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Pneumatic Conveying System

INTRODUCTION

With continuous improvement in technology over the past 20 years,

pneumatic conveying now competes favorably with conventional bulk material

conveying systems both in terms of operational cost and conveying reliability. In

addition to improvement in basic system design, a variety of reliable control

components and equipments are available that enable both vendors and users to

exploit the flexibility and relative ease of operation of such systems.

Basically the system can be used for application like conveying

plastic granules in plastic industries, an a vacuum cleaner, in sugar industries, on

shipyards, in agricultural departments and much more which in discussed further.

Various systems are available for conveying materials but we have

decided pneumatic system as it gives solution for automation at low cost. Also the

advantages of pneumatic system are discussed later on.

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SELECTION OF SYSTEM

We have selected here the pneumatic conveying system for conveying

plastic granules as well as dust free operation

1. Operating under vacuum provides the advantage of dust free conditions

around the inlet and because any accidental leakage is inward, provides

maximum safety in handling toxic products.

2. Ease of automation and control.

3. One pipeline can be used for variety of products.

4. High operation reliability due to few moving machine parts.

5. Flexibility in routing.

6. Careful and gentle handling of produces.

7. Low maintenance and low manpower cost.

8. Minimum floor space.

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THEORY

(A) TYPES OF CONVEYING SYSTEM :

There are basically three types of conveying systems which are used

for conveying material in the industries.

(i) Mechanical conveying System

(ii) Pneumatic conveying system

(iii) Hydraulic conveying System

ADVANTAGE OF PNEUMATIC CONVEYING SYSTEM OVER

MECHANICAL

Pneumatic conveying System Mechanical conveying System


1) Used to convey bulk material in the 1) Used to convey material which is

form of powder, short fibres and solid and lumpy.

granules.
2) This can process material 2) Only convey material.

simultaneously with conveying.


3) These systems have air and gas 3) These systems have dust problems.

tightened so eliminates dust hazards and

dust nuisances.
4) Less reduction of losses. 4) More losses as compared.
5) Less floor space. 5) More floor space.
6) These system required high power (10 6) Less them pneumatic conveyor

to 15 times more than mechanical

conveyor)
7) Rapid wear of equipment. 7) Less wear of equipment.

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8) Noisy 8) Less noisy as compared to

pneumatic.
9) Horizontally as well as vertically 9) Only horizontally and slightly

(inclined) material can be conveyed. inclined (10 to 15 degree) material can

be conveyed.

(B) TYPES OF DUST COLLECTOR :

Depending upon the type of plant, the type of dust, size of dust,

working conditions, efficiency required, cost of device, availability of space, water

and power requirements etc., various types of dust collectors are available. These

devices take the advantage of certain physical or electrical properties of particular

matter of the dust stream.

Dust collecting devices can be classified as below :

Dust collection Devices

Mechanical Electrical

Electrostatic
Precipitator (ESP)
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Dry type Wet type

Gravitational sep. Packed type


(Scrubber)

Inertial Sep.
(Knock-out or Spray Tower
Baffle type)

Centrifugal Collector Venturi Scrubber


(Cyclone dust collectors )

Fabrics Filters Cyclone


Scrubber

But whatever type of collecting device be employed, following

requirements must be satisfied

1) It should be leak-proof.

2) It should withstand the abrasive and corrosive properties of dust.

3) It should be inert with the gas containing dust.

4) It should withstand the working condition like temperature working velocity etc.

(C) PNEUMATIC CONVEYING SYSTEM

Pneumatic conveying is a method of transporting bulk materials in the

form of powder, short fibre and granules over a pipeline as a mixture with air or due

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to pressure of air such an installation will convey over more than 2 km at a rate of

upto 400 tones per hour. It is also capable of lifting loads to a height of 100 meters.

