Effect of Particle Properties on Slug Flow Conveying in a Horizontal Pneumatic Pipeline

The influence of particle properties on slug flow conveying was experimentally examined by using polyethylene particles of different densities from 825 kg/m³ to 945 kg/m³ in a horizontal pipeline 5.5 m in length, inside diameter of 32 mm, for air speeds below 8 m/s. It was found that hardness affects the slug flow conveying in such a way that for soft particles lower limiting velocity as well as boundary air velocities for suspension flow and slug flow increases. Additionally, it was found that the frictional characteristics of a particle influence its flow pattern. Also, there are two types of slug flow, that is, a solitary slug flow and a consecutive slug flow. In a solitary slug flow, there is at most only one plug in the pipeline. In a consecutive slug flow, the particles are conveyed continuously as slugs. There is always at least one slug in the pipeline.     

Effect of Particle Properties on Slug Flow Conveying in a Horizontal Pneumatic Pipeline

The influence of particle properties on slug flow conveying was experimentally examined by using polyethylene particles of different densities from 825 kg/m³ to 945 kg/m³ in a horizontal pipeline 5.5 m in length, inside diameter of 32 mm, for air speeds below 8 m/s. It was found that hardness affects the slug flow conveying in such a way that for soft particles lower limiting velocity as well as boundary air velocities for suspension flow and slug flow increases. Additionally, it was found that the frictional characteristics of a particle influence its flow pattern. Also, there are two types of slug flow, that is, a solitary slug flow and a consecutive slug flow. In a solitary slug flow, there is at most only one plug in the pipeline. In a consecutive slug flow, the particles are conveyed continuously as slugs. There is always at least one slug in the pipeline.     

Analysis of Gas-Solids Feeding and Slug Formation in Low-Velocity Pneumatic Conveying

Gas and solids feeding is a key operation in pneumatic conveying of particulate materials. This article presents an analysis of the interfacing effects between a nozzle gas supplier, a rotary valve solids feeder with dropout box, and the pipeline of a pneumatic conveying test rig for low-velocity dense-phase flow. Experiments were carried out to examine the flow pattern of slugs in different combinations of gas flow conditions and solids loading ratios. The effect of gas and solids feeding on the formation of slugs is analyzed by using both experimental data and computer-modeled results. Solids accumulation and sliding motion at the bottom of the dropout box and near the entrance of the downstream pipe, which happen prior to the bulk motion in the form of a slug, are found important in determining the size of a slug. Gas retention and pressure buildup characteristics in the feed section are also found crucial in influencing the flow patterns of slugs.     

Stress-Field Modeling and Pressure Drop Prediction for Slug-Flow Pneumatic Conveying in an Aerated Radial Stress Chamber

Slug-flow pneumatic conveying is a full-bore mode of flow within the dense-phase flow regime where bulk materials are transported in the form of slugs at conveying speeds below saltation velocity. The mechanism of slug-flow pneumatic conveying consists of the particles being picked up from the stationary bed in front of a moving slug while the same amount of material is deposited behind the slug. Stress field modeling of the material slug is the first step in developing a prediction model for the pressure drop along a pneumatic conveying line. However, a reliable prediction strongly relies on an accurate assessment of several factors, including the particle properties, pipeline dimensions, and operating conditions. So far, the particle diameter has always been one of the crucial parameters, which is not desirable in regards to the limitations it imposes on the choice of bulk materials. This article focuses on one parameter, the stress transmission coefficient k_w, which relates the lateral wall stress within a slug of material to the axial stress. To date, this parameter could not be measured directly in an aerated material bed and had to be estimated. Inaccuracies within the prediction were therefore unavoidable. A newly designed test chamber now enables the measurement of the lateral and axial stresses within a slug, which leads directly to this stress transmission coefficient. This article outlines the design of the test apparatus and reports on the experimental results. For the two materials tested, an exponential correlation between the pressure on top of the slug (frontal stress) and the stress transmission coefficient was obtained. Calculating the wall friction coefficient leads to a constant value above a certain material-specific air velocity.     

