Bulk Handling Materials

MECH4220
Bulk Material Handling & Transport

Henrique Santos (3193471)
Pneumatic Conveying Design

The following report will provide detail for and justification of a proposed dense-phase pneumatic conveying
system for the transport of 40 tonnes per hour of Fly ash.


Submitted: Monday, 01st of September 2013
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MECH4220 Bulk Material Handling & Transport

A. EXECUTIVE SUMMARY

This report sets an appropriate pneumatic conveyor redesign that would transport Flyash at a time-weighted
average of 40 tonnes per hours.
The Pneumatic conveying design will operate in dense phase utilising the efficiency of its conveying. The design
system would utilise the current air move (0.45kg/s). Since it is capable of meeting the requirement of the
chosen system. The pipeline layout will be a single stepped pipeline situated 286m along the horizontal section.
The feeder will operate continuously to maximise tonnage rates. In order o minimise the cost the current blow
tank system will be utilised as well. The blow tanks provided are four 2 ! pressurised blow tanks rated at a
maximum of 700kPa each. The maximum pressure proposed is 552Kpa, so this system is acceptable.
In order to justify this recommendation the report will present results from a series of tests conducted that
were used to characterise the particular conveying properties of the Fly ash being transported. It will explain
how the results of this testing were used to produce a spreadsheet with potential designs to transport Fly ash as
was required. Furthermore, this report will explain why a design choice was made over another

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B. CONTENTS
Henrique Santos (3193471) ...................................................................................................................................................................... 1
A. Executive Summary .................................................................................................................................................................................. 2

1. Introduction and background ............................................................................................................................................................... 4
1.1. Fly ash plant ......................................................................................................................................................................................... 4
2. Development of fly ash conveying characteristics ...................................................................................................................... 5
2.1. Test method ......................................................................................................................................................................................... 5
2.2. Solids loading ratio, m*, .................................................................................................................................................................. 6
2.3. Mean Pressure, Pavg, ....................................................................................................................................................................... 6
2.4. Mean Density, m, ............................................................................................................................................................................. 6
2.5. Mean velocity, Cavg, ......................................................................................................................................................................... 6
2.6. Reynolds Number, Re, ..................................................................................................................................................................... 6
2.7. Air alone friction factor, f, ............................................................................................................................................................. 6
2.8. Development of particle friction factor; s ............................................................................................................................. 6
2.9. Plots to check the model ................................................................................................................................................................... 8
3. Fly ash system design ............................................................................................................................................................................ 10
3.1. Modes of flow in pneumatic design ........................................................................................................................................ 10
3.2. Pneumatic conveyor system Design ....................................................................................................................................... 10
3.2.1. Assumed or restricted variables ................................................................................................................ 10
3.2.2. Development of design spreadsheet ......................................................................................................... 11
3.2.3. Analysis of selected design ........................................................................................................................ 11
3.3. Resulting directives for conveying properties .................................................................................................................. 14
3.3.1. Air requirements ....................................................................................................................................... 14
3.3.2. Solids feeder .............................................................................................................................................. 14
3.4. Scaling ........................................................................................................................................................... 15
I. References ................................................................................................................................................................................................... 17
II. Appendices ................................................................................................................................................................................................ 18
a. Minimum safe air velocity in vertical and horizontal lines for materials with different bulk densities and
sizes ................................................................................................................................................................................................................... 18
b. Developed test data spread sheet ............................................................................................................................................... 19
c. Developed pipeline design spread sheet .................................................................................................................................. 22

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1. INTRODUCTION AND BACKGROUND

1.1.Fly ash plant

This report will propose a pneumatic conveying design to satisfy a desire for a fly ash plant to be able to convey
fly ash at a rate of 40 tonnes per hour utilising the same pipeline routing that is currently used. The power
station currently conveys 25 t/hr of fly ash using a flow rate of 0.45 kg/s of air fed via four 2m3 pressurized
blow tanks each rated to 700 kPa through a single pipeline. The geometry of the pipeline consists of a
horizontal section 455 m long with 5 long radius bends of 4 (100mm) internal pipe diameter. The pipeline then
travels vertically upwards and is stepped up to a 5 (125mm) internal diameter pipeline with the fly ash
diverted at the start of the vertical section to one of two possible silos:

