Pneumatic Conveying

Ducon Infratechnologies Ltd

There is virtually no limit to the range of materials that

can be conveyed with dilute – phase pneumatic system.
Products commonly conveyed in dilute
phase systems include: flour, resins, specialty chemicals,
ground feeds, and granular and palletized products.
Of the various types of
pneumatic systems, a dilute phase system will generally be
lowest in capital cost.
-
The dilute phase system requires relatively high
conveying air velocities depending on the material type.
This is typically in the region of 15 m/s
for a fine powder, to 20 m/s for a granular material, and beyond
for larger particles and higher density materials.

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.
At the point at which the
material is fed into the pipeline, the material will essentially
have zero velocity. In order for material to accelerate to
conveying velocities, an initial section of straight piping is
necessary.
-
Good engineering practice dictates that a
straight section equal to 25 times the pipe diameter is required
before the first bend.
The conveying velocity and hence air
flow rate is greatly influenced by material characteristics.
-
Particle shape, size distribution,
mean particle size and particle density; all have an effect on
minimum conveying velocity, pressure drop, air flow, etc.
Properties such as moisture content, cohesiveness and
adhesiveness may cause flow problems through vessels and
valves.
-
Although both materials can be conveyed pneumatically, the
pneumatic conveying regime for cement powder is likely to be
quite different for the regime selected for wet lump coal.
-
The reason for this concerns the properties of
the bulk material and how these properties interact during the
pneumatic conveying process.
-
For example, cement powder
may be easily fluidized and mixed with air.
When conveyed at
high velocities, it will not degrade to the detriment of the bulk
material. -
Wet,
lump coal (2" mean size), on the other hand, cannot be
fluidized without severely degrading the material to the
extreme detriment of the coal product.
-
These factors affect the choice of allowable
may be easily fluidized and mixed with air.
When conveyed at
high velocities, it will not degrade to the detriment of the bulk
material. -
Wet,
lump coal (2" mean size), on the other hand, cannot be
fluidized without severely degrading the material to the
extreme detriment of the coal product.
-
These factors affect the choice of allowable
material velocities through the pipeline.
-
Different grades of exactly the same
material can exhibit totally totally different performances.
For practical purposes, a
conservative design approach is to keep the ratio of standard
cubic feet of air to pounds of material below a 2.25:1
proportion. -
Successful systems
have been designed using air-material loadings of 1:1 or more
when the system components are well-designed and eliminate
sharp turns, abrupt junctions, or other potential points of
binding, clogging, or drop-out. different performances.

Sufficient velocities must be maintained throughout the conveying

system to avoid material settling. When settling occurs in the
horizontal plane, it is known as saltation.
-
When settling occurs in the vertical plane, it is called choking.
-
Saltation is
the process of deposition of solid particles along a horizontal
pipeline. This phenomenon occurs when the air velocity falls below
the minimum conveying value.
-
Caution – Don’t select a velocity higher than needed. The
additional velocity would be detrimental to the system by causing
increased friction, wear, and operating costs.
-
Choking in downward movement often occurs in the vertical line as
a direct result of saltation in the adjacent horizontal line.
-
Upward movement is often easier to control because all that is
needed is sufficient momentum (velocity) to keep the material in
suspension. -
-
All falling materials simply drop back into the airstream.
However choking in the upward flow directly above
the fan discharge will exhibit premature wear due to excessive
loading.
-
To minimize the potential for saltation or choking, it is
recommended to minimize bends and elbows and also remove any
leaks because velocity will be less downstream of leaks.
-
It is good to consider some excess air in the system
design that will effectively increase velocities in the system to assist
material transportation.
Some provisions may be included to keep in the
system for bleeding excess air through adjustable vents or
dampers.
material transportation.
Some provisions may be included to keep in the
system for bleeding excess air through adjustable vents or
dampers.

