Thread: Unloading Fly Ash from Bulk Tanker s

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o Switch to Hybrid ModeSwitch to Threaded Mode25th October 2005, 11:12 #1
bharat Guest
Fly ash
I want to unload fly ash bulk tanker of 30ton with the help of compressor/roots blower.

Now maximum time which i required is 30min to unload tanker.

Now what pressure and what capacity of Compressor /roots blower i will required to unload tanker.

And which is convenient from roots blower and reciprocating compressor.
Why?
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2. 25th October 2005, 15:44 #2

Mantoo
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Most of the tankers are 2 barg rated so max. conveying pressure in a tanker is about 1.8 barg. In
Europe most of the tankers have a tractor based screw compressor capable of 2 barg. They come in
three sizes approx. 400, 600, 900 m^3/hr depending on the product. Since roots blower has a limit of
1 barg it will not be able to achieve 30 min target but can be used if time is not critical. Reciprocating
compressors are can give 8 -10 bar and will have to be regulated to 2 bar. They can work but then
you will use extra power.

Type of tanker is also very important if its a tipping tanker it usually discharges faster then a belly
tanker. Last but not least the conveying pipe distance and number of bends also have massive
influence. Typically 30 ton cement tanker unloading into a silo takes less then 30 min.
Mantoo
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3. 25th October 2005, 18:33 #3

Teus Tuinenburg

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dear mr bharat

please can you give the following additional information
- pipeline geometry , s.a. length horizontal, length vertical, number of bends.

optionally

- if there is an existing pipeline also the diameters.
- if you have a bulktruck in mind, also the compressor characteristics (volume and pressure)


These data will enable me to calculate the installation and the expected performance.

best regards
Teus
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4. 26th October 2005, 6:20 #4
bharat Guest
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Dear Sir,

Horizontal:5mtr
Vertical:-15 mtr
Bend:90 deg -3 nos

Compressor characteristics is FAD :19 cu m/min
and pressure is 2.5 bar

If this compressor is sutable or not please guide me
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5. 26th October 2005, 8:52 #5

Mantoo
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Assuming it is a 4" pipe line with 19m^3/ min the exit velocities will be 35-36 m/s. These are too high
velocities to convey at high SLR + don't forget fly ash is highly abrasive. You should be looking at 8 -
10 m^3/min range to give you approx 15-18 m/s
exit velocity.
Mantoo
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6. 26th October 2005, 13:01 #6
bharat Guest
Thanks
Thanks,

But sir if i go for 8-10 cu m/ min
then can i able to discharge 30 ton capacity bulk tanker within 25-30 min and

If i go for 8-10 cu m/min then what will be the system pressure .

If you do not mind can u able to provide me calculation of this system.
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7. 26th October 2005, 15:15 #7

Mantoo
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600 m3/hr and 2 barg pressure will be a good point to unload a tanker. Do not worry about the
system pressure it is reasonably easy to control on tankers and general rule of thumb is higher
pressure gives u shorter unloading times. But then there is a limit of max. phase density for every
product.

At 30 min time and these conditions the phase density will be 85. In my experience not every type
flyash can do this phase density so with out testing it is difficult to say yes or no.
Mantoo
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8. 26th October 2005, 17:55 #8

Teus Tuinenburg

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dear Mr bharat

based on your info, I made the following calculation :
As you did not specify any pipe diameters, I assumed that the pipe diameter is still free to choose.

FORUM bharat d 10-26-2005
Pressure discharge Fly-ash

Convey length = 25 m
Nu of bends= 3
Pump vol = .31 + .31 m^3/s
q-convey = 0.32 m^3/s
Dia begin = 193 mm (8)
Dia end = 193 mm (8)
Kettle volume = 40.0 m^3
Fly ash volume.= 32.0 m^3
C-Vessel = 600 tons/hr
Kettle cement content = 31.0 tons
Pipevolume = .73 m^3
Tabel 1
Press. PipelineCap. Syst. Cap. mu Nr ofbulktrucks Req.kettle fact v-begin v-end kWh/ton .res.time
2.500 196 138 147 4.7 687 4.4 12.4 0.34 4.96
2.250 183 129 140 4.5 595 4.6 12.3 0.34 4.91
2.000 166 117 130 4.1 500 4.7 12.1 0.33 4.80
1.750 153 108 122 3.9 422 4.9 12.0 0.32 4.68
1.500 141 99 114 3.6 353 5.2 11.9 0.31 4.55
1.250 125 89 104 3.3 283 5.5 11.7 0.30 4.35
1.000 109 77 91 2.9 220 6.0 11.6 0.29 4.09
0.750 92 65 79 2.5 161 6.8 11.4 0.29 3.79
0.500 71 50 64 2.0 108 7.7 11.2 0.29 3.46
0.250 44 31 41 1.3 55 9.0 11.0 0.35 3.10

Maximum system capacity : 140 t/hr 2.26 bar(o)

From this table you can read that 4 bulk trucks of 30 tons each can be unloaded in 1 hr.

May some time has to be spend on changing bulk trucks and necessary connecting.
(Or use 2 pipelines or 2 inlets with valves on one pipeline)

The question at this moment is, will the bulk truck release enough fly ash per unit of time
to cope with the pipeline capacity of approx 175 tons/hr at approx. 2,25 bar(o)

On a 6 pipeline (143 mm inner dia) I calculated approx 90 tons/hr # approx 3 bulk trucks per hour

I assumed a normal type of fly ash of 30 micron, which can deviate from your fly ash.

Take care of the maximum allowable pressure in the bulk truck tank.

Did I help you ?
best regards
Teus
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9. 7th October 2005, 5:48 #9
bharat Guest
Thank you
Sir,

I am really thankful for your guidline

Fly ash of 3000 blaine and density is 0.65 t/cu m

We have proposed diameter of 4" for conveying Fly ash

Reciprocating Compressor capacity is 19 m^3 / min and pressure of 2.5 bar.

maximum unloading time is 25-30 min but it may be less.

Now this recommended compressor is suitable or we can go for lower capacity and lower pressure
compressor for this system.
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10. 27th October 2005, 18:04 #10

Teus Tuinenburg
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dear Mr bharat

Your compressor is OK

You can read from the table the 5th figure in each row, which represents the number of trucks that
can be unloaded in 1 hour (time loss for swapping trucks NOT included)

Maybe you should type this table out on your computer and repair the table, then it will be clear(er)

For good understanding, I assumed that you will use an external compressor to the bulk truck,
because regular bulk trucks have smaller compressors (may be up to 12 m3/min)

The outlet of the bulk truck should be at least 6 (which is normal).
A pipe adaptor from 6 to 8 should be used right after the bulk truck

Do not forget a 40 m2 filter + fan of 80 m3/min at 450 mmWC + safety over- and under pressure
valve on the silo roof.

Also leveltesters should be installed, which will cause a butterfly valve to close the pipeline to prevent
overfilling.

Note:
if you are interested in a full calculation for a 4 pipeline I will be more than willing to do that for you

success
Teus