1. Silo 1
a. Has a vertical height of 29 m, then a long radius bend and finally a 5 m horizontal section
b. A total pipeline pressure drop from the blow tank to the Silo 1 of 450 kPa

2. Silo 2
a. Has a vertical height of 29 m, then a long radius bend and finally an 11 m horizontal section
b. A total pipeline pressure drop from the blow tank to Silo 2 of 462 kPa

The silo 2 will be consider due to a longer final section of 11m in length.
Figure 1 Pneumatic conveying system
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2. DEVELOPMENT OF FLY ASH CONVEYING CHARACTERISTICS

2.1.Test method

Initially conveying trials were made using a sample of the fly ash conveying material. The trial data system
consists in 1m3 blow tank that feeds a 176m long pipeline of 53mm ID and having 24 long radius bends with a bend
factor of 0.6. The data produced from the conveying trials is given in Table 1.

Test

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Ma
Ms
Kg/s
Kg/s

0.0809
0.0585
0.0810
0.0653
0.0726
0.0461
0.0764
0.0339
0.0512
0.0287
0.0361
0.0601
0.0503
0.0398
0.0299
0.0257
0.0221
0.0199
0.0179
0.0568
0.0188
0.0223
p
Kpa

3.60
3.14
2.77
3.02
2.75
2.72
2.51
2.35
2.38
2.13
2.08
1.79
2.02
1.93
1.79
1.67
1.63
1.49
1.52
1.37
1.37
1.18
377.0
343.0
332.0
327.0
314.0
317.0
307.0
308.0
280.0
308.0
270.0
232.0
253.0
251.0
251.0
260.0
278.0
294.0
317.0
197.0
248.0
186.0
Physical
Parameters
Horizontal
Vertical
Number of Bends
Bend factor
Pipe diameter
Pipe roughness
Gas Constant
Temperature
Gravity
Air viscosity
Lh
Lv
N
B
D

R
T
G
0
176
0
24
0.6
0.053
4.60e-05
287
293
9.81
1.8E-05
m
m

m
m
J/KgK
K
m/s2
Pa.s
Table 1 - Supplied test data and Physical parameters adopted

The intention of this analysis was to develop a series of known relationships between key conveying
parameters for the particular fly ash, which the designed system must be able to convey. From this data was
constructed a spreadsheet to evaluate the relation of this parameters in important variables to the redesign of
the pneumatic conveying. This method of calculation knows, as Barth method is show below.

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2.2.Solids loading ratio, m*,

=
!

!
2.3.Mean Pressure, Pavg,

=
2 +

2
2.4.Mean Density, m,
m =
m =
2.5.Mean velocity, Cavg,
2.6. Reynolds Number, Re,

Re =
m. C.

2.7.Air alone friction factor, f,

The air alone friction factor, f, was calculated using the streeter equation for turbulent pipe flow;

! =
1.325
5.74
ln
+
3.7 !.!
This equation can only be used if:

10!! <
!
!
< 10!!
5000 < < 10!

These conditions will be satisfied, so the air alone friction factor can be calculated using this equation. The air
alone friction factor for each test is a dimensionless variable that is used for further pressure drop calculations.

2.8.Development of particle friction factor; s

The particle friction factor was then calculated for each test point using the relationship;

! =

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!"!#$ !"# !"#$% 2

!
!" !"


The solids friction factor model is assumed to be of the following form. The coefficients
a and b are produced using a best fit model for the data:

! !.! = !

Values for ! . to be plotted against values of Fr from the test data. A power series curve was fitted to these
data points in order to develop values for coefficients b and a to finally describe the behaviour of the fly ash that
needs to be conveyed.

s.m*0.5 vs FR for given test data

1.0000
0.9000
0.8000
s.m*5
0.7000
0.6000
0.5000
Series1
0.4000
Power (Series1)
0.3000
0.2000
0.1000
0.0000
0.000
y = 11.594x-1.973
R = 0.9989
5.000
10.000
15.000
20.000
Fr

Figure 2 - Solids friction factor constants given by power series fit to test data

This graph leads us to the following general relationship:

! !.! = 11.594 !!.!"#

Regardless to this personal result a and b will be, as suggested, 10.579 and -1.909 respectively.