Types of pneumatic conveying system as follows :

Pneumatic conveying system

Suspension flow Non-suspension flow


( Dilute phase ) (Dense phase)

Pressure Single plug

Vacuum Multiple plugs (Timed pulse)

Combination Pressure vacuum External air bypass

Internal air bypass

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a) SUCCTION TYPE CONVEYOR

b) PRESSURE TYPE CONVEYOR

Engineers planning to install a pneumatic conveying system will head

to decide whether to use 'dilute' of 'dense' phase system or commercial variations of

these basic types. A dilute phase conveying will mean suspension flow where the

conveying pipe at relatively low pressure and high velocities. The material to be

conveyed is introduced into pipeline in a controlled manner allowing the particles to

be carried in suspension to the destination point. The material loading factor, the

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weight ratio of material to air is generally in the range of 10- 15 at the higher ends

(i.e. 10 kg to 15 kg of material per kg of air).

In dense phase conveying, however the material is moved in the

conveying pipe to the destination in non suspension flow in collapsing/ reforming

dunes or in plugs of full pipe cross section. The pressure required are higher than

those required for dilute phase conveying and the material loading considerably

grater even going upto 200 depending on the ability of material to be conveyed in

this mode. Dense phase conveying is essentially a batch operation as compared to

dilute phase conveying which is a continuous operation. The higher pressure

involved in dense phase conveying and higher material loading require robust

equipment and specification of valve, actuator etc. should consider the cyclic nature

of operation.

Vacuum system

This consists of piping and pick up manifold which can be y - branch

where the material drops into the air system and is pulled vacuum thereby

eliminating dust at pickup source.

Negative Pressure Conveying System


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This type of system can be used in these operations where product

must be fed into a dump hopper. The conveying air can be used to control the dust

that is generated from the dumping operation. An air intake scoop or filler is

required depending on the products to be handled. The receiver can be a cyclone

connected with a centrifugal fan that will tolerate small amount of product and dust

passing through it. However, if a rotary positive displacement blower is the vacuum

source, the receiver must be a filler type to prevent any product passing through the

blower because of its close tolerances.

These systems are particularly suited to moving material from

multiple pickup points to a single location, the reason being that the bulk of systems

expense is in the terminal end where the receiver, rotary valve and vacuum source

are located.

These systems are particularly suitable for unloading railroad cars

from above the rail. They are also used for picking up from boxcars or flat storage.

The advantage of vacuum system is that it provides air to purge grinding

equipment, pulls the product into the grinder and dissipates the heat of grinding.

These system are excellent for handling toxic materials or corrosive materials

because all leakage is inword so there is less danger of any product escaping into the

atmosphere. Vacuum systems have been used extensively for flash drying and

cooling.

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Fig. (A) Simple vacuum system

These systems can be arranged in closed loop to assure that no

product gets out into atmosphere or that b minimum product gets into the

atmosphere should a bag break fig. B.

Fig. (B) Closed Loop Vacuum System with Fan


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It helps to economize on the size of filler in this particular

arrangement because the filler is only handling about 10% of the conveying air. The

primary cyclone collector as a carryover of 1% or less, passing enough the fan and

being blown into the filler. The other 90 % of air continuous on down the outlet of

the so that dust in the air eventually gets separated.

Fig. C shows a closed loop vacuum system utilizing a rotary positive

displacement blower. But in this case the filter must handle 100% of the air because

the blower can not tolerate any product passing through it. The zero point is on the

discharge of that blower (As the system is entirely vacuum) as indicated in the fig.

by the negative signs all the way to the inlet of the blower.

Fig. (C) Closed loop vacuum system with rotary positive displacement blower.

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The only pressure in the system is from the blower discharge to the

zero point, which need be nothing more than a tee open to the atmosphere. Since

this is the vacuum system, air will leak in through the rotary valves at the pick and

terminal points of the system. This filtered leakage air is exhausted at the zero point.

The dust that is collected by the filter is set up to drop right back into conveying

line, eliminating the need for rehandling the dust.

Application of Pneumatic conveying system :

There are huge application of pneumatic conveying system. Some are

given below

1) It is used in plastic industries for conveying plastic granules.

2) It is used for collecting dust (as a vacuum cleaner) in officer, bank, departmental

stores, houses, colleges.

3) It is used in steel industries.

4) It is used in sugar industries.

5) It is used in shipyards.

