Pneumatic Conveying Consultancy

Aeration systems like pneumatic conveyors, vertical lifters or air slides are dominated by the air-particle interactions within the pipeline, which are numerous depending on mode of flow. In dilute or lean systems, this is dominated by lift, drag and collision forces. In dense particle laden flows, the air-particle interactions are much more complex and are largely dependent on the size distribution and density of the conveyed product.

Pneumatic Conveying Characteristics for New Design or Optimisation of Existing Systems

For both short and long distance transport as well as for both dilute and dense-phase, the pneumatic conveying characteristics can be determined either based on experimental trials, industrial data, predictive models or on both measured and predicted data depending on material and conveying system design requirements. Determination of conveying characteristics such as minimum and optimal conveying gas volume flow rate, optimal pipe diameter or diameters (for stepped pipelines), solids to gas ratio and pressure gradient along the pipeline is conducted. This provides detailed information to realise optimal design of conveying system to minimise energy use and pipeline wear in conjunction with appropriate choices for feeding, receiving and air-particle separation systems. Prediction of pneumatic conveying characteristics requires experimental determination of material flow properties.

Scale-up

Scale-up of existing pneumatic conveying systems is achieved by applying predictive scale-up rules. The scale-up procedure takes into account new process requirements such as solids mass flow rate requirements, required gas volume flow rate at pipe inlet, solids to gas ratio and pressure requirements and profile along the full length of the conveying pipeline system. Accurate scale-up requires prior determination of material flow properties described above.

Selection of appropriate feeding and separating devices

The process requirements are reviewed for recommending feeding and/or separating device that will allow process optimisation.

Process Optimisation for Minimising Wear and Maximising Service Life Based on Wear

A review of the existing conveying system is conducted with the focus on wear. Optimal conveying flow mode is determined with respect to wear minimisation using either experimental testing or predictive methods. The service life of the pipeline, especially the bends, is conducted to estimate replacement time for the pipeline and its components.

Selection of Appropriate Liner for Maximising Service Life

Wear tests are performed in a horizontal circular wear tester to assess the wear properties of a number of different wear liner materials when abraded with a material sample. The test is generally conducted over a time period of 40 hours or longer if required. This test gives outputs of the best wall material to maximise service life and an estimation of life expectancy for each liner material tested.

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