! !.! = 10.579 !!.!"!

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2.9. Plots to check the model

Other graphs were made during analysis of the test data to assist the report in delivering the most effective
recommendation for the final design

P as function of mass concentration and Froude number

These graphs indicate how the values calculated are representative of real-life situations, once these graphs
show us the level of confidence of the design developed
The ratio between measured and calculated pressure differentials tend to one unity as the solid loading ratio
increases (nearer 80) and the Froude number decrease (4)

RaFo of measured Pm/Pc vs m*
Pm/Pc
1.10
y = 0.0019x + 0.8402
1.00
0.90
Series1
0.80
Linear (Series1)
0.70
20.00
40.00
60.00
80.00
m*

Figure 3 - Accuracy of measured vs. calculated P vs. m*
RaFo of measured Pm/Pc vs Fr

y = -0.0033x + 1.0035
Pm/Pc
1.10
1.00
Series1
0.90
0.80
2.00
Linear (Series1)
7.00
12.00
17.00
Fr

Figure 4 - Accuracy of measured vs. calculated P vs. Froude number
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Pick velocity

Pick up velocity vs m*
12.0
10.0
ci
8.0
6.0
Series1
4.0
Power (Series1)
2.0
0.0
20.00
40.00
60.00
80.00
y = 644.52x-1.292
m*

Figure 5 - Pickup velocity dropped as m* values increased; that is as more solids were introduced
The graph suggests that an increase in the solids loading ratio (m*) causes a decrease in pick up velocity. Pickup
velocity (the slowest point in the system) remains above safe minimums (4.6m/s for fly ash (Jones & Wypych,
2007, p. 27) & appendix item 5.1) during the design phase in section 3.

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3. FLY ASH SYSTEM DESIGN

3.1.Modes of flow in pneumatic design

Pneumatic conveying systems differ in design because of the mode of flow in which they transfer particles in
the conveying pipeline. The two major modes of flow are:

1. Dilute Phase
2. Dense Phase

Dilute phase flow occurs when the majority of the product being conveyed remaining in a gas-solid fluid
mixture.
Dense phase flow occurs when the product is conveyed out of suspension in slugs or fluidised dunes.
However, dilute phase flow is most often selected for pneumatic Conveying due its flexibility, simplicity and
larger knowledge base. (Jones & Wypych, 2007) FLSmidth (2011) suggest that for Fly ash conveying we must
choose dense Phase due to the fact it reduces costs and maintenance, also it has high efficiency,

3.2.Pneumatic conveyor system Design

3.2.1. Assumed or restricted variables

Some restrictions and guidelines were calculated for pneumatic conveying model in the section above. The
variables are used as a guide and it is not obligatory met all of these guidelines. The basic references are show
below:

Variable
m*
Fr
Ci (Pick-up velocity)
Description
Moderately high values suggested to increase accuracy (>70)
Low numbers suggested to increase accuracy (<6)
>4.6m/s suggested by the table of minimum air velocity (appendix item
5.1
Co (Exit Velocity)
< 25m/s assumed maximum exit velocity
P (Pressure)
<700kPa suggested maximum pressure in the system
D Pipe Diameter
<150mm maximum diameter of pipe that will be considered
Table 2 - Supplied test data and Physical parameters adopted

These restricted variables were used to develop a design spreadsheet for the conveyor design. Different
combinations of the design variables are compared on it. Combinations of solids loading ratio, pipeline steeps
and diameter were used to develop different designs. The mass flow rate of the air was modified in order to
change the solids loading ratio (m*) since the mass flow rate of the solids was a fixed value 40 tonnes per hour
or 11.11kg/s). For a number of different designs for the conveyor line were chosen different pipeline steeps
The number of steps vary from no step to 3 steps. It was selected different diameter for the pipeline and for
each of the stepped pipeline.