6) It is used in agriculture department.

7) It is used as a chip collector in machines.

8) It is used in chemical industries to remove harmful gases.

9) It is used in marble industries.

10) It is used in cosmetics industries.

11) It is used in power plant as well as in coal industries.

12) It is used in cotton industries.

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13) It is used in post office and much more.

Key system components : -

The key components of the system are as follows:

 Source of negative pressure air Fan/Vacuum pump.

 Receiving equipments like bagfilter, cyclone.

 Conveying piping, bends.

 Rotary airlock border.

 Pick up devices like nozzles or a pipe.

 Electric drive.

Fig. Pneumatic (Vacuum) System for conveying plastic granules/ dust collector
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(1) BLOWER :

A blower according to the compressed Air institute is a machine to

compress air or gas by centrifugal force to a final pressure not existing 35 lb per sq.

in. ga. It is not water cooled as the added expense of the cooling system is not

justified in view of the relatively slight gain at these pressure.

When used for special application the blowers are some times given

other names. In gas service a blower used to remove gas from a coke oven is known

as an exhauster. If the pressure at the suction is about atmospheric (as some times

used in chemical industry where sufficient head must be developed to circulate the

gases through the pressure) the blower is known as booster or circulator.

The terms blower, compressor and fan are frequently used

interchangeably. In general a fan operates at low pressure upto 1 psi whereas

blower operates at a pressure upto 35 psi.

Types of Blower:-

Types of blower are as follows :-

a) Roots blower

i) Two lobe type

ii) Three lobe type

iii) Four lobe type

b) Vane type blower

c) Centrifugal blower

i) Airfoil type blower (92% efficiency)

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ii) Backward-curved type blower (85% efficiency)

iii) Backward - inclined type blower (78% efficiency)

iv) Radial - tip type blower (70 % efficiency)

v) Forward-curved type blower (65% efficiency)

vi) Radial-blade type blower (60% efficiency)

d) Cross-flow blower

e) Vortex blower

f) Cupola blower.

g) Sewage accretion blower

h) Blast furnace gas blower

i) Air-actuated (fluidized) conveying type blower.

(2) FAN :-

In selecting fans, the manufacturer's charts should be consulted. The

fan tends to run wild, making motor selection difficult.

The fan consists of a rotating member, called the wheel or impeller,

and a stationary member called the housing. The housing is provided with an intake

opening (inlet) and with a discharge opening (outlet). The flow of air or gas is

caused by the pressure differential created by the energy transmitted to the gas by

the rotating wheel. If no resistance to flow exists, as in the case of a fan in free

space with no inlet and no outlet duct, the fan provides the gas with velocity energy

only, and no compression or refraction occurs. When either inlet or outlet duct is

added frictional resistance is imposed and partial compression occurs on the outlet

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side, whereas partial refraction occurs on the inlet side. The extent of the resistance

imposed at the discharge governs the quantity of gas delivered by the fan. The

greatest volume is delivered under zero resistance or "free delivery" conditions. As

the resistance to flow is increased, the volume is decreased progressively until at

infinite resistance the volumetric delivery is zero, corresponding to "blocked tight"

or "static no delivery" condition.

In case of blowers the fans are used to force air under pressure, that is,

the resistance to gas flow is imposed primarily upon the discharge.

Laws of fans :-

1) The volume of air delivered by a fan is directly proportional to its speed and

rotation.

2) The pressure developed by a fan is directly proportional to square of fan speed.

These laws are mainly of interest to for operations of engines driving

fan, speed of rotation which can be instantly changed. They are of importance when

engines and motors are being matched to fan with regard to the power will be

absorbed as the result of altering fan speed.

Types of fans :-

Various types of fans are as follows -

a) Propeller Fan :- A propeller fan consists of a propeller or disk type wheel within

a mounting ring or plate and including driving mechanism supports either for

belt drive or direct connection.