Stress-Field Modeling and Pressure Drop Prediction for Slug-Flow Pneumatic Conveying in an Aerated Radial Stress Chamber

Slug-flow pneumatic conveying is a full-bore mode of flow within the dense-phase flow regime where bulk materials are transported in the form of slugs at conveying speeds below saltation velocity. The mechanism of slug-flow pneumatic conveying consists of the particles being picked up from the stationary bed in front of a moving slug while the same amount of material is deposited behind the slug. Stress field modeling of the material slug is the first step in developing a prediction model for the pressure drop along a pneumatic conveying line. However, a reliable prediction strongly relies on an accurate assessment of several factors, including the particle properties, pipeline dimensions, and operating conditions. So far, the particle diameter has always been one of the crucial parameters, which is not desirable in regards to the limitations it imposes on the choice of bulk materials. This article focuses on one parameter, the stress transmission coefficient k_w, which relates the lateral wall stress within a slug of material to the axial stress. To date, this parameter could not be measured directly in an aerated material bed and had to be estimated. Inaccuracies within the prediction were therefore unavoidable. A newly designed test chamber now enables the measurement of the lateral and axial stresses within a slug, which leads directly to this stress transmission coefficient. This article outlines the design of the test apparatus and reports on the experimental results. For the two materials tested, an exponential correlation between the pressure on top of the slug (frontal stress) and the stress transmission coefficient was obtained. Calculating the wall friction coefficient leads to a constant value above a certain material-specific air velocity.     

Investigating Straight-Pipe Pneumatic Conveying Characteristics for Fluidized Dense-Phase Pneumatic Conveying

This article presents results from an investigation into the pneumatic conveying characteristics (PCC) for horizontal straight-pipe sections for fluidized dense-phase pneumatic conveying of powders. Two fine powders (median particle diameter: 30 and 55 µm; particle density: 2300 and 1600 kg m^?3; loose-poured bulk density: 700 and 620 kg m^?3) were conveyed through 69 mm I.D. × 168 m, 69 mm I.D. × 148 m, 105 mm I.D. × 168 m and 69 mm I.D. × 554 m pipelines for a wide range of air and solids flow rates. Straight-pipe pneumatic conveying characteristics obtained from two sets of pressure tappings installed at two different locations in each pipeline have shown that the trends and relatively magnitudes of the pressure drops can be significantly different depending on product, pipeline diameter and length and location of tapping point in the pipeline (indicating a possible change in transport mechanism along the flow direction). The corresponding models for solids friction factor were also found to be different. There was no distinct pressure minimum curve (PMC) in any of the straight-pipe PCC, indicating a gradual change in flow transition (change in flow mechanism from dense to dilute phase). For total pipeline conveying characteristics, the shapes of the PCC curves and the location of the PMC were found to be significantly influenced by pipeline layout (e.g., location and number of bends) and not entirely by the dense-to-dilute-phase transition of flow mechanism. Seven existing models and a new empirically developed model for PMC for straight pipes have been evaluated against experimental data.     

Analysis of Forced Flow of Granular Materials in Vertical Pipes without and with Air Permeation

The problems associated with grain elevation and conveying under forced flow in vertical pipes are discussed. Based on experimental results, a theory is presented to describe forced flow with varying degrees of air permeation up to and just beyond the fluidization point. The theory takes into account the boundary and internal frictional properties, the degree of consolidation of the bulk granular material, and the stress fields that occur during forced flow. The force to elevate grain in a vertical tube is shown to be composed of two components, one to overcome Coulomb friction and initiate motion, and the other a time-dependent component that depends on the stiffness and damping characteristics of the granular material. The Coulomb friction component increases approximately exponentially with column height due to the positive feedback effect of the shear stresses at the pipe wall opposing the motion. Air permeation is shown to significantly reduce this component of the conveying force by reducing both the internal friction and the apparent bulk specific weight, the latter being the actual bulk specific weight less the air pressure gradient. Air permeation has a very significant effect on reducing both the bulk stiffness and, particularly, the damping characteristics, thereby reducing the time-dependent component of the conveying force.     