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3.2.2. Development of design spreadsheet

The options that were considered for analysis appeared on the design spreadsheet. It was considered 8 options
including an analysis of the currently system without a step to demonstrate the importance of the stepped
pipeline. The effect on the velocity and pressure was viewed differing the mass flow rate of solids od the first
option once to desire a new rate it was raised. The following conclusions were reached.

i.
Analysing the system without stepped pipeline was possible to conclude that the pressure drop and the
velocity variation were extremely high for a productive and safe transportation; as a result different
positions of the step were considered and compared in the design spreadsheet.

ii.
the variations of the system are greatly affected by the new rate of mass flow of solid . by using the same
system, but with different values for Ms was possible to demonstrate that, as we can see in the design
sheet the pressure drop increases more than 500Kpa.Therefore, is necessary a design change to deal
with the upgrade conveying rate.
iii.
It was possible to demonstrate that the current diameter of 100mm to a stepped diameter of 125 mm
leads to a pressure drop of greater than recommended pressure value. A change from 0.125mm to a
stepped pipeline diameter of 0.15mm results in a pressure drop under the maximum reference value.

The option four of the design spreadsheet (appendix II. C) will be selected for the conveyor redesign system.
The recommended system show below maintain the original air flow rate (0.45 kg/s) .the solids loading ratio of
the design is 24.7, which is an acceptable effect on the mode of flow of the design. The required system will be a
single stepped pipeline situated 286m along the horizontal section.

Test Ms

40
40
Ms
11.1111
11.1111
Ma
m*
Po
Lh
Lv
Ci
Co
P - Total

0.45 24.69135802 101 180 29 0.15 10.70679866 21.2015815 99.08915416
0.45 24.69135802 200 286 0 0.125 5.58615582 15.41779006 352.0712263
Table 3 Recommended design for Pneumatic Conveying.
3.2.3. Analysis of selected design

Values for velocity and pressure are extremely important for this redesign. However the pick-up velocity shold
remain under the minimum value required (4.6m/s) it is 5.56m/s in the system. Therefore the recommended
design has its limits as we can see in the figure below:

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Design
Ci
Co
C-avg

1. No step - original flow rate
2. 1 Step - original flow rate

3. 1 Step - new flow rate

4. 1 Step - Change of step
position and diameter
5. 1 Step - Change of step position
and diameter, change in Ma
6. 2 step - Change in diameter
and step position

and step position

and step position, change in Ma

m/s
5.147499
26.13185
5.41355
24.66846
3.082572
10.7068
5.586156
3.806862
1.4848
16.66788
10.97508
6.598951
12.74619
10.52409
7.990148
6.465458
4.994425
3.521973
m/s
47.70356
30.53028
40.83101
30.53028
38.54448
21.20158
15.41779
9.422925
5.481881
30.53028
26.04356
24.128
21.20158
18.35451
21.31885
11.77866
9.31026
10.295
m/s
9.292304
28.16035
9.559642
27.28812
5.708601
14.2283
8.200952
5.42288
2.336693
21.56334
15.4425
10.36351
15.92089
13.37769
11.62379
8.348381
6.501282
5.248431
P -
Total
kPa
835.4409
16.71492
771.6629
23.92981
1438.3
99.08915
352.0712
149.3742
673.2422
83.54119
254.021
943.3491
66.64996
125.2322
376.5793
82.87237
159.2226
499.9274
P Total
Combined

788.3778

1462.23

451.1604

822.6164

1280.911

568.4615

742.0223

Table 4Velocity and pressure drop values of design options.

This Table demonstrates in underline the velocity values that are unacceptable because they are under the
minimum velocity. Therefore, the design 3,5 and 8 will be eliminated. The values that are too high as we can see
in bold will be eliminated. The highlighted velocity value is the most appropriate as a result these are the
selected values. Moreover, it table shows in underline the pressure drop that is over the reference value. The
highlighted pressure drop value satisfies the requirement of the design. Therefore, the only option that reaches the
requirements for velocity and pressure drop is option four.

In order to evaluate the power requirement, this report has used the isothermal power model,

, = !
!

!

Mills (2011) claim that these values should be multiply by two in practical situations.

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Design



5. 1 Step - Change of step position
and step position

and step position

and step position, change in Ma

Power
kW
168.5054
174.114

201.3604

135.8053

133.8815

68.60684

83.07397

131.6513

Table 5Power requirement for each option

This table shows that the effect of this factor on the system is minimum due to the fact that variations between each
option are small. The highlighted value shows the power required for the chosen design.

To sum up, the selected design would require a maximum pressure of 552 kPa, a pick-up velocity of 5.59 m/s and the
same airflow of the current system.

