Theory and Design of Dilute Phase Pneumatic Conveying System
Theory and Design of Dilute Phase Pneumatic Conveying System
Theory and Design of Dilute Phase Pneumatic Conveying System
1 January/February 2005
Introduction
This article describes the theory and calculation method for designing dilute phase pneumatic conveying systems. It is based
on the work of Dr. F.A. ZENZ and Dr. D.F. OTHMER as described
by them in their book "Fluidization and Fluid-Particle Systems"
published in 1960 (Ref. 1). This method was later modified by
Dr. ZENZ based on his research work during the 70's and 80's
and published in the proceedings of the Particle Science Research Institute (PSRI). Although, several other methods have
been published since then, this method has been used widely
and has been found to be within about 10% of the actual measured pressure drop.
This calculation method can be used to perform the following
functions:
2.
Calculation Method
In their book published in 1960, ZENZ and OTHMER give the following two equations for calculating pressure drop in dilute
phase conveying systems:
Horizontal Lines:
PT(HOZ) =
Vertical Lines:
1.
The calculations for the design of a dilute phase conveying system are based on determining the pressure drop that is generated in the system due to the flow of gas and solids. ZENZ and
OTHMER state that this pressure drop, for both dilute and dense
phase conveying, is composed of six effective forces:
1. Friction of the gas against the pipe wall.
2. Force required for moving the solids mass through the conveying pipeline.
Vg2 g W Vp 2 g Vg2 L
+
+
2 g
g
g D
PT(VERT) = PT(HOZ) +
WL
Vp
For horizontal lines, the first term is the pressure drop due to the
acceleration of gas, the second term is the pressure drop due to
the acceleration of solids, the third term is the pressure drop
due to friction between the gas and the pipe wall, and the fourth
term is the pressure drop due to the flow of solids through the
pipeline.
For vertical flows another term (WL/Vp) is added to represent
the weight of the supported solids in the vertical line.
The nomenclature used in the above equations is given below:
Vg = Gas velocity
g = Gas density
W = Solids mass velocity, [lbs/secft2]
Vp = Particle velocity
= Fanning friction factor
L = Length of pipeline
18
p Vp
W
1 +
Vg Vg g
Eq. 2:
Based on this work the term for solids pressure drop was
changed to:
Eq. 3:
Ps = Pg K
Pg
4 L g Vg2
2g D 144
4 L g Vg2
9266 D
Eq. 4:
Ps
Pg =
W
= Pg K R
Vg g
where,
Eq. 5:
Eq. 6:
Z g
144 gc
Z W g
144 Vp gc
Nomenclature
The nomenclature and the units that are used in the above six
equations are given below:
D
gc
Vg
Vp
These six pressure drop terms given above are related to the
two pressure drop equations given by ZENZ and OTHMER. These
terms are then converted to the units that are commonly used in
pneumatic conveying systems, resulting in the following equations where pressure drop is expressed in lbs/square inch.
Eq. 1:
= Friction multiplier
Vp
= Solids velocity
where,
PT
Ps
W VP
W VP
=
144 g
4640
2.1
2.4
D Vg g
g
0.331
7 2
+
logn
3.7
D
N
Re
where is the pipe roughness factor. Pipe roughness factor depends on if the pipe is internally smooth, rough, or very rough.
The value of this factor based on test data is given below:
for internally smooth pipes,
= 0.00015;
= 0.0005;
2.2
Degree of bend
(1 0.8) Vp1
Vp2 = 1
90
After leaving a 90 degree bend, use a default value of 20 pipe diameters to calculate the length of the straight pipe for the solids
to re-accelerate to their original velocity at the inlet of the bend
(Vp1).
2.3
2.5
Component:
Equivalent Length
Bends
90 bend, long radius,
(10 to 1 radius to diameter ratio):
40, or 20 ft
whichever is more
Diverter Valves
45 degree divert angle:
20
10
Flexible Hoses
Stainless steel, with lined interior:
3 x pipe length
5 x pipe length
For bends that are less than 90, use equivalent length as:
= 40
Degree of Bend
90
W
m
=
Vg g
A Vg g
2.6
section. Then use this exit gas density as the inlet gas density
for the next pipe section. Repeat this procedure until reaching
the end of the conveying line. For vacuum systems, start from
the pick-up point and end at the blower inlet. For pressure systems, start from the end of the conveying line and return to the
pick-up point.
2.7
3.
Calculation Procedure
3.1
Step 1:
The first step is to define the objectives for the calculations and
to gather data that is needed for these calculations.
Flow of Solids:
Pg K R
Elevation of gas:
Z g g
144 gc
Elevation of solids:
Z W g
144 Vp gc
3.3
Step 3:
Enter the input data in a spreadsheet form as shown in worksheets 1 and 2. Enter all of the input data in worksheet 1 except
for the conveying pipeline data. Enter the pipeline data as
shown in worksheet 2 starting from the beginning of the pipeline
and finishing at its end.
Prepare worksheet 3 for running the pressure drop calculations. In this sheet, before starting the calculations, all of the
cells will be empty except for the known inlet conditions: gas
temperature, inlet gas density, inlet pressure, and inlet gas
(pick-up) velocity. Pipeline sections are numbered the same as
in worksheet 2.
3.2
Step 2:
From the equations given above, retrieve the formulae that will
be required in the calculations. These formulae are given below:
Formulae used in Calculations:
Gas pressure drop:
Gas density:
4 L g Vg2
9266 D
28 inlet pressure
28 inlet pressure
=
R T
19.32 (inlet temp. + 273)
Solids acceleration:
0.331
7 2
+
logn
3.7 D NRe
W Vp
4640
3.4
Step 4: Calculations
worksheet 1, B16
For L
worksheet 2, F2
For g,
worksheet 3, J2
For Vg,
worksheet 3, N2
For D,
3.5
Step 5
results and if the pressure drop in the 6 inch line is too low, use
a stepped pipe line starting from 4 inch and increasing to 6 inch
about midway in the conveying line.
4.
Conclusion
References
"Fluidized and Fluid Particle Systems", book by Zenz and Othmer, published in 1960 (Chapters 10 and 11) by Reinhold Publishing Corporation, New York, NY
Research papers published by Dr. F. A. Zenz in the 70's and
80's.
Particle Science Research Institute (PSRI) Reports published by
Dr. Zenz
php
Appendix 1
WORKSHEET NO. 1: CONVEYING SYSTEM INPUT DATA
Cell
Numbers
Vacuum type
Material to be conveyed
Polyethylene pellets
10,000 lbs/hr
Pipeline Material
See Worksheet 2
Conveying Line
Configuration
Pipe Inside Diameter
25 C
0.075 lbs/cu ft
10
65 ft/sec
Vg
11
12
13
14
15
16
22
Based on Test
Data
0.8 x Vg
Vp
Based on Test
Data
Hand calculate based on pipe diameter, gas density, and gas velocity (all at
inlet conditions) = 1528 lbs/hr
Hand calculate based on solids conveying rate and
R
gas mass flow rate, lbs/hr (= B3/B12) = 6.54
1.2
K
Based on Test
Data
0.0005
Based on Test
Data
f
Use Excel to calculate based on solids friction factor
K, pipe diameter D, and Reynolds Number, using
Equation 7 in the formula bar = 0.00592
Appendix 2
Section
Number
Pipe line
component
Orientation
Length in
feet
Pipe
Horizontal
10
Inside
Diameter (d),
inches
4
Section
Equivalent
Length (L), feet
10
Cumulative
Equivalent
Length, feet
10
Pipe
Horizontal
10
10
20
Pipe
Horizontal
10
10
30
Pipe
Horizontal
10
10
40
Pipe
Horizontal
10
10
50
Pipe
Horizontal
10
10
60
Pipe
Horizontal
10
10
70
Pipe
Horizontal
10
10
80
10
90 Bend
Horizontal to Vertical
20
100
11
10
Pipe
Vertical
10
10
110
12
11
Pipe
Vertical
10
10
120
13
12
Pipe
Vertical
10
10
130
14
13
Pipe
Vertical
10
10
140
15
14
90 Bend
20
160
16
15
Pipe
Horizontal
10
10
170
17
16
Pipe
Horizontal
10
10
180
18
17
Pipe
Horizontal
10
10
190
19
18
Pipe
Horizontal
10
200
20
19
90 Bend
21
20
Pipe
Vertical to Horizontal
10
Horizontal to Horizontal
20
220
Horizontal
10
230
10
Appendix 3
WORKSHEET NO. 3 : PRESSURE DROP CALCULATIONS
Cell
No.
1
A
Section
Numbe
r
Gas
temp.
Inlet Gas
Density
Outlet
Gas
Density
Inlet
Pressure
Outlet
Pressure
Inlet Gas
Velocity
Outlet
Gas
Velocity
Total Pressure
Drop in Section
Degrees
C
lbs/cu ft
lbs/cu ft
psia
psia
ft/sec
ft/sec
Flow of
Gas
Solids
Accel.
Flow of
Solids
Elevation of
Gas
Elevation of
Solids
Misc.
0,024
0,372
0,194
0,000
0,000
0,589
25
0,075
0,071
14,700
14,111
65,00
67,71
0,024
0,006
0,199
0,000
0,000
0,229
25
0,071
0,069
14,111
13,882
67,71
68,83
0,025
0,006
0,202
0,000
0,000
0,233
25
0,069
0,067
13,882
13,649
68,83
70,00
0,025
0,007
0,205
0,000
0,000
0,237
25
0,067
0,066
13,649
13,412
70,00
71,24
0,025
0,007
0,209
0,000
0,000
0,242
25
0,066
0,065
13,412
13,170
71,24
72,55
0,026
0,008
0,213
0,000
0,000
0,247
25
0,065
0,064
13,170
12,923
72,55
73,93
0,026
0,008
0,217
0,000
0,000
0,252
25
0,064
0,063
12,923
12,671
73,93
75,40
0,027
0,009
0,222
0,000
0,000
0,257
25
0,063
0,062
12,671
12,414
75,40
76,96
10
0,027
0,009
0,226
0,000
0,000
0,263
25
0,062
0,060
12,414
12,151
76,96
78,63
11
10
0,057
0,020
0,468
0,000
0,000
0,544
25
0,060
0,059
12,151
11,607
78,63
82,32
12
11
0,029
0,013
0,243
0,004
0,033
0,323
25
0,059
0,056
11,607
11,284
82,32
84,67
13
12
0,030
0,014
0,250
0,004
0,032
0,330
25
0,056
0,055
11,284
10,954
84,67
87,22
14
13
0,031
0,015
0,258
0,004
0,031
0,339
25
0,055
0,053
10,954
10,615
87,22
90,01
15
14
0,066
0,034
0,541
0,007
0,059
0,708
25
0,053
0,052
10,615
9,907
90,01
96,44
16
15
0,035
0,020
0,285
0,000
0,000
0,340
25
0,052
0,048
9,907
9,567
96,44
99,86
17
16
0,036
0,021
0,296
0,000
0,000
0,353
25
0,048
0,046
9,567
9,214
99,86
103,68
18
17
0,037
0,024
0,308
0,000
0,000
0,369
25
0,046
0,045
9,214
8,845
103,68
108,00
19
18
0,039
0,027
0,321
0,000
0,000
0,387
25
0,045
0,043
8,845
8,458
108,00
112,94
20
19
0,084
0,066
0,690
0,000
0,000
0,840
25
0,043
0,041
8,458
7,618
112,94
125,39
21
20
0,046
0,046
0,376
0,000
0,000
0,668
25
0,041
0,037
7,618
7,150
125,39
133,59
0,200
7,550
23