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b) Tube axial Fan :- A tube axial fan consists of a propeller or disk type wheel

within a cylinder and including driving mechanism supports either for belt drive

or direct connection.

c) Vane axial Fan :- A vane axial fan consists of a disk type wheel within a

cylinder, a set of air guide vanes located either before or after the wheel and

including driving mechanism supports either for belt drive or direct connection.

d) Centrifugal Fan:- A centrifugal fan consists of a fan rotor or wheel within a

scroll type of housing and including driving mechanism supports either for belt

drive or direct connection.

Fan Outlet :

The outlet of the centrifugal fan is the termination of scroll shape

housing i.e. the point of connection of fan to external system.

The arrangement of the outlet connection can contribute to the

elimination of losses, making more of the total input available to the system.

Avoidance of abrupt or excessive expansion, restrictive sections, abrupt turns or

rapid change in directions is good practice. Fig. shows more common precautions to

be exercise in disposition of fan outlet connections.

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(A) Ideal conditions – straight outlet duct


Excessive expansion Normal expansion
High turbulence Minimum
losses turbulence losses

(B) Poor (C) Good

Abrupt expansion Controlled


Complete velocity expansion
head loss Minimum velocity
head loss
(D) Poor (E) Good
Restrictive turn Efficient turn
High pressure losses Low pressure
2 to 4 velocity heads losses
½ to 1 velocity
heads
(F) Poor (G) Good
Restrictive turn Efficient turn
High losses 1 to 3 Low losses
velocity heads ½ to 1 velocity
heads
(H) Poor (I) Good

Interference Noninterference
and high losses and minimum
losses

(J) Poor (K) Good


Fig. Outlet Connections

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Schematic sketch of a typical centrifugal fan wheel with ten

backward-curved airfoil blades having the maximum permissible width b. Note : d1,

blade o.d.; b, blade width; l, blade length; β1, blade angle at leading edge; β2 blade

angle at blade tip; V B1, blade velocity (fpm) at leading edge of blade; V B2, blade

velocity (fpm) at blade tip; W 1, relative air velocity (fpm) at leading edge of blade;

W2, relative air velocity air velocity (fpm) at blade tip; V 1, resulting absolute air

velocity (fpm) at leading edge of blade; resulting absolute air velocity (fpm) at blade

tip.

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Six blade shapes commonly used in centrifugal fans. The approximate

maximum efficiency attainable for each type is shown.

(3) BAG FILTER :-

Filtration is one of the most reliable, efficient and economic methods

by which particulate matter can be removed from gases. Bag filter provide a

physical barrier ( the filter cloth ) for the separation of material and air and are

essential where fine particles are being conveyed. Bag filters can efficiently

separate fine dusts. The bags need to be cleaned continuously to provide continued

efficiency of separation. Reverse pulse jets of compressed air perform this function

and are timed to release into the bags in bursts of 100 to 300 milliseconds at

frequencies between 1 and 30 seconds. They can be cleaned by rapping, shaking or

vibration.

The filter is in the form of a fabric bag arrangement tubular bags or as

cloth envelops, and is suitable for a dust loading of the order of 1 gm/m 3. A bag

house or bag filter consists of numerous vertical bags 120-400 mm diameter and 2-

10 m long. They are suspended with open ends attached to a manifold. The hopper

at the bottoms serves as a collector for the dust.

The gas entering through the inlet pipe strikes a baffle plate, which

causes the larger particles to fall into a hopper due to gravity. The carrier gas then

flows upwards into the tubes and then outward through the fabric leaving the

particulate matter as a 'cake' on the inside of the bags. Fabric filters are gaining

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importance in cement industry as problems like binding tendency, insufficient

cleaning, maintenance difficulty etc. are solved satisfactorily by those.

(4) CYCLONE COLLECTOR ( CHAMBER ) :-

It consists of a vertically placed cylinder which has an inverted conic

attached to its base. The particulate laden gas stream enters tangentially at the inlet

point into the cylindrical opening at the top. The dust particulate are collected at the

bottom in a storage hopper.

The gas path generally follows a double vortex. First, the gas spirals

downwards at the outer periphery of the cylindrical portion continues through the

conical portion and reaches the bottom. The gas stream then moves upwards in a

narrower inner spiral, concentric with the first and leaves through the outlet pipe.