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3.3.Resulting directives for conveying properties

Having established and selected a basic system layout the report will make a series of recommendations
directing the reader to components appropriate to satisfy this design.

3.3.1. Air requirements

The recommended final redesign will be the same air mass flow rate of the currently power station which is
0.45kg/s at a maximum pressure of 552kPa. The air mover provided in the currently system, four pressurised
blow tanks rated at a maximum of 700kPa will be utilised for the redesign since the original blow tanks are
acceptable for the redesign. Costs can be reduced using the original air blower system

3.3.2. Solids feeder

The design recommended above requires the installation of a continuous feed system due to the demand of a
system that will run continuously 24 hours a day to ensure maximum tonnage per hour of material.
Blow tanks are suited to high pressure applications such as the design recommended, have few moving parts
(for ease of maintenance and reliability) and in twin arrangements allow for continuous operation.

Figure 6 - Series twin blow tanks, capable of continuous operation (Mills, 2004, p. 101)
A rotary air lock feeder controls the feeding of the material. The currently power station has four 2 !
pressurised blow tanks each rated to 700kPa. This layout is a duplicate and used side-by-side version of the
layout show in figure 6 to ensure that flow rates of the material will met the requirement. The use of these
systems will not only provide adequate pressures and flow rates, but also allow the current system to be
utilised rather than developing and installing a new system. Therefore, costs will be minimized.

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3.4. Scaling

The mills scaling technique will be used to verify and provide a design check on the chosen system.

Test pipeline conveying characteristics:
176m long
24 long radius bends
Pipe bore = 53mm
Power Station pipeline:
466m long horizontal length

29m vertical length
6 long radius bends
Pipe bore = 100mm stepped to 150mm
The test pipeline values are when we use the maximum value for P from the given data :
Mass flow rate of air ! = 0.0809kg/s
P = 377kPa
Mass flow rate of solid ! = 3.60kg/s

There are two rules for use the Mills scaling technique. One for conveying distance and one for pipeline cross-
sectional area. Scale up of the solids mass flow rate with respect to conveying distance can be carried out as
follows:

Scaling for length

!
!
!!
Therefore, ! = ! .
!!!
!!!

Where ! = ! + 2! + . !"
! = Horizontal pipeline length
! = Vertical pipeline length
!" = Equivalent length of a bend
N = Number of bends

!!!"#! = 176 + 20 + 24!"
Where, !" is obtained from a look-up chart after the inlet velocity is calculated by;

! =
4!
40.08287293
=
= 6.4 /
!
!
(377 + 101)10! 0.053!

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Figure 7- Equilibrium length vs. inlet air velocity

Using figure 7, a value of !" = 5m

!!!"#! = 176 + 20 + 245 = 296

!!!"#$ = 466 + 229 + 65 = 554

Using this values into the scaling length equation:

! = ! .
!!!"#!
296
= 3.6
= 1.92 /
!!!"#$
554

A tube of larger diameter will be necessary due to the fact that the flow rate of solids is 40 tonnes per hour

The new value of mass flow rate of solids leads us to the follow diameter:

! =
40
0.053! = 0.241
1.92

Therefore, the pipe diameter will be 250mm. Using this value for the new flow rate;

250 !
= 42.7 /
53
250 !
= 0.08
= 1.77 /
53
!! = 1.92
!!

The pressure will be over compensated due to the large amount of bends in the test pipeline, so these values
agree with the proposed design

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I. REFERENCES

FLSmidth. (2011). Pneumatic conveying for the fly ash management industry. Retrieved from FLSmidth:
http://www.flsmidth.com/en-
US/Industries/Categories/Products/Material+Handling/Pneumatic+Transport/Fly+Ash+Handling/Tan
k+Systems
Jones, M. G. (2007). Characterisation for pneumatic conveyor design. Newcastle: Centre for bulk solids and
particulate technologies.
Jones, M., & Wypych, M. (2007). Introduction to Pneumatic Conveying. Newcastle and Wollongong: Centre for
Bulk Solids and Particulate Technologies.
Mills, D. (2004). Pneumatic Conveying Design Guide. Oxford: Elsevier Butterworth-Heinemann.