Industrial Multi-Plug Conveying Analysis

Single-plug conveying systems have the advantage of being easy to handle and highly controllable. In industry, however, multi-plug conveying systems are the most common choice due to their high transporting capacity. In order to study a multi-plug industrial conveying system, the system parameters were varied along with the materials being conveyed. The responses obtained were compared to the single-plug laboratory system, noting differences and similarities. The pneumatic conveying system at an industrial facility consisted of a 0.01 m Schedule 10 aluminum pipe, approximately 100 m long. To measure the pressure at different points along the system, a total of seven transducers were installed, four air transducers and three flush transducers. This study also used a high-speed video camera to view the plugs as they passed through the transparent viewing port, providing more detailed information on the multi-plug conveying process. Three materials were tested at different superficial air velocities and solid mass flows. In each experiment all transducers took data with a sample rate of 1,000 Hz, giving a highly detailed overview of the conveying process. The analysis included plug velocity and plug size with respect to the superficial air velocity. The Mi model for plug-flow pressure drops was found to yield agreement with the data within ±25%. For this type of industrial operation, this agreement is considered acceptable. The visual observations recorded with the camera showed that there were conditions of stable plug formation as well as varying degrees of plug stability and integrity depending on the operational conditions.     

Industrial Multi-Plug Conveying Analysis

Single-plug conveying systems have the advantage of being easy to handle and highly controllable. In industry, however, multi-plug conveying systems are the most common choice due to their high transporting capacity. In order to study a multi-plug industrial conveying system, the system parameters were varied along with the materials being conveyed. The responses obtained were compared to the single-plug laboratory system, noting differences and similarities. The pneumatic conveying system at an industrial facility consisted of a 0.01 m Schedule 10 aluminum pipe, approximately 100 m long. To measure the pressure at different points along the system, a total of seven transducers were installed, four air transducers and three flush transducers. This study also used a high-speed video camera to view the plugs as they passed through the transparent viewing port, providing more detailed information on the multi-plug conveying process. Three materials were tested at different superficial air velocities and solid mass flows. In each experiment all transducers took data with a sample rate of 1,000 Hz, giving a highly detailed overview of the conveying process. The analysis included plug velocity and plug size with respect to the superficial air velocity. The Mi model for plug-flow pressure drops was found to yield agreement with the data within ±25%. For this type of industrial operation, this agreement is considered acceptable. The visual observations recorded with the camera showed that there were conditions of stable plug formation as well as varying degrees of plug stability and integrity depending on the operational conditions.     

Measurement of the Stress Transmission Coefficient of Material Slugs in an Aerated Radial Stress Chamber

In dense-phase pneumatic conveying, particles are transported along a pipeline at relatively low conveying speeds. Due to the relatively gentle handling characteristics of this mode of flow, it is suitable for conveying fragile and brittle bulk materials used in the food and chemical industries. The simulation of the stress field within a slug aims at developing an accurate prediction model for the pressure drop along a pneumatic conveying line. A reliable prediction of the pressure drop strongly depends on an accurate assessment of the particle properties, the pipeline dimensions, and the operating conditions. In past decades, a few models have been developed to serve this purpose, most of them including the mean particle diameter as a crucial parameter. This generally limits the selection of materials to those of nearly spherical particle shape, as it is extremely difficult to obtain a representative diameter for irregularly shaped particles or bulk commodities comprising differently sized and/or shaped particles. Another previously conflicting parameter is the so-called stress transmission coefficient k w , which relates the lateral wall stress within a slug of material to the axial stress. Previously, this parameter could not be measured directly in a test rig and had to be estimated; therefore, inaccuracies within the prediction were unavoidable. Consequently, a new test chamber was developed to measure the lateral and axial stresses within a slug, which leads directly to the stress transmission coefficient. The design of the test apparatus is outlined and the initial tests undertaken are reported. A strong dependence of the radial stress measurements on temperature changes of the test rig induced by the airflow was discovered. Possible solutions to compensate for this influence are addressed and further discussed.     

Modeling Dense-Phase Pneumatic Conveying of Powders Using Suspension Density

This article presents results of an investigation into the modeling of pressure drop in horizontal straight pipe section for fluidized dense-phase pneumatic conveying of powders. Suspension density and superficial air velocity have been used to model pressure drop for two-phase solids-gas flow. Two applicable models formats (developed by other researchers using two different definitions of suspension density) were used to represent the pressure drop due to solids-gas flow through straight pipe sections. Models were generated based on the test data of conveying power-station fly ash and electrostatic precipitator (ESP) dust (median particle diameter: 30 and 7 µm; particle density: 2300 and 3637 kg m^?3; loose-poured bulk density: 700 and 610 kg m^?3, respectively) through a relatively short length of a smaller diameter pipeline. The developed models were evaluated for their scale-up accuracy and stability by using them to predict the total pipeline pressure drop (with appropriate bend model) for 69 mm I.D. × 168 m; 105 mm I.D. × 168 m and 69 mm I.D. × 554 m pipes and comparing the predicted versus with experimental data. Results show that both the models with suspension density and air velocity generally provide relatively better prediction compared to the conventional use of solids loading ratio and Froude number. For fly ash, the two formats result in considerable different predictions, whereas they provide relatively similar results for ESP dust.     

An Experimental Technique for the Analysis of Slug Flows in Pneumatic Pipelines Using Pressure Measurements

An experimental technique has been developed to measure the flow characteristics of slugs in dense phase pneumatic conveying using pressure measurements. This method is based on the unique characteristics of slug flows in pipes, i.e., an axial pressure fluctuation along the pipeline and a pressure difference in the radial direction at the back of a slug. Standard differential pressure transducers were used in this study and the influence of the finite response time of these transducers was considered. Experiments were conducted over a range of gas-solids flow conditions and experimental data were analyzed to describe the behavior of solids slugs through pipes. The calculated slug velocity and length using axial pressure measurements were confirmed by video recordings, and the synthesis between axial and radial pressure signals showed reasonable agreement in flow pattern analysis. This relatively simple measuring technique has been found effective in detecting solids slugs traveling through horizontal pipes and will distinguish various flow regimes. It provides a useful and easily applied tool for system optimizing and benchmarking in industrial applications.     

An Experimental Technique for the Analysis of Slug Flows in Pneumatic Pipelines Using Pressure Measurements

An experimental technique has been developed to measure the flow characteristics of slugs in dense phase pneumatic conveying using pressure measurements. This method is based on the unique characteristics of slug flows in pipes, i.e., an axial pressure fluctuation along the pipeline and a pressure difference in the radial direction at the back of a slug. Standard differential pressure transducers were used in this study and the influence of the finite response time of these transducers was considered. Experiments were conducted over a range of gas-solids flow conditions and experimental data were analyzed to describe the behavior of solids slugs through pipes. The calculated slug velocity and length using axial pressure measurements were confirmed by video recordings, and the synthesis between axial and radial pressure signals showed reasonable agreement in flow pattern analysis. This relatively simple measuring technique has been found effective in detecting solids slugs traveling through horizontal pipes and will distinguish various flow regimes. It provides a useful and easily applied tool for system optimizing and benchmarking in industrial applications.     

Nonintrusive Monitoring of Slug Sequence and Flow Stability in Dense-Phase Pneumatic Conveying

This article presents three sensing methods developed for the nonintrusive monitoring of important flow parameters in dense-phase pneumatic conveying. With the optical measurement system, images of the flow are acquired and an image analysis is used to determine the sequence, length, and velocity of slugs for given materials and operating conditions. The conveying parameters of interest are also monitored with a capacitive sensor by means of exploiting electrical properties of the flowing media. The charge-based measurement system uses a field meter to determine the electric field strength caused by charged particles and provides information about the sequence and regularity of the moving slugs. The noninvasive principle of all three methods avoids concerns about particle contact effects (e.g., wear of the measurement equipment or interference with the flow). All three prototype sensors have been tested under slug flow conditions. A comparison of the three sensing methods against key requirements in pneumatic conveying reveals that capacitive sensing seems to be best suited for reliable flow determination in slug flow.     

Nonintrusive Monitoring of Slug Sequence and Flow Stability in Dense-Phase Pneumatic Conveying

This article presents three sensing methods developed for the nonintrusive monitoring of important flow parameters in dense-phase pneumatic conveying. With the optical measurement system, images of the flow are acquired and an image analysis is used to determine the sequence, length, and velocity of slugs for given materials and operating conditions. The conveying parameters of interest are also monitored with a capacitive sensor by means of exploiting electrical properties of the flowing media. The charge-based measurement system uses a field meter to determine the electric field strength caused by charged particles and provides information about the sequence and regularity of the moving slugs. The noninvasive principle of all three methods avoids concerns about particle contact effects (e.g., wear of the measurement equipment or interference with the flow). All three prototype sensors have been tested under slug flow conditions. A comparison of the three sensing methods against key requirements in pneumatic conveying reveals that capacitive sensing seems to be best suited for reliable flow determination in slug flow.     

Plug conveying in a horizontal tube

Plug conveying along a horizontal tube has been investigated through simulation, using a discrete element simulation approach for the granulate particles and a pressure field approach for the gas. The result is compared with the simulation of the vertical plug conveying. The dynamics of a slug are described by porosity, velocity and force profiles. Their dependence on simulation parameters provides an overall picture of slug conveying.     

Minimum Transport for Dense-Phase Conveying of Granules

The minimum transport or capacity limitation boundary for low-velocity slug-flow pneumatic conveying affects the design and operation of conveying systems. Unfortunately, the relevant mechanisms involved with this boundary still lack full understanding and assessment. Investigations have been carried out to model the capacity limitation for the low-velocity slug-flow pneumatic conveying of poly granules through horizontal pipes. Pipeline diameter, air mass flow rate, and operating pressure have been found to affect the maximum slugging capacity of this material. A semiempirical equation has been established to predict the maximum solids mass flow rate for a given air mass flow rate and conveying pipeline. Good agreement has been achieved between the model predictions and the experimental results over a wide range of airflows and pressures.     

Minimum Transport for Dense-Phase Conveying of Granules

The minimum transport or capacity limitation boundary for low-velocity slug-flow pneumatic conveying affects the design and operation of conveying systems. Unfortunately, the relevant mechanisms involved with this boundary still lack full understanding and assessment. Investigations have been carried out to model the capacity limitation for the low-velocity slug-flow pneumatic conveying of poly granules through horizontal pipes. Pipeline diameter, air mass flow rate, and operating pressure have been found to affect the maximum slugging capacity of this material. A semiempirical equation has been established to predict the maximum solids mass flow rate for a given air mass flow rate and conveying pipeline. Good agreement has been achieved between the model predictions and the experimental results over a wide range of airflows and pressures.     

MEASUREMENT OF AGGLOMERATE DENSITY IN FLOCCULATED FINE PARTICLE SUSPENSIONS

An experimental procedure has been developed for estimating agglomerate densities in flocculated suspensions. The basic technique involves simultaneous measurement of floe size and free-settling velocity in the suspending fluid. Floc density is calculated using standard expressions for free settling under the appropriate flow conditions. Experiments have been carried out using a variety of solids flocculated with commercial, polymeric flocculants. The results indicate that floc density generally decreases with increasing floc size and is limited at the smallest sizes by the density of the solid particles and at the coarsest sizes by the solids concentration in the original suspension. The experimental data have been evaluated statistically in order to establish confidence limits on the observed density-size relationships. The results are compared with previously reported experimental measurements and floc simulation studies and a simple model is proposed in which it is postulated that large flocs consist of random aggregates of relatively dense floe nuclei.     

Analytical prediction of pressure loss through a sudden-expansion in two-phase pneumatic conveying lines

Estimation of separation or minor pressure losses for pipe fittings of a pneumatic conveying system at design stage is critical as much as determination of frictional pressure losses through it. The flow in many pneumatic conveying systems is a two-phase flow; it is so complex and difficult to be investigated by experimental techniques. The static pressure recovery and the minor loss coefficient through an axis-symmetric, circular cross-section, sudden-expansion fitting of a horizontal pneumatic conveying line with air–solid particle flow are analytically studied. The theoretical models proposed in the literature are scarce, and do not confirm the experimental studies. The well-known homogeneous and separated flow models proposed in the literature are initially applied to the case by means of mass and momentum conservation laws. The predictions of both the models on the pressure recovery were compared with the experimental and the numerical data in the literature and a bad agreement was observed between them; therefore, a new original analytical model is proposed by the present study. The new model is called as the slip flow model, which takes into account the slip velocity between gas and solid phases evaluated by coupling the well-known separated flow model with the empirical slip ratio predictions in the literature. The predictions of the proposed slip flow model on both the pressure recovery and minor loss coefficient are found in good agreement with the corresponding data in the literature.