END OF WORKSHEET
matic Conveying
ratechnologies Ltd
Source: http://www.foxvalve.com
Fox Valve is the leading global supplier of venturi eductors
and venturi transport systems for pneumatic conveying of
powders, pellets, and bulk solids. They enable the use of
low pressure air ( below 14 psig or 1 bar) to be used
to move powders, pellets, and bulk solids with no moving
parts. Fox has sold venturi eductors continuously since our
first sale, in 1963, of a stainless eductor for use in
transporting plastic pellets with air at 4 psig.
PNEUMATIC CONVEYING SPREADSHEET-CONTENT
2 PDH Professional Development Hour course content
© Copy right John Andrew P.E., 30 July 2012

TURBULENT FLOW PNEUMATIC CONVEYOR

To scroll, roll the mouse wheel.

To zoom in, depress the Ctrl key and roll the mouse wheel away from you.
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To lock the cells of this spreadsheet: Home > Format > Protect Sheet.

Dilute Conveying
Ratio of standard cubic feet of air to pounds of material below a 2.25:1 proportion.
Dilute conveying stream flow is the most common pneumatic method.
Dilute conveying stream flow; air volume / solids weight > 2.25
Dilute and pulse conveying stream flow; 2.25 < air volume / solids weight < 0.20
Pulse conveying stream flow; air volume / solids weight > 2.25
High linear air velocities (4,200 to 6,500 ft/min)

Pipe Internal Diameter

Input
Pipe outside diameter, de = 12.000 in
Pipe wall thickness, t = 0.280
Calculate
Pipe inside diameter, d = d - 2*t
= 11.440 in
Pipe inside section area, A = π*(d/12)^2 / 4
= 0.7138 ft^2

Conveyor Pipe Friction Head Loss Quiz 6

Input-1 Input-1
Material conveyed is; Sawdust Sawdust
Bulk mMaterial flow rate is, W = 1800 lb/hr 1800
Bulk material density is, ρm = 11.0 lb/ft^3 11.0
Air volume flow rate, q = 785.0 cfm 785.0
Pipe internal diameter, d = 6.065 in 6.065
Roughness in inches, ei = 0.0018 in 0.0018
Suction + Discharge length of straight pipe, L = 100.0 ft 100.0
Air viscosity, µ = 0.0000003750 ft^2/sec 0.0000003750
Air density, ρ = 0.075 lbs/ft^3 0.075
Blower efficiency, EffP = 60% % 60%
Drive efficiency - Gear or Belt, EffD = 80% % 80%
Motor efficiency, EffM = 90% % 90%
 Output-1
Solids volume flow rate, Qs = W / 60
= 30.000 lbs/min
Ratio: air cfm volume / lb/min solids weight , R = Qs / q
= 26.2 R > 2.5 OK, dilute air flow
Gravitational constant, g = 32.2 ft/sec^2
Round pipe hydraulic dia = internal diameter, D = d/12
= 0.5054 ft
Pipe internal area, A= 3.1416*D^2/4
= 0.2006 ft^2
Air flow volume, Q = q / 60
= 13.083 ft^3/sec
Air flow velocity, V = Q / A
= 65.21 ft/sec
= 3913 ft/min
Air mass density, ρM = ρ / 32.2
= 0.002329 slugs/ft^3
Reynolds number, Re = D * V * ρM / µ
= 204,716 OK, turbulent air flow
Note that the velocity of the flow in the Reynolds calculation
is based on the actual cross section area of the duct or pipe.
Reynolds number Re

The flow is:

laminar when Re < 2300
transient when 2300 < Re <
4000
turbulent when Re > 4000
Click GOAL SEEK tab below for friction factor f calculation method.
Darcy-Weisbach friction factor f calculated from the Colebrook-White equation.
http://www.engineeringtoolbox.com/darcy-weisbach-equation-d_646.html
Input-2
Guess friction factor, f = 0.01616 ft 0.01616
Output-2
Roughness, e = ei / 12
= 0.00015 ft
Relative roughness, e / D = 0.00030 << See Moody diagram >>
1 / f^0.5 = -2*LOG10((e / 3.7*D) + (2.51 / (Re*f^0.5)))
Both sides of equation are divided by (f^0.5), 1 = f^0.5* (-2*LOG10((e / 3.7*D) + (2.51 / (Re*f^0.5))))
SOLVED IF: 0.9990 < f < 1.0002, 1 = 0.9997
Output-3
Air flow head loss, ΔP = f*(l / dh) (ρ v / 2)
2

ΔP = f*(L/d)*(ρ*V^2 /2)
ΔP = 42.49 in H2O/100 ft
Minimum blower motor power, PM = q * (ΔP /12) / (3960 * EffP * EffD * EffM)
 = 1.62 hp
Use a standard blower motor = 2.0 hp

Ref: http://www.engineeringtoolbox.com/darcy-weisbach-equation-d_646.html
Pressure Loss
The pressure loss (or major loss) in a pipe, tube or duct can
be expressed with the Darcy-Weisbach equation
Δp = f (l / dh) (ρ v2 / 2)
where
Δp = pressure loss (Pa, N/m2)
f = Darcy-Weisbach friction coefficient
l = length of duct or pipe (m)
dh = hydraulic diameter (m)
ρ = density (kg/m3)

The friction coefficients used to calculate pressure loss

(or major loss) in ducts, tubes and pipes can be calculated with
the Colebrook equation
1 / f1/2 = -2 log [ 2.51 / (Re f1/2) + (k / dh) / 3.72 ] (1)
where
f = Darcy-Weisbach friction coefficient
Re = Reynolds Number
k = roughness of duct, pipe or tube surface (m, ft)
dh = hydraulic diameter (m, ft)
The Colebrook equation is only valid at turbulent flow
conditions.

END OF WORKSHEET
DENSITY CONVERTER
http://www.flowmeterdirectory.com/densitycalculator.php
pneumatic conveying.xls PNEUMATIC CONVEYING (dilute phase)
Solids mass flow rate: 800 kg/h
Mean particle size: 80 micron
Density of gas: 1.2 kg/m^3
Density of solids: 2500 kg/m^3
Vertical distance: 30 m
Horizontal distance: 15 m
Number of 90' bends: 8
Gas viscosity: 0.0000184 Pa.s
********************************************
Solids mass flow rate: 0.222222222 kg/s
Mean particle size: 0.00008 m
********* ********* ********* ********* *********

Pipe Saltation Superf'l Solid Solids Porosity

diameter velocity gas vel. velocity flux

(mm) (m/s) (m/s) (m/s) (kg/m^2s) (-)

78 9.53 14.30 11.61 46.51 0.9984
63 9.94 14.91 12.10 71.29 0.9976
50 10.40 15.60 12.67 113.18 0.9964
40 10.87 16.30 13.23 176.84 0.9947

Pipe Interst'l Slip Particle Drag Flow Gas

diameter Gas velocity Re coeff't Reynolds friction
velocity number number factor
(mm) (m/s) (m/s) (-) (-) (-)
78 14.32 2.71 14.16 1.6326 72840.96153 0.004820935
63 14.95 2.84 14.83 1.5833 61404.5076 0.005031241
50 15.66 2.99 15.62 1.5299 51063.4214 0.00526863
40 16.39 3.16 16.47 1.4776 42760.32266 0.005507632

********* HORIZONTALLY *********

Pipe Solid Pressure Pressure Pressure Pressure Total
diameter friction loss by loss by loss by loss by Pressure
factor gas ac'n sol ac'n gas fr'n sol fr'n drop
(mm) (-) (Pa) (Pa) (Pa) (Pa) (Pa)
78 0.0313 123 270 455 6506 7355
63 0.0247 134 431 641 10168 11374
50 0.0192 147 717 927 16534 18325
40 0.0151 160 1170 1325 26558 29214

********* VERTICALLY ********* ** * BENDS * **

Pipe Solids Gas Friction Total ** Pressure **
diameter static static losses pressure ** drop in **
 head head drop ** bends **
(mm) (Pa) (Pa) (Pa) (Pa) ** (Pa) **
78 1179 353 1803 3335 ** 6670 **
63 1733 352 2802 4888 ** 9776 **
50 2630 352 4565 7546 ** 15092 **
40 3932 351 7385 11669 ** 23337 **
TOTAL Gas flow
PRESSURE rate
DROP
(bar) (m3/s)
0.17 0.0683213322
0.26 0.0464835359
0.41 0.0306413346
0.64 0.0204906787
PNEUMATIC CONVEYING SPREADSHEET-CONTENT
2 PDH Professional Development Hour course content
© Copy right John Andrew P.E., 30 July 2012

HYDRAULIC DIAMETER
http://www.engineeringtoolbox.com/hydraulic-equivalent-diameter-d_458.html
The hydraulic diameter - dh - is used to calculate the dimensionless Reynolds Number
to determine if a flow is turbulent or laminar.
A flow is:
laminar if Re < 2300
transient for 2300 < Re < 4000
turbulent if Re > 4000

Note that the velocity of the flow in the Reynolds calculation is based on the
actual cross section area of the duct or pipe.
The hydraulic diameter is also used to calculate the pressure loss in a ducts or pipe.

The hydraulic diameter is not the same as the geometrical diameter in a non-circular
duct or pipe and can be calculated with the generic equation.

Hydraulic Diameter of a Circular Tube or Duct = the diameter

Input
Duct internal diameter, d = 10.136 in
Calculate
Duct internal section area, A = π*(d/12)^2 / 4
= 0.5604 ft^2
Wetted perimeter of the duct , p = π*d / 12
2.653605 ft
Hydraulic diameter , dh = 4*A / p
= 0.8447 ft
= 10.136 in

Hydraulic Diameter of a rectangular duct.

Input
Duct internal section width, w = 10 in
Duct internal section height, h = 5 in
Calculate
Duct internal section area, A = w*h/144
= 0.3472 ft^2
Wetted perimeter of the duct , p = 2*(w + h)
= 2.500 ft
Hydraulic diameter , dh = 4*A / p
= 0.5556 ft
= 6.667 in
0.1
END OF WORKSHEET
Pipe Internal Diameter
Input
Pipe external diameter, de = 10.75 in
Pipe wall thickness, t = 0.25
Calculate
Pipe internal diameter, d = d - 2*t
= 10.250 in
Duct internal section area, A = π*(d/12)^2 / 4
= 0.5730 ft^2
Standard Pipe Fittings Dimensions
http://www.steelindiaco.com/pdf/buttweld%20fittings.pdf
http://www.hackneyladish.com/DimensionData-pr1.aspx

Standard Pipe Dimensions

http://www.hackneyladish.com/DimensionData-pr5.aspx
PNEUMATIC CONVEYING SPREADSHEET-CONTENT
2 PDH Professional Development Hour course content
© Copy right John Andrew P.E., 30 July 2012

GOAL SEEK

Some advantages of spreadsheet calculations over

hand written include:
1. easier to read.
2. better recall from archives.
3. greater accuracy.
4. faster with repeat use.
5. graphs are created automatically.
6. numerous useful formulas.
7. "Goal Seek" enables optimization.
8. solve any equation with, "Solver".
9. solve sets of linear and non-linear
equations.

To scroll, roll the mouse wheel.

To zoom in, depress the Ctrl key and roll the mouse wheel away from you.
To open another, "Work Sheet Lesson" select a tab at the bottom of this spreadsheet.
To unlock the cells of this spreadsheet: Home > Format > Unprotect Sheet.
To lock the cells of this spreadsheet: Home > Format > Protect Sheet.

GOAL SEEK OPTIMIZATION

Use these live cells for Goal Seek
Conveyor Pipe Air Flow Velocity
Input
Material conveyed is; Sawdust
Air volume flow rate, q = 785.0 cfm
Round pipe internal diameter, d = 7.500 in
Air density, ρ = 0.075 lbs/ft^3
Calculate
Round pipe hydraulic dia = internal diameter, D = d/12
Insert "Goal Seek"
= 0.6250 ft dialog box here.
Pipe internal area, A= 3.1416*D^2/4
= 0.3068 ft^2
Air flow velocity, V = Q/A
= 2559 ft/min or fpm

Step-1 Select cell containing a formula: G38 (Yellow)

Step-2 Pick drop-down menu: Data > What-If Analysis > Goal Seek
Step-3 Pick the "To value" cell and type 1
Step-4 Pick the "By changing cell" next pick cell that needs to change "G30" > OK
GOAL SEEK EQUATION SOLVING
Use these live cells for Goal Seek
Friction Factor f Calculation
Input-2
Guess friction factor, f = 0.02 ft Insert "Goal Seek"
Round pipe hydraulic dia = internal diameter, d = 10.000 in dialog box here.
Roughness, e = 0.000150 ft
Reynolds number, Re = 165,000 -
Colebrook-White Equation Output-2
Round pipe hydraulic dia = internal diameter, D = d/12
= 0.8333 ft
-2*LOG10((e
1 / f^0.5 = / 3.7*D) + (2.51 / (Re*f^0.5)))
Both sides of equation are divided f^0.5* (-2*LOG10((e
by (f^0.5), 1 = / 3.7*D) + (2.51 / (Re*f^0.5))))
SOLVED IF: 0.9990 < f < 1.0002, 1 = 1.0889

GOAL SEEK METHOD

Step-1 Select cell containing a formula: G60 (yellow)
Step-2 Pick drop-down menu: Data > What-If Analysis > Goal Seek
Step-3 Pick the "To value" cell and type 1
Step-4 Pick the "By changing cell" next pick cell that needs to change "G52" > OK > OK
Darcy-Weisbach friction factor f calculated from the Colebrook-White equation.
http://www.engineeringtoolbox.com/darcy-weisbach-equation-d_646.html

END OF WORKSHEET
 GOAL SEEK OPTIMIZATION
Example only cells are locked
Conveyor Pipe Air Flow Velocity
Input
Material conveyed is; Sawdust
Air volume flow rate, q = 785.0 cfm
Round pipe internal diameter, d = 7.500 in
Air density, ρ = 0.075 lbs/ft^3
Calculate
Round pipe hydraulic dia = internal diA, D = d/12
sert "Goal Seek"
alog box here. = 0.6250 ft
Pipe internal area, A= 3.1416*D^2/4
= 0.3068 ft^2
Air flow velocity, V = Q / A
= 2559 ft/min or fpm

Step-1 Select cell containing a formula: G38 (Yellow)

Step-2 Pick drop-down menu: Data > What-If Analysis > Goal Seek
Step-3 Pick the "To value" cell and type 1
Step-4 Pick the "By changing cell" next pick cell that needs to change "G30" > OK
 GOAL SEEK EQUATION SOLVING
Example only cells are locked
Friction Factor f Calculation
Input-2
rt "Goal Seek" Guess friction factor, f = 0.01694 ft
og box here. Round pipe hydraulic dia = internal dia, d = 8.000 in
Roughness, e = 0.000150 ft
Reynolds number, Re = 165,000 -
Output-2
Round pipe hydraulic dia = internal diameter, D = d/12
= 0.6667 ft
1 / f^0.5 =-2*LOG10((e / 3.7*D) + (2.51 / (Re*f^0.5)))
Both sides of equation are divided by (f^0.5), 1 = f^0.5* (-2*LOG10((e / 3.7*D) + (2.51 / (Re*f^0.5))))
SOLVED IF: 0.9990 < f < 1.0002, 1 = 1.0001

GOAL SEEK METHOD

Step-1 Select cell containing a formula: G62 (yellow)
Step-2 Pick drop-down menu: Data > What-If Analysis > Goal Seek
Step-3 Pick the "To value" cell and type 1
Step-4 Pick the "By changing cell" next pick cell that needs to change "G52" > OK > OK
s to change "G30" > OK
D) + (2.51 / (Re*f^0.5)))
e / 3.7*D) + (2.51 / (Re*f^0.5))))

e "G52" > OK > OK

DUCON TECHNOLOGIES (I) PVT.LTD.
Ducon house, Plot no. A/4
Road no. 1, MIDC, Wagle Industrial Estate
Thane (W), 400601
Tel: 91-22-41122114,41122180 (D)
Fax: 91-22-4112 2115
Project Name : Nalco Anode Slot cutting conveying Date : 24/7/2018
Project No. : DTI-075 Made By : NK
Title : Design of Conveying rate & Compressor sizin Chckd By : RR
Input for conveying ( Carbon dust).
Surge hopper capacity ( Tag. No. SH001) ( 1.5 m3). 2.4 Tons
Transfer rate of screw conveyor below surge hopper 6.4 Tons/Hr.
Conveying vessel capacity ( Tag. No. CV-001) (1 m3) 1.6 Ton
Filling time of conveying vessel 15 min

Conveying rate after conveying vessel 40 Kg/min

Time required to convey 1.6 T of material from conveying 40 min

A) Air requirement / Cycle for 96.36m 50 NB sch 40 line

Density of material max 1600 Kg/M3
Volume of Blow tank 1 M3
Effective volume of tank to material fill 0.9 M3
Hence per batch 1440 Kg
No of batch estimated 1 Batches
Air to Material Ratio 10
Wt of Air required/ batch 144 Kg
Air density @ 50°C @ ATM 1.096 Kg/M3
Pressure correction at 3 barg ( 4 bar abs) 4.288 Kg/M3
Volume air required/ batch @ 4 bar 33.5856 M3
Maximum capacity of blow tank for 50mm ID is 12 TPH @ 100% . Average capacity 6 TPH
Total Air Consumption / Cycle 34 M3

B) Conveying time calculation / cycle 33.5856 M3

Total volume of air / cycle 0.9 M3
Total volume of material /cycle 34.4856 M3

Size of conveying line( pipe I.D) 0.05248 M

Area of conveying line 0.00216 M2
Air velocity considered 12 M/sec
Volumetric flow rate of conveying line 0.02594 M3/sec

Hence time requirement for conveying / cycle 1329.23 Sec

22.1538 Minutes
No of batch estimated 1 Batches
 Hence Conveying time / Cycle 22 Minutes
Blow tank characteristic curve for 50 NB 150 m long ( Ducon propritery detail).
Time conveying rate Time
0 0 6
2 5
5
4 5
6 4 4
8 4
3
10 4
12 4 2
14 4
1
16 3
18 2 0
0 2 4 6 8 10 12 14 16 18 20 22 24 26
20 1
22 0
Total 36 Vessel empty graph.
Averge 1.636 > 1.44

C) Hence Air Consumption @ 4 bar abs. / Hr (A/B) 91 M3/hr ( @ rated capcity)

D) Calculation of FAD of compressor

P1 Pressure ATM 1 Bar(abs)
T1 Intial Temp 273 °K
P2 Pressure at outlet 4 Bar(abs)
V2 Volume 91 M3/hr
T2 Outlet Temp 313 °K

V1 Volume FAD @ 0°C 317 M3 / Hr FAD 0.097 kg/s

Per batch 1440 kg conveyed at 22 minutes and hence rated capacity of system
:. Conveying Rate determined as (Calculated) 3900 Kg/hr (rated capcity)
4463 Kg/hr (Design capcity)
:. Conveying Rate determined as (Calculated) 65 kg/min
Exit velocity = 44.6874 m/sec
DUCON TECHNOLOGIES ( I ) PVT. LTD.
Ducon house, Plot no. A/4
Road no. 1, MIDC, Wagle Industrial Estate
Thane (W), 400601
Tel: 91-22-41122114,41122180 (D)
Fax: 91-22-4112 2115
Project Name : Nalco Anode Slot cutting conveying Date : 24/7/2018
Project No. : DTI-075 Made By : NK
Title : Design of Conveying rate & Compressor sizin Chckd By : RR
INPUT DATAs
Volumetric flow of compressor 317 M3/h FAD 0.097 kg/sec
Inlet pressure @ conveying pipe 3 bar abs
Inlet Tempreture @ conveying pipe 80 °C
Conveying pipe line size 2 in
Conveying length - Horizontal 242 ft
Conveying length - Vertical 74 ft
No of bends 6 Nos
Bending radious D/d =5 K= 0.15 280 mm
Hence @ Inlet condition of conveying pipe
V1 = 70.65 ft3/min
P1 = 43.50 lbf/in2
T1 = 635 R

Finding @ outlet condition of conveying pipe

V2 = 187 ft3/min
P2 = 14.7 lbf/in2
T2 = 582 R

Finding pipe line Velocity

Inlet condition C1 = 3239 ft/min

Exit condition C2 = 8553 ft/min

CALCULATION OF CONVEYING CAPABILITIES BY

UNIVERSAL CONVEYING CHARACTERISTIC METHOD

Air only Pressure drop

∆Pa = f L S k r C22
+ x
21600 d 1036800 gc
Lb= equivalent length of bend = Kd/4f 0.488 1.598
f = Pipe friction coefficient 0.004
d = Diameter of pipe 0.052 m
Sk = Bend loss co-efficient 0.15
r = Air density @ end of pipe line 0.0765 lb/ft3
 gc = Gravitational constant 32.2 ft lb / lbf s2
L = Equivalent length of conveying pipe
Le = Lh + 2 Lv + (N *2Leb) 409 ft 124.8 m

∆Pa = ( 3.7887067E-05 + 9.2497723E-06 ) x 82583.46

∆Pa = 3.893 lbf/in2

Pressure drop with material

In Straight pipe line

By scaling method equivalent pressure gradient as worked as 8 PSI/100ft.

∆Pp = 3 ( 242 + ( 2x 74 ) )
x
100

∆Pp = 19.50 lbf/in2

In bends

∆Pb = N x 0.8

∆Pb = 4.80 lbf/in2

Total System Pressure drop

∆Pc = ∆Pp + ∆Pb + ∆Pa

∆Pc = 28.19 lbf/in2

Mass Air flow rate ma (as per Ideal Gas law)

( @ Inlet condition )
ma = p p d2 C x 60
4R T

R = Characteristic gas constant of air 53.3 ft lbf / lb

C = Velocity of pipe line

ma = 784.575 lb/h

Mass Material flow rate mp

mp = ma ( P / ∆Pa - 1)
 = 785 ( 43.50 / 3.893 - 1) P = Gauge

mP = 7982.81 lb/h

mP = 3.6 T/h
Air to Material Ratio
f = mp / ma

f = 10

Inlet conveying velocity ( as above )

= 16.46 m/s

STEADY FLOW ENERGY EQUATION METHOD

Wa = Ep + Ea

Wa Energy Input to conveying pipeline

Ep Energy transferred to conveyed material
Ea Energy transferred to conveying air

Wa = ma ( p1 v 1 - p2 v 2 )
229.2 x ( n - 1)
ma - Mass Air Flow rate 13.08 lb/min
P1 - Inlet pressure 43.50 lbf/in2
P2 - Outlet pressure 14.70 lbf/in2
V1 - Specific volume RxT / 144 p 5.40 ft3/lb
V2 Specific volume RxT / 144 p 14.65 ft3/lb

= 256.52
45.84

Wa 5.60 hp

Ep = mp x g x hp
1.98 x gc x 106

mp - Mass Air Flow rate of conveyed material lb/min

g - gravitational accelration 32.2 ft / s2
gc - Gravitational constant 32.2 ft lb / lbf s2
 hp - Total system head loss ft
hk + hh + hv + Nhb

Accleration loss hk

hk = ( 0.8 x C22 )
7200 x g

hk = 0.02951 ft
Horizontal line loss

hh = lh x Lh lh = 0.5

hh = 121 ft

Vertical line loss

hv = lv x Lv lh = 1

hh = 74 ft

Bend losses
hb = lv x C2 lh = 1.5
7200 x g

C = ( C12 + C22 )0.5

2
= 6466.99

hb = 180.39 ft

Total system head loss

:. hp = 205.85 ft

Ep = mp X 6628.47
63756000

= 1.040E-04 mp hp ( 0.82994 )

Ea = ma x g x ha
33000 x gc

ma - Air Mass Flow rate 13.0762

 g - gravitational accelration 32.2 ft / s2
gc - Gravitational constant 32.2 ft lb / lbf s2
ha - Total system head loss ft
hf + Nhba

Pipe line friction loss

hf = 48 x f x L C2
X
d 7200 x g

Where

f - Pipeline friction coefficient 0.0045

L - Total pipeline length Lh + Lv 316 ft

hf = 61.56 ft

Bend Losses

Nhba = N x d
1.44

= 8.33 ft
Total head loss
ha = 69.90 ft

Ea = ma x g x ha
33000 x gc

Ea = 0.028 hp

Wa = Ep + Ea

5.60 = 0.0001039662 mp + 0.028 ( 0.858 )

:. mp = 53558.96 lb/h

MASS FLOW RATE CAN BE ACHIVED

= 24.34 T/hr

Mass flow rate confirmed by Air pressure only method 3.63 T/hr
Mass flow rate confirmed by Steady flow energy equation Method 24.34 T/hr
CONCLUSION
Design check made in both Energy flow study model & Universal conveying characteristic
Methods Both result shows system can convey upto 3.63 TPH. Hence design OK.
By Error Margin of head loss by 20%, system can optimized to 4.5 TPH minimum.
Air to material ratio to be optimized up to 1:25 as per cocke dust characteristic.
Pressure of compressor shall be selecter 4.5 bar as per Maximum requirement.

COMPRESSOR SIZING CALCULATION WITH RELEVANT AIR TO MATERIAL RATION 1:25

A) Air requirement / Cycle
Density of material 1600 Kg/M3
Volume of Blow tank 1 M3
Effective volume of tank to material fill 0.9 M3
Hence per batch 1440 Kg
No of batch estimated 1 Batches
Air to Material Ratio 10
Wt of Air required/ batch 144 Kg
Air density @ 50°C @ ATM 1.096 Kg/M3
Pressure correction at 3 barg ( 4 bar abs) 4.288 Kg/M3
Volume air required/ batch 33.5856 M3

Total Air Consumption / Cycle 34 M3

B) Conveying time calculation / cycle 33.5856 M3

Total volume of air / cycle 0.9 M3
Total volume of material /cycle 34.4856 M3

Size of conveying line( pipe I.D) 0.05248 M

Area of conveying line 0.00216 M2
Air velocity considered 12 M/sec
Volumetric flow rate of conveying line 0.02594 M3/sec

Hence time requirement for conveying / cycle 1329.23 Sec

22.1538 Minutes
No of batch estimated 1 Batches

Hence Conveying time / Cycle 22 Minutes

C) Hence Rating of Air Consumption / Hr (A/B) 91 M3/hr

D) Calculation of FAD of compressor

P1 Pressure ATM 1 Bar(abs)
T1 Intial Temp 273 °K
P2 Pressure at outlet 4 Bar(abs)
V2 Volume 91 M3/hr
T2 Outlet Temp 313 °K
 V1 Volume FAD @ 0°C 317 NM3 / Hr

:. Conveying Rate determined as (Calculated) 3900 Kg/hr

COMPRESSOR SELECTION IS NEAREST MODEL OF 317 NM3/Hr,

HENCE EXCESS AIR CAN UTILISED FOR SYSTEM BETTERMENT.
ACTUAL PRESSURE DROP AS PER SYSTEM DESIGN SHALL BE 2 BAR 2 . 8.19 PSI
SELECTED PRESSURE OF COMPRESSOR SHALL BE 4.5 BAR CONSIDERING CHOCKING .
BUSTER LINE OF 25 NB WITH 4.5 BAR SHALL BE PROVIDED TO RELEASE CHOCKING .
SELECTED PRV 50 NB PRESSURE RATING 2 TO 3 BAR . WITH FLOW RTE 317 Nm3/hr.

REFRANCE CHARACTERISTIC CURVE

Pneumatic Conveying Design Guide( Second Edition) David Mills.