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II. APPENDICES
a. Minimum safe air velocity in vertical and horizontal lines for materials with
different bulk densities and sizes

Figure 8 - Minimum safe air velocity for ash is 4.6 m/s (Jones & Wypych, 2007, p. 27)
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b. Developed test data spread sheet
Test Ma
Ms
p
m*
Po
Pavg

Kg/s
Kg/s
Kpa

KPa-abs KPa-abs

1 0.0809
3.60 377.0 44.50 101.00 289.50
2 0.0585
3.14 343.0 53.68 101.00 272.50
3 0.0810
2.77 332.0 34.20 101.00 267.00
4 0.0653
3.02 327.0 46.25 101.00 264.50
5 0.0726
2.75 314.0 37.88 101.00 258.00
6 0.0461
2.72 317.0 59.00 101.00 259.50
7 0.0764
2.51 307.0 32.85 101.00 254.50
8 0.0339
2.35 308.0 69.32 101.00 255.00
9 0.0512
2.38 280.0 46.48 101.00 241.00
10 0.0287
2.13 308.0 74.22 101.00 255.00
11 0.0361
2.08 270.0 57.62 101.00 236.00
12 0.0601
1.79 232.0 29.78 101.00 217.00
13 0.0503
2.02 253.0 40.16 101.00 227.50
14 0.0398
1.93 251.0 48.49 101.00 226.50
15 0.0299
1.79 251.0 59.87 101.00 226.50
16 0.0257
1.67 260.0 64.98 101.00 231.00
17 0.0221
1.63 278.0 73.76 101.00 240.00
18 0.0199
1.49 294.0 74.87 101.00 248.00
19 0.0179
1.52 317.0 84.92 101.00 259.50
20 0.0568
1.37 197.0 24.12 101.00 199.50
21 0.0188
1.37 248.0 72.87 101.00 225.00
22 0.0223
1.18 186.0 52.91 101.00 194.00
Continued

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Rho-i
Rho-o Rho-avg Ci
Co
Kg/m3
Kg/m3 Kg/m3
m/s m/s

5.684318
1.20
3.44 6.5
30.6
5.279994
1.20
3.24 5.0
22.1
5.149184
1.20
3.18 7.1
30.6
5.089724
1.20
3.15 5.8
24.7
4.935130
1.20
3.07 6.7
27.4
4.970805
1.20
3.09 4.2
17.4
4.851887
1.20
3.03 7.1
28.9
4.863779
1.20
3.03 3.2
12.8
4.530806
1.20
2.87 5.1
19.3
4.863779
1.20
3.03 2.7
10.8
4.411887
1.20
2.81 3.7
13.6
3.959996
1.20
2.58 6.9
22.7
4.209725
1.20
2.71 5.4
19.0
4.185941
1.20
2.69 4.3
15.0
4.185941
1.20
2.69 3.2
11.3
4.292968
1.20
2.75 2.7
9.7
4.507022
1.20
2.85 2.2
8.3
4.697292
1.20
2.95 1.9
7.5
4.970805
1.20
3.09 1.6
6.8
3.543780
1.20
2.37 7.3
21.5
4.150266
1.20
2.68 2.1
7.1
3.412969
1.20
2.31 3.0
8.4

Test

Cavg
m/s

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Continued

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10.7
8.2
11.6
9.4
10.7
6.8
11.4
5.1
8.1
4.3
5.8
10.6
8.4
6.7
5.0
4.2
3.5
3.1
2.6
10.9
3.2
4.4
Re

107971.8
78076.0
108105.2
87151.5
96894.3
61526.6
101965.9
45244.0
68333.2
38304.0
48180.2
80211.4
67132.0
53118.4
39905.5
34300.1
29495.4
26559.2
23889.9
75807.1
25091.1
29762.3
f
DP- air
Dp- bends s
Fr
s*m*0.5