Due to the rapid spiraling movement of the gas, the deeper solids are projected

towards the wall by the centrifugal force and then they drop by gravity to the bottom

of the body, where they are collected in the storage.

One particular cyclone efficiency problem is the formation of eddies

at the top of the unit where the dirty gas is introduced. The turbulence in the eddies

causes some of the incoming dirty gas to be mixed with the outgoing clean gas of

stream. The effect of this problem can be minimized by adding a central tube called

a vertex finder which projects into the cyclone body below the turbulent entry

region to confine the rising inner gas spiral.

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To get increased efficiency, specially for the collection of smaller

sized particles, a small diameter, lone taper cyclone should be used. Centrifugal

action increases with decreasing radius of rotation.

(5) ROTARY AIR LOCK VALVES :-

The one item in a pneumatic system that is hardest to properly size is

airlock or rotary valve. These not any vane valves can be airlocks or feeder valves

or a combination of the two.

One type is gravity feeder. It is usually underneath a container, bin or

hopper where it measures out an amount of product into another piece of equipment

without any differential pressure across the valve. There is no pressure differential

to consider so air flow and leakage are not concerns. To size such valves take the

displacement figure of the rotor in cubic feet per revolution and figure out the speed

the valve must run to deliver and multiply by cubic feet per hr.

Another typical gravity feeder application is the same unit feeding out

of a container into a negative system at the pickup pt, such that air leakage will be

down through the rotary valve in same direction of flow as the product. This

indicates that there is no reverse flow of air or blow back to consider. This valve is

sized the same as previous one because it, too serves as a metering device with no

regard for any problems with reverse air flow.

An airlock serving as an air seal only, is used when introducing

product from another feeding device into a pressure (positive) pneumatic system.

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Another application of pure airlock is at the outlet of a vaccum

system. This is similar to inlet of a pressure system. There is a pressure differential

across the valve and the leakage air is going to move from atmosphere into the

vaccum receiving vessel in a reverse direction to the product passing through the

valve. The product coming into this vaccum receiver is fed into vaccum system by

another means, so that it is an stream with no head of product above the valve. If

there is head of material above the valve, it is considered as feeder. If it is sealing a

pressure differential at the same time, it is airlock feeder.

If it is vast a feeder, it would have a head of material with no pressure

differential. If it is just airlock, it would have no head, but does have pressure

differential.

Following table shows criteria for picking a size and valve for a

particular application. 1 st column show size of valve ( if diameter and length ).

Next column cubic feet displacement of rotor, third column shows normal speed for

valve, next 4th column shows total displacement of rotor in cubic feet per hr, 5 th

column shows 50% of total displacement and last one shows displacement of rotor

at 25 rpm in cubic feet per hr.

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Selection Table

Size Ft3/rev. Normal Total 50% total Gravity


rpm for displacement displacement. feeder
airlock (ft3/hr) (ft3/hr.) 100%
capacity at
25 rpm
4x3 0.0119 45 32 16 18
6x4 0.03 45 82 41 45
8x6 0.118 45 314 157 171
10x8 0.24 45 648 324 361
14x10 0.68 45 1,836 918 1021
16x14 1.2 45 3,306 1653 1800
20x18 2.5 35 5,250 2625 3750
24x22 4.5 31 8,370 4185 6760
30x26 8.3 30 14,940 7470 12450

(6) DUCTING :-

Also called pipeline. Pipelines are generally of steel/ERW pipes.

Where the conveyed material is not compatible with steal, stainless steal and

aluminium are generally used. Stainless steal pipes can be this walled for economy.

In petrochemical industry, Special internal treatment to pipelines is sometimes

required to reduce frictional heat and consequent pellet melting when the pellets hit

the pipe inside during pneumatic transport. This leaves a characteristic

streamer/angel to hair which is result of solidification of pellet.

Long radius bends have radii generally in the range of 12/15 times

pipe dia. The bends must be crinkle free on the insides. In case of choked pipelines

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use of separate compressed air in lets at critical sections of conveying pipeline,

especially at bends, is also resorted to. In long conveying lines, the pipelines should

be stopped to higher diameters towards the discharge end to reduce conveying

velocities. This is specially required where delicate materials are handed and needs

controlled conveying velocities.

(7) NOZZLE :-

There are three types and nozzles

1) Convergent nozzle

2) Divergent nozzle

3) Convergent - divergent nozzle

1) Convergent Nozzle 2) Divergent Nozzle 3) Convergent-Divergent Nozzle

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(8) ARRANGEMENT OF DRIVES.

Arrangement 1. Arrangement 5.
For belt drive. Wheel For direct drive, Wheel
overhung. Bearings on overhung. Includes housing,
pedestal. wheel, shaft, one intermediate
bearing, flanged coupling and
pedestal only for motor or
engine.

Arrangement 2. Arrangement 6.
For belt drive. Pulley For direct drive. Three bearing
and wheel overhung. arrangement with fan bearing at
Bearings in bracket on inlet side. Includes housing,
fan housing. Made only wheel, shaft, one bearing (in
inlet), rigid coupling, and
in smaller sizes for pedestal only for motor or
reversible discharge. engine.

Arrangement 3. Arrangement 7.
For belt drive. Pulley For direct drive, similar to
overhung. Bearings arrangement 6, but with two
supported on fan. bearings on fan, and flexible
housing. instead of rigid coupling.

Arrangement 4. Arrangement 8.
For direct drive. Wheel Similar to arrangement 5, but
overhung. No bearings with two bearings on pedestal
on fan. Wheel mounted with motor, and flexible
on motor or engine shaft. instead of rigid coupling.
Pedestal for motor or
engine.

(D) DESIGN

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Design Parameters

Before designing or selecting pneumatic system, same factors must be

known. Most important is capacity to be conveyed, the distance over which the

product will be moved and no. of elbows involved. Elbows create large pressure

drop in air system so it is required to minimize elbows. The no. and type of pick up

location must be known as well air requirements for then. If any heating, cooling or

drying is to be accomplished, these factor too could be major sizing section.

In the conveying medium is air or gas. In product explosive, does it

requirement gas blankets. Should system be open or closed. Are notary valves

permissible. To product non abrasive so rotary valve . Works satisfactorily or will

it degraded. A pneumatic system has to be fed evenly to prevent plugging of

system.

Approach towards Design of System

Basic Data

1) Material Density

2) Distance of Conveying

3) Quantity to convey ( Volume )

Design

1) Ducting length and diameter.

2) Blower capacity.

Pressure Air Volume (CFM)

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Accordingly to blower design on basis of data of pressure and Air

volume.

Chamber Size Design

Filter Design :- Filter is designed on basis of dust size. We have taken 5 micron

Valve Design :- Valve in Designed on basis of discharge rate rpm.

We have selected rotary our lock valve.

Design Considerations.

As per following considerations we have to design our system.

We have, Total Pressure = Static Pressure + Velocity Pressure.

For finding pressure on granules we have

Static Pressure = ( weight of granules/Area )icy/Cm 2

For calculating power output of fan in HP

We have Hp = CFM × TP

6356

We have considered hp = 1

Therefore, 2 CFM = ( 6356/TP )

For calculating external and internal

CFM
We have Internal dia, d 1 = 10 3
rpm

= 8.1216 inch = 203.04 mm

18000 
External diameter, d 2 =   * SP
 rpm 

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= 15.74 inch = 393.5 mm

Blade width, b = (0.46)d1

= (0.46) * 8.1216

= 3.73 inch = 93.25 mm

Number of blades = 10

Casing dimensions

Width of casing w = 2.14 * blade width

= 7.98 inch = 199.5

r1 = 71.2 % of d2

= 10.72 inch = 268 mm

r2 = 83.7% of d2

= 10.55 inch = 313.75 mm

r3 = 96.2 % of d2

= 14.43 inch = 360.75 mm

Cut of clearance C = 5 % of d2

= 0.75 inch = 18.75 mm

Outlet diameter of housing h = 1.12*d2 – 0.3 (1.12 * d2 )

= 11.76 inch = 2.94 mm

 Velocity of air 
Now, Velocity pressure =  
4005

 5000 
= 
 4005 

= 1.55 inch = 38.75 mm


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and static pressure = 6 inch = 152.44 mm

therefore, Total pressure = 6 + 1.55

= 7.55 inch = 188.75 mm

CFM × T .P.
Power =
6356

1500 × 7.55
=
6356

= 1.76 H.P.

Therefore use 2 H.P. motor.

Belt Design :

We have selected here V-belt (B-54) for transmission of power from

motor to blower.

Length of belt = π( R 1 + R 2 ) + 2X +
( R 2 − R1 ) 2
X

L = Belt length

R1 = Radius of smaller pulley in mm

R2 = Radius of larger pulley in mm

X = Centre distance of two pulley in mm

= 3.14 ( 37.5 + 75) + 2 × 506 +


( 75 − 37.5) 2
506

= 1371.6 mm = 54 inch

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Fig. Impeller Design

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Fig. Chamber Design

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The successful and efficient operation of complete pneumatic

conveying system will depend primarily an proper system design and correct

specifications of components should be properly matched to system requirement

specially with relation to product handled.

(E) SYSTEM RELIABILITY :

A reliable pneumatic conveying system will deliver the required

capacity with no associated problems. However it is easier said than done because

of large no. of variables involved. The designer should consider each part of system

independently of system while designing at same time should be able to match

interfaces between units of each section.

Some of common system problems are

1. System Choker

2. Excessive dust and blow back

3. Excessive power consumption

4. Low throughput.

Component Reliability.

Failure of operating component of pneumatic system like slide gates

diverter valves etc are largely due to the all - pervasive nature of dust. The features

which are valve looked for individual components are effective sealing, low friction

of sliding materials and methods to prevent powder from remaining and collecting

in the units.

Practical Trouble Shooting Tips

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(1) Confirm Correct Conveying Velocity.

(2) Confirm feed rate into system.

(3) Confirm Phase Density.

(4) Check Adequacy of filter Area

(F) PERFORMANCE AND TESTING OF BLOWER :-

In performance and testing of blower, we consider the calculation of

static pressure as well as velocity pressure.

1) Static pressure calculation :-

Fig. Static pressure Calculation

Fig. Shows a cylinder with a piston that can be moved up or down. It

also shows a U-tube manometer indicating zero pressure. This means that the

pressure below the piston is same as the barometric pressure in the surrounding air.

As the piston is moved down, the air volume below the piston is compressed

manometer will register a positive static pressure relative to the atmospheric

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pressure, which is considered as zero pressure. This compressed air then has

potential energy i.e. the potential to expand to its original volume. If on the other

hand, the piston is raised, the air volume below the piston is expanded and the

manometer will register a negative static pressure relative to the atmospheric

pressure. This expanded air has also potential energy i.e the potential to contract to

its original volume. This explains the concept of positive and negative static

pressure in stationary air.

Velocity pressure calculation :

CFM is find out by means of anemometer.

Velocityofair
Velocity pressure =
4005

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MODIFICATION

The reader should regret that we have manufactured the system

according to our convenience and in the era of some limitation of source of

manufacturing. But some good modifications can be done in the system likewise,

a) Suction points may be increased as per requirement.

b) Also the delivery points may be increased

c) System may be used as the separator e.g. for removal of smokes, very find dust

particle.

d) Rotary air lock valve may be used instead of dead weight

e) System may be used for conveying heavy particles by increasing R.P.M. of

drive(motor).

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COST ESTIMATION

Definition :-

“Cost estimating may be defined as the process of fore costing the

expenses that must be incurred to manufacture a product.” Cost estimates are the job

product of the engineer and the cost accountant, and involves two factor: physical

data and closing data. The cost complies and applies the costing data.

Cost Structure :-

The elements of cost can be combined to give following type of cost

1) Prime Cost :- Prime cost or direct cost is given as

Prime cost = Direct material cost + Direct labour cost + Direct expenses.

