CEMENT

Pneumatic Conveying System, Introduction, Theory

Pneumatic Conveying Systems (PCS) Training

Introduction Section contents

1. 2.

Presentation of the team and 3-day program (annex) Safety

Safety during training, local information

Safety during the visit on site (day 3) - Organization Safety relating to PCS included in the relevant sub-sections

3. 4.

Pneumatic Conveying definition, technologies detailed in training DVD (general presentation)

Theory
Material, Pressure Drops, Terminology and key points, Pipeline

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General

What is a pneumatic conveying? Where can pneumatic transport be found? The pneumatic conveying consists in handling solid bulk material suspended in or forced by a gas stream through a dust proof piping We will find pneumatic transport systems where there is dry and solid bulk material

Raw mix (mill to silo, kiln feed) Pulverised coal (hopper to burner with dosing, burner) Cement (conveying to silo) Some additives: Ash, Dust, Gypsum

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Technology developed during training

Refer to the training course program: Screw-pump systems:

Mainly based on FK pumps (H, Z-flap, M type)

Overview of other technologies

Pressure vessel systems

Single or twin vessel systems

Airlift system Miscellaneous

Aero-slides Rotary valves + ejectors

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Theory - Contents

DVD presentation (20 min) The material (characteristics to be considered)

Pressure drop overview, Conveying classification (phase types, pressure)

Terminology & key points

Conveying pipeline tips

Power estimation

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Material Hardness MOHS scale

1 = Talc 2 = Gypsum

3 = Calcite
4 = Fluorine 5 = Apatite 6 = Feldspar 7 = Quartz 8 = Corundum 9 = Diamond

Cement industry: raw material 3 to 4

Cement industry: cement = 6 to 7

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Material Hardness MOHS scale

Abrasion f (speed 3.5)

Pressure f(speed 2)
Abrasion f(speed 3.5)

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Material characteristics to be considered

Moisture content (hot, dry material better for pneumatic transport)

(H2O weight / Dry material weight) % Inherent moisture + air high in moisture (dry air required) => build-up

Particle size distribution and Specific Size Area

diagram of cumulated rejects at x m, BLAINE

Bulk density kg/m3

theoretical, & actual bulk density at inlet (aerated product?)

Temperature Abrasion (see MOHS)

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Material characteristics to be considered

Angle of repose Compressibility

Ratio btw bulk material / packed tight material density

Cohesion

Fine powder = high cohesion Fluidisation aptitude of the product Aptitude to get the same behaviour as a fluid when mixed with gas Note: in a two-phase mix (gas + solid), experience is crucial for a proper understanding of behaviour, loss of pressure, friction

All these criteria will impact the conveying system design: choice of material to air ratio, air-flow, conveying velocity

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Pressure Drop, Loading Ratio (material to air ratio)

Biphasic flow (air + solids) higher P drop than air alone see next slide
Q (loading ratio) = kg material / kg air [or kg mat. / m3 air] = basic data

Pressure drop = f (loading ratio) in a range 0-10 kg/kg

Lean phase

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Dense phase

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Pressure Drop = f (gas velocity) for biphasic

A curve = P due to the air only (# proportional to v2) W curve = Wedging of the material

F curve = sliding friction of the material (slow down, reacceleration)

C = Total P = f (m/sec)

C = at higher mat./air ratio

Phase types & characteristics:

lean phase (pure suspension)

dense phase, continuous

dense , waves-motion solid phase (plugs, low speed)
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Conveying system possible classification

PRESSURE Qualified as: CONCENTRATION Material to air ratio Qualified (kg/kg - approximate) HP < 6 bar Dense (continuous or Compressor + Vessel > 40 High Wave motion) System HP < 3 bar Dense (continuous or Compressor + Vessel 15 to 40 Wave motion) System HP < 2 bar Dense (continuous) Compressor + Screw 15 to 30 Pump MP 0.5-1 bar Lean or semi-dense Roots Blower + Airlift # 13 Medium MP Lean or semi-dense Roots + Rotary 8 to 15 Feeder / MLLER P. MP Lean Roots + airlock / 4 Low ejector LP 0.3 bar Lean Multi-stages blower <3 LP < 0.15 b Lean Fan + airlock /ejector <1 Special: Fluidized aero-slide Blower or Fan PHASE TECHNOLOGY

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Terminology and key points in conveying systems

Concentration (loading ratio) = material to air ratio

Material (kg/h) /Air (m3/h) - or kg/kg Air flow QV = volume at ambient, site conditions (air compressor intake) Air (mass) flow = QV x 1.293

Loading ratio is inherent to the pipeline length and to the choice (capacity) of the conveying system technology

Refer to the previous table usually between 15 and 40 for common systems in cement industry

Next, required airflow to be calculated from this ratio & expected output Then, from a first pipeline sizing (refer to next slide), pressure Drop calculations, and finally optimization

Iterative calculation needed to optimize both conveying velocity & P

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Terminology and key points in conveying systems

Gas Velocity = actual air flow (at P bar, TC) / pipe cross-sectional area

Basic characteristics to ensure transportation of the particles and minimize wear

Pick-up Velocity (at the conveying pipeline inlet)

For common products in cement industry, usually recommended 10 m/sec, Take care to calculate the actual airflow at P bar (P1 V1 at compressor intake, P2 V2 at the pick-up point, P1 V1 = P2 V2 ) & at the estimated temperature

Exit Velocity (at the discharge point)

Exit velocity usually recommended 30 m/sec, usually at ambient pressure condition and at conveying temperature)

Gas expansion along the pipeline (speed mastering = stepped pipeline)

The air will expand as it moves down the pipeline. In a pipeline with fixed diameter, this can result in a high velocity at the end of the circuit. The pipe diameter can be increased by step to keep the velocity within a proper range (next slide).

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Terminology and key points in conveying systems

Stepped Pipeline: from the graph (principle), it is useful in a long distance system (>150m?) to keep the gas velocity in an envelope

Most economical system = minimizing both air flow (wasted energy for the air, wear) and pressure drop. Length and of each section to be carefully designed, f( material and rate)

Upper limit required to prevent wear

Lower limit required 10m/sec pick-up & conveying velocity

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Terminology and key points in conveying systems

Conveying Pipeline equivalent length E.L. (m) formula used to carry out pressure drop estimations - example: E.L. = LH + 2^LV + 5^NB = (220 m) LH = actual horizontal pipe length (150 m) LV = actual vertical pipe length (25 m)
ID 183mm L1 = 25m

ID 207mm L1 = 25m
ID 207mm L1 = 0m

NB = number of bends (4)

singular P drop Diverters, feeder TOTAL required P

ID 183mm L1 = 25m

ID 183mm L2 = 100m

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Conveying Pipeline Many types of bends can be used: Long radius bends

Recommended radius = 6 x pipe to avoid excessive P drop. With or without wear-back (thick wall)
DENSIT wear-cast 2000 type inside (corundum aggregate)

Spherical fabricated bends (permanent settling inside protecting the bend)

No problem in horizontal planes

Other types (tees,)

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Conveying Pipeline

Do not forget expansion joints wherever it is required (air intake or conveying pipe)

Ex: DILATOFLEX type, allowed pressure 1.5 to 12 bars depending on the

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Power Estimation

Rough figures, kWh/t and per m. of pipe E.L.

- From 0.01-0.02 (vessels, screw pumps) 0.02-0.03 (airlifts, MLLER pumps, rotary valves) 0.03-0.04 (rotary valve + ejector)

Simplified formulae
PKW pump = 1,3 x Q material x p P QV 60 p Patm
0,78

p = bar
Q material = kg/h

P = 900kg/m3 raw material P = 600kg/m3 dust P = 1100kg/m3 for cement

PKW compressor =

x 1,72 x

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