Kpa
Kpa

0.0263 17.0647 127.9537
0.0080
14.772
0.0536
0.0268
9.6613
85.4151
0.0128
11.348
0.0939
0.0263 18.5473 107.5895
0.0085
16.036
0.0499
0.0266 12.3162
94.7510
0.0103
13.050
0.0699
0.0265 15.5111
98.8018
0.0090
14.875
0.0554
0.0273
6.4081
61.1266
0.0180
9.391
0.1382
0.0264 17.3646
96.5829
0.0089
15.869
0.0512
0.0280
3.6203
39.4227
0.0296
7.027
0.2462
0.0271
8.4448
64.2499
0.0143
11.230
0.0974
0.0285
2.6380
30.2227
0.0400
5.949
0.3447
0.0278
4.4102
40.2652
0.0247
8.086
0.1874
0.0268 12.7825
63.7395
0.0109
14.640
0.0597
0.0271
8.6453
56.9402
0.0146
11.688
0.0927
0.0276
5.5378
43.0562
0.0208
9.289
0.1449
0.0283
3.2099
29.8847
0.0321
6.978
0.2487
0.0288
2.3631
23.4676
0.0439
5.881
0.3542
0.0293
1.7116
18.9241
0.0598
4.868
0.5133
0.0297
1.3607
15.0712
0.0809
4.242
0.7003
0.0301
1.0670
13.1960
0.1007
3.646
0.9275
0.0269 12.4650
50.5321
0.0120
15.050
0.0588
0.0299
1.3485
14.4349
0.0707
4.417
0.6037
0.0293
2.1536
17.1915
0.0428
6.076
0.3116

Dp-Guess
Kpa
377
343
332
327
314
317
307
308
280
308
270
232
253
251
251
260
278
294
317
197
248
186
Pavg
KPa-abs
289.5
272.5
267.0
264.5
258.0
259.5
254.5
255.0
241.0
255.0
236.0
217.0
227.5
226.5
226.5
231.0
240.0
248.0
259.5
199.5
225.0
194.0
Rho-avg
Kg/m3
3.44
3.24
3.18
3.15
3.07
3.09
3.03
3.03
2.87
3.03
2.81
2.58
2.71
2.69
2.69
2.75
2.85
2.95
3.09
2.37
2.68
2.31
Figure 9 displays the test data sheet
21 | P a g e

Cavg
m/s
10.7
8.2
11.6
9.4
10.7
6.8
11.4
5.1
8.1
4.3
5.8
10.6
8.4
6.7
5.0
4.2
3.5
3.1
2.6
10.9
3.2
4.4
Re
Fr
107971.8
78065.9
108091.2
87140.2
96881.8
61518.6
101952.7
45238.2
68324.3
38299.0
48174.0
80201.0
67123.3
53111.5
39900.3
34295.6
29491.6
26555.7
23886.8
75797.3
25087.8
29758.4
0.0263
0.0268
0.0263
0.0266
0.0265
0.0273
0.0264
0.0280
0.0271
0.0285
0.0278
0.0268
0.0271
0.0276
0.0284
0.0288
0.0293
0.0297
0.0301
0.0269
0.0299
0.0293
14.772
11.347
16.034
13.049
14.873
9.390
15.867
7.026
11.229
5.949
8.085
14.638
11.686
9.287
6.977
5.880
4.867
4.241
3.646
15.048
4.416
6.076
0.009286
0.013990
0.009057
0.011542
0.009934
0.019153
0.009428
0.030732
0.015336
0.040816
0.025788
0.011549
0.015289
0.021572
0.033517
0.044593
0.060058
0.077521
0.097159
0.012174
0.072737
0.046430
DP- air
Kpa
17.06
9.66
18.54
12.31
15.51
6.41
17.36
3.62
8.44
2.64
4.41
12.78
8.64
5.54
3.21
2.36
1.71
1.36
1.07
12.46
1.35
2.15

c. Developed pipeline design spread sheet

Ms
tonne/hr kg/s
25
Ma
m*
Po
Lh
kg/s
kPa - abs
6.944444444 0.45
15.43209877
101
176
25
6.944444444 0.45
15.43209877
101
11
25
6.944444444 0.45
15.43209877
118
455
40
11.11111111 0.45
24.69135802
101
11
40
11.11111111 0.45
24.69135802
125
455
40
11.11111111 0.45
24.69135802
101
180
40
11.11111111 0.45
24.69135802
200
286

position
40
11.11111111 0.2
55.55555556
101
180
40
11.11111111 0.2
55.55555556
250
286
6. 2 step - Change in diameter 40
11.11111111 0.45
24.69135802
101
100
and step position
40
11.11111111 0.45
24.69135802
185
170
40
11.11111111 0.45
24.69135802
355
196
11.11111111 0.45
24.69135802
101
120
and step position
40
11.11111111 0.45
24.69135802
168
150
40
11.11111111 0.45
24.69135802
226
196
11.11111111 0.25
44.44444444
101
120
and step position, change in