2) Factory cost : This cost is given as

Factory cost = Prime cost + Factory expenses.

It is also called as ‘ Works costs’

3) Manufacturing cost : It is given as

Manufacturing cost = Factory cost + Administrative expenses.

4) Total cost :- It is given as

Total cost = Manufacturing cost + Selling and distribution expenses.

5) Selling price :- It is given as -

Selling price = Total cost + Profit

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COST ESTIMATION OF THE SYSTEM

Sr.No. Parts Material Qty. Cost in Rs.


1 Chamber M.S. 1 1600
2 Chamber Stand M.S. 1 200
3 Bag fitter M.S. 1 200
4 Blower M.S. 2 3500
5 Bearing M.S. 1 500
6 Pulley (Big) dia.150mm C.I. 1 200

Pulley (Small) dia. 75mm C.I. 1 145


7 V- belt B – 54 1 225

leather
8 Ducting PVC 1 800
9 Motor 2 HP - 1 3000
Total 10370

CONCLUSION

This concept of conveying plastic granules solved lot of problems

arised in the convey of granules in plastic Industries. Our system not only have

application in plastic industries but also has wide important in various field because

of its following benefits.


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Pneumatic Conveying System

1) Completely dust free operation

2) Flexibility in routing

3) Careful and gentle handling of product

4) Low maintenance and low manpower cost

5) Minimum floor space.

6) Ease of automation and control.

7) One pipeline can be used for variety of products.

8) High operational reliability due to few moving machine parts.

9) System is used for lifting the material upto 100 meter and convey the

material over more than 2 km at a rate of upto 400 tones per hour.

BIBLIOGRAPHY

1) Material handling handbook

- Mr. B. Velan

2) Material handling Handbook

2nd edition, edited by Raymond – A Kulwiec

3) Kent’s mechanical Engg. Handbook


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Pneumatic Conveying System

- By J. Kenneth Sdisburg

4) Thermal Engg.

- By R.K. Rajput

5) Fan handbook.

- By Bleier.

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SYNOPSIS

The trend of material handling has catched popularity in every nook and corner of

the world. If you consider modern industry you will find 95% of activities in industry are

being carried out automatically.

There are various ways or systems that are used to automatic work within

industries. But number of experts who have studied the system in details, they come to a

conclusion that the automation in material Handling through pneumatic can be carried out

at low cost and hence we call it as low cost automation.

Pneumatic conveying can be a viable alternative to conventional conveying

systems for bulk solids especially for in-plant applications. Types of system and

commonly specified, components are described in this article. System and component

design is discussed here. Reliability is also discussed so that the end user can specify,

evaluate and operate pneumatic conveying systems satisfactorily.

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Pneumatic Conveying System

Why A project?

An engineer discovers new ideas and, identifies


opportunities in various sectors of national economy. He
exports the possibility of standing a venture in
Agriculture, Trade Industry, Transport, Communication
and computer science etc.
An engineer project is culmination of numerous
activities on the part of enterprises, organizes designer,
developer, planner, workers and many others. Project is
a selection of hard but harmonious labors on the part of
above agencies.
An engineer is a key element in any project and it is
not possible for every engineer to attain success. An
engineer should possess certain qualification or
characteristics to achieve success on project or task
undertaken. The characteristics that contribute to the
success of engineer is of his technical competence good
judgment, leadership, self confidence, attitude,
creativeness, honesty and emotional stability.
Today the role of an engineer is entirely different
than prior to independence. He is exposed to the world
of fast changing and challenging technology. With this

C.O.E. & T.,Akola


Pneumatic Conveying System

view in mind our first Prime Minister ‘Pandit Jawaharlal


Nehru’ expressed the following thoughts.
“It is not possible for developing country like us to
borrow the technical knoe how, technicians, engineers
and scientist and financial assistance from developing
countries should develop all their aspects themselves.”
To put the thought of this great man, in execution,
engineering project is the first step for an engineer. An
engineering project is a balanced cocktail of the practical
aspect of humanities and economics. An engineer’s
ultimate aim is to do well for the society and himself for
the same.

C.O.E. & T.,Akola

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