A comparison of the potential performance and air requirements of a system required to convey different materials over a distance of 200 m. such a wide range of air movers available, each with it own operating characteristics, it is quite impossible to offer general recommendations on system control in this respect. High, low and negative pressure systems all require separate treatment, with control of the air mover being necessary in some cases, and control by means of the air supply line being possible in other cases. The important points to bear in mind are that different materials are quite likely to have different volumetric air flow and power requirements, and that the air supply should be capable of meeting both the maximum demand and being conveniently controlled to lower demand levels.
11.VENTURI FEEDER
COMPONENTS OF PROJECT
Centrifugal Blower
Conveying pipes
Throat
Differential Manometer
Capable of measuring pressure Difference between conveying pipe to throat. Water and Air Mixture is Use.
HOPPER
No of Hopper -: One Shape-: Conical Use-: Feed the Powder Material From Hopper to Venturi
SOCKET
No of Socket-: 2 Material- : Mild steel Use- : Made Connection between Venturi & Conveying Pipes .
Valve
Base
Air Blower
Pneumatic Pipes Venturi Manometer all Placed on the Base Which made of Ply Wood..
Threading
Threading is done on the Lathe Machine Threading is use to couple venturi to main conveying line. Pitch of thread:- 3mm Thread:-V thread
Processing of venturi
Sheet metal Cutting for manufacturing of venturi's Convergent and Divergent Part.
Drawing on sheet metal Cut Sheet according to Drawing Bent Sheet into Conical Sh Now weld to form convergent and divergent shape.
Drawing
1. Length of converge part:-55mm 2. Diameter of throat:-20mm 3. Length of throat:-45mm 4. Length of divergent part:-90 mm
2nd venturi detail:1. 2. 3. 4. Length of converge part:-90 mm Length of throat:-85mm Length of divergent part:-130 mm Diameter of throat:-25mm
3rd venturi detail:1. Length of converge part:-45 mm 2. Length of throat:-85 mm 3. Length of divergent part:-60 mm 4. Diameter of throat:-30mm
Drilling on Throat
Drilling on Throat to make a passage to inlet powder material. Another hole for pressure measurement by Manometer.
Gas welding used to join converging throat & diverging part of venturi.
Arc welding is used for joining the pipes Mild steel pipe is used for conveying the material.
All parts of Pneumatic pipes , Venturi joined with the help of Valve and Socket . final Shape Placed on the Bed.
VENTURI FEEDER
Since the basic problem with feeding positive pressure systems is that the air leakage arising from the adverse pressure gradient can interfere with the flow of the material into the pipeline, this situation can be improved, to a certain extent, by using venture feeders. These work on the principle of reducing the pipeline cross-sectional area in the region where the material is fed from the supply hopper, as shown in Figure 3.16. It will be seen that there are no moving parts with this type of feeding device, which has certain advantages with regard to wear problems. There are, however, no inherent means of flow control either, and so this has to be provided additionally. A consequence of the reduction in flow area is an increase in the entraining air velocity and a corresponding decrease in pressure in this region. With a correctly designed venturi the static pressure at the throat should be the same as that in the supply hopper which, for the majority of applications, is atmospheric pressure. This then encourages the material to flow more readily under gravity into the pipeline, since under these conditions there is no leakage of air in opposition to the material feed. In order to keep the throat at atmospheric pressure, and also of a practical size that will allow the passage of material, and for it to be readily conveyed, a relatively low limit has to be imposed on the air supply pressure. These feeders, therefore, are usually incorporated into systems that are required to convey free flowing materials at low flow rates over short distances.
Venturi feeder work on the principle of reducing the pipeline cross sectional area in the region where the material is fed from the supply hopper .
1st venturi detail:5. Length of converge part:-55mm 6. Diameter of throat:-20mm 7. Length of throat:-45mm 8. Length of divergent part:-90 mm
2nd venturi detail:5. 6. 7. 8. Length of converge part:-90 mm Length of throat:-85mm Length of divergent part:-130 mm Diameter of throat:-25mm
3rd venturi detail:5. Length of converge part:-45 mm 6. Length of throat:-85 mm 7. Length of divergent part:-60 mm 8. Diameter of throat:-30mm
Divergent cone has a total included angle lying between 5 to 15. Diameter of throat varies from 1/3 to of the pipe diameter(Generally times diameter of pipe). After this consideration we use Pythagoras theorem to calculate the length of converge part and diverge part.
Drawing on sheet metal Cut Sheet according to Drawing Bent Sheet into Conical Shape. Now weld to form convergent and divergent shap
Fabrication of venturi
Gas welding used to join converging throat & diverging part of venturi.
Venturi
Blower opening
Pressure at inlet
System 1
1 3/4
57 55.1
1.069 1.067
12.9 15.5
SYSTEM 01
1.08 1.068 1.06 1.049 1.04 1.069
1.02
1 0.993
0.98
0.96
0.94
SYSTEM 02
1.055
1.04
1.02
1.005 1 0.998 0.992 0.98 Inlet Pressure Throat Pressure
0.96
0.94
1/2 Opening
3/4 Opening
Full Opening
SYSTEM 03
0.98
0.96
Applications: The applications of pneumatic conveying systems can be seen in many industrial sectors. A list of industrial fields where it has extensively been used is given below Chemical process industry Pharmaceutical industry Mining industry Agricultural industry Mineral industry Food processing industry
CONCLUSION
The main objective of the work was to use venturi-feeding system for the pull push type pneumatic conveying system, thereby developing the suction effect at the venturi throat. This will help to create the automatic suction of the material into the system through the inlet provided at the throat. This system then can be operated by the single person and has numerous practical applications for the automatic transportation of powdered and granular material.
Filter Receivers
Filter receivers separate solids from the air stream using filter media and gravity, and are generally specified when materials contain smaller particles that are prone to dusting and/or when dust containment is a primary requirement. They are normally located above material use points, and employ reverse-pulse jet filter cleaning to dislodge accumulated dust from filter surfaces, allowing continuous and efficient
separation of material from the air stream. These can be used in both pressure and vacuum systems.
Cyclone Separators
Cyclones operate by generating a vortex of particulate laden air. Centrifugal force pushes the particulates toward the outer cyclone wall where they lose velocity and spiral downward to the discharge. The relatively particulate-free air is then exhausted through the clean air discharge port which is attached to the top of the cyclone. Filters of various types and with various methods of solids recovery are used to clean up the transport gas before discharge or recycle.
Fill/Pass Valves
Fill/pass valves are commonly used to discharge material directly into individual or multiple process vessels and/or to deliver it to several destinations along a common conveying line. Downstream of the last fill/pass valve, the conveying line is normally routed to the original material source point or into a dust collection device. It is used only in pressure systems.
8. Check that cyclones have an unobstructed outlet. If there is intermittent or periodic discharge, allow clear buffer capacity to avoid interfering with the cyclone operation. 9. Allow for the pressure drop on the supply line to the blower. Include an allowance for any filter, silencer, acoustic box or compressor enclosure and extended supply run, as may be appropriate. Be sure to compensate for the temperature increase due to gas compression. 10. Provide adequate instrumentation; this is essential to know what is going on and to facilitate a proper investigation of any problems that may arise.