Ma
40
11.11111111 0.25
44.44444444
184
150
40
11.11111111 0.25
44.44444444
260
196
Continued
22 | P a g e

Ms

Lv
D
N
B

P-avg Rho - i
m
mm
kPa -
abs
kg/m3

Rho- o
Rho-avg Ci
kg/m3
kg/m3
Co
m/s
m/s
0.053
24
0.6
0.046
1051
23.80
1.20
12.50
8.57
169.82
29
0.125
0.6
0.046
111
1.44
1.20
1.32
25.48
30.53
0.1
0.6
0.046
508
10.68
1.40
6.04
5.37
40.83
29
0.125
0.6
0.046
113.5
1.50
1.20
1.35
24.47
30.53
0.1
0.6
0.046
845
18.61
1.49
10.05
3.08
38.54
29
0.15
0.6
0.046
151
2.39
1.20
1.80
10.65
21.20
0.125
0.6
0.046
375
6.54
2.38
4.46
5.61
15.42
29
0.15
0.6
0.046
176
2.98
1.20
2.09
3.79
9.42
0.125
0.6
0.046
590
11.06
2.97
7.02
1.47
5.48
29
0.125
0.6
0.046
143.5
2.21
1.20
1.71
16.58
30.53
0.1
0.6
0.046
312
5.22
2.20
3.71
10.98
26.04
0.075
0.6
0.046
826.5
15.44
4.22
9.83
6.60
24.13
29
0.15
0.6
0.046
136
2.03
1.20
1.62
12.52
21.20
0.125
0.6
0.046
230.5
3.48
2.00
2.74
10.52
18.35
0.1
0.6
0.046
416
7.21
2.69
4.95
7.95
21.32
29
0.15
0.6
0.046
146
2.27
1.20
1.74
6.23
11.78
0.125
0.6
0.046
267
4.16
2.19
3.18
4.89
9.31
0.1
0.6
0.046
513
9.11
3.09
6.10
3.49
10.29
Figure 10 Appendix item II.c displays the design spread sheet, but is not complete on this report.
23 | P a g e

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MECH4220

Bulk Material Handling & Transport

Henrique Santos (3193471)

Pneumatic Conveying Design

Submitted: Monday, 01st of September 2013

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

Henrique Santos (3193471) ...................................................................................................................................................................... 1

A. Executive Summary .................................................................................................................................................................................. 2

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

1. INTRODUCTION AND BACKGROUND

1.1.Fly ash plant

Figure 1 Pneumatic conveying system

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

2. DEVELOPMENT OF FLY ASH CONVEYING CHARACTERISTICS

Table 1 - Supplied test data and Physical parameters adopted

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

2.2.Solids loading ratio, m*,

2.3.Mean Pressure, Pavg,

2.5.Mean velocity, Cavg,

2.6. Reynolds Number, Re,

2.7.Air alone friction factor, f,

This equation can only be used if:

5000 < < 10!

2.8.Development of particle friction factor; s

!"!#$ !"# !"#$% 2

MECH4220 Bulk Material Handling & Transport

s.m*0.5 vs FR for given test data

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

2.9. Plots to check the model

RaFo of measured Pm/Pc vs m*

RaFo of measured Pm/Pc vs Fr

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

3. FLY ASH SYSTEM DESIGN

3.2.Pneumatic conveyor system Design

3.2.1. Assumed or restricted variables

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

3.2.2. Development of design spreadsheet

Table 3 Recommended design for Pneumatic Conveying.

3.2.3. Analysis of selected design

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

Table 4Velocity and pressure drop values of design options.

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

Table 5Power requirement for each option

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

3.3.Resulting directives for conveying properties

3.3.1. Air requirements

3.3.2. Solids feeder

MECH4220 Bulk Material Handling & Transport

Henrique Santos (3193471)

Power Station pipeline: