ENGINEERING LETTER

The New York Blower Company 7660 Quincy Street, Willowbrook, Illinois 60521 -5530

P N E U M AT I C C O N V E Y I N G
INTRODUCTION
A well designed pneumatic conveying system is often a more
practical and economical method of transporting materials from
one point to another than alternative manual or mechanical
systems. This Engineering Letter outlines some of the
fundamental principals of pneumatic conveying systems and
explains various special considerations for fan selection.
TYPES OF PNEUMATIC CONVEYING
Pneumatic conveying encompasses numerous different system
designs, technologies, and pressure ranges; however, there are
only three basic methods for moving material with air. These
can be categorized into the following system types:
Dilute-phase conveying is the process of pushing or pulling
air-suspended materials from one location to another by
maintaining a sufficient airstream velocity to capture and
convey the suspended particles.

DUST COLLECTION AND FUME REMOVAL

Dust collection, fume removal, and material conveying systems
each have unique characteristics, but all three are similar in their
dependence upon proper air velocities.
Dust collection and fume removal are generally thought of as
housekeeping systems that usually incorporate a hood at the
system entry point. There are many types and styles of hoods in
common use, and hood design is a subject in itself. Some state
and local codes offer hood design criteria, and there are several
reference texts, such as Industrial Ventilation - A Manual Of
Recommended Practices, that can assist in the selection and
design of hoods. In all cases the hood design should minimize
turbulence and offer the lowest possible entrance losses.

Air-film or air-float conveying is a means of moving product

along a conveyor on a cushion of air.

Determining the minimum velocity for dust collection or fume

removal is often a matter of practical trial-and-error judgment.
State and local codes may dictate minimum velocities for certain
materials. Where no codes apply, the velocities shown in Figure
1 can be used as conservative estimates. Since these velocities
are conservative, it is often possible to reduce them through
experimentation. Reducing the velocity to near the settling point
will generate the lowest overall operating cost but raises the risk
of system plugging, increased maintenance costs, and lost
production.

The use of fans for pneumatic conveying is generally limited to

dilute phase conveying and air film conveying.

Dust Collecting and Fume Removal

Duct Velocities

Dense-phase conveying relies on a pulse of air to force a slug

of material from one location to another. This form of conveying
usually requires positive displacement blowers or compressors
to generate the necessary pressure of 1.5 to 30 psig or more.

DILUTE-PHASE CONVEYING
In this method of conveying, material is suspended in the
airstream. Suction or vacuum are not factors in this type of
system and fan static pressures are no greater than 60" WG. If
the system uses a fan on the exhaust end and the material is
collected or separated from the airstream before it reaches the
fan, the fan itself can be of a more efficient type such as
backwardly inclined. If the system is designed so that the
combined material and air mixture passes through the fan,
selection is limited to the more rugged but less efficient fan
types intended for material laden airstreams. A number of
radial-blade wheel designs are available to handle various
concentrations, sizes, and types of airborne particles. Radial-tip
wheel designs are tolerant of airborne contaminants, but radialtip fans are not generally thought of as bulk material handling
designs. In all cases, the fan manufacturer should be consulted
to determine the most appropriate fan type available to handle
the specific material quantity and type, but it must be understood
that the fan manufacturer can neither control the variables in
pneumatic conveying systems nor provide any guarantee of the
service life of the fan itself.
Applications requiring fans for dilute-phase pneumatic conveying
fall into one of three basic categories: dust collection, fume
removal, or material conveying.

Material
1. Grinding Dust
2. Foundry Dust
3. Sand Blast Dust
4. Wood Flour
5. Sander Dust
6. Shavings, Dry
7. Shavings, Wet
8. Sawdust, Dry
9. Sawdust, Wet
10. Wood Blocks
11. Hog Waste
12. Buffing Lint, Dry
13. Buffing Lint, Wet
14. Metal Turnings
15. Lead Dust
16. Cotton
17. Cotton Lint
18. Wool
19. Jute Lint

Velocity
in FPM
5000
4500
4000
2000
2000
3000
4000
3000
4000
4500
4500
3000
4000
5000
5000
3000
2000
4000
3000

Material

20. Jute Dust

21. Grain Dust
22. Shoe Dust
23. Rubber Dust

24. Rubber Buffings

25. Bakelite Moulding
Powder
26. Bakelite Moulding
Dust
27. Oven Hood
28. Tail Pipe Exhaust
29. Melting Pot and
Furnace
30. Metallizing Booth
31. Soldering Fumes
32. Paint Spray
33. Carbon Black
34. Paper

Figure 1

Velocity
in FPM
3500
3000
4000
3500
4500
3500
2500
2000
3000
2000
3500
2000
2000
3500
3500

MATERIAL CONVEYING
Although the differences between dilute-phase material
conveying systems and dust collection or fume removal systems
might appear to be minimal, there are certain distinctions that
are critical to the successful operation of material-conveying
systems. These differences include the method of introducing
the material to the hood, the velocity requirements, the duct
configuration, and the fan type.
The introduction of material into a material conveying system
can be difficult. The most important criterion is to feed the
material into the airstream evenly. This can be accomplished by
means of gravity or by a mechanical device.
A hood or hopper can be used as a gravity feeder. Use of these
components is limited to dry, free-flowing materials. It is
important to remember that it is the velocity moving around and
past the material that induces it to flow. If the entry becomes
plugged with material, the required velocity cannot be
maintained, significantly impeding air and material flow.
A venturi feeder can be used to introduce material into the
airstream. Like the hood, it has no moving parts so there is
virtually no maintenance. However, the design of the venturi
must be tailored to each application and even the best ones can be
rather easily blocked if system conditions vary. Typical throat
velocities are 2 to 3 times the velocity in the main duct . . . see
Figure 2.

Figure 3 Typical Rotary Valve Feeder

Since the purpose of a conveying system is to move quantities

of material suspended in air, the ratio of material to air (by
weight) is critical. The most common form of reference is to
state the ratio according to the combined weight in pounds per
hour. A conservative design approach is to keep the ratio of
matter-to-air below a 1:2 proportion. However, successful
systems have been designed using 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 and the material being
conveyed is well-defined and consistent.
Certain minimum conveying velocities must be maintained to
keep the material in suspension and flowing. To some extent
these velocities are dictated by, or at least related to, the material-to-air ratio. For example, conveying sawdust at a rate of
1800 lbs./hr. through a 6" pipe with a material loading ratio of
1:2 will result in an air velocity of 4073 FPM.
1800 lbs./hr. material = 30 lbs./min.

Figure 2 Typical Venturi Feeder

60 lbs./min. air .075 lbs./ft. std. density = 800 CFM.

Rotary valves and screw-type (auger) feeders (see Figure 3) are
the most common mechanical devices used to introduce
material into the airstream. Both types offer a controllable flow
rate and are readily available in a number of standard designs to
handle pressures common to dilute phase conveying. However,
there are some precautions. Both are typically more expensive
than gravity-feed alternatives. Rotary valves can experience
internal air recirculation which causes a reduction in material
through-put. The screw-type feeder is a relatively high
maintenance device. In either case, the manufacturer of the
specific feeder should be consulted for selection, equipment
recommendations, and system limitations.

6" pipe = .1964 ft.2 area inside.

2

800 CFM .1964 ft. = 4073 FPM.

Figure 4 provides conservative minimum conveying velocities
to be used for some common materials. The velocity shown for
sawdust is 4000 FPM. If the same 1800 lbs./hr. of sawdust had
been introduced to a system with a 1:1 design ratio and there
were no other changes to the system, the resulting velocity would
only be half and the material would probably settle and clog. To
compensate for the lower ratio, the pipe size could be reduced to
4", but this might introduce new problems in feeding the
material to the pipe or transitioning to the fan. In this example,
the 1:2 ratio would seem to be ideal.

Page 2

Material Conveying
Duct Velocities
Material
1. Wood Chips
2. Rags
3. Ground Feed
4. Powdered Coal
5. Sand
6. Wood Flour
7. Sawdust
8. Hog Waste
9. Pulp Chips
10. Wood Blocks
11. Cement

Velocity
in FPM
4500
4500
5000
4000
7500
4000
4000
4500
4500
5000

6000

Material
12. Cotton
13. Wool
14. Jute
15. Hemp
16. Vegetable Pulp,
Dry
17. Paper
18. Flour
19. Salt
20. Grain
21. Coffee Beans
22. Sugar

FAN SELECTION

Velocity
in FPM
4000
4500
4500
4500
4500
5000
3500
6000
5000
3500
6000

Just as designing around a velocity that is too low will impede

the material conveying capability of the system, unnecessarily
high velocities can also be detrimental. System resistance
increases as the square of the increase in velocity. Therefore,
additional energy is required to overcome that resistance.
Also, the abrasive or erosive characteristics of the material
being conveyed will increase with an increase in velocity,
shortening the service life of all system components.
Only the air volume is considered in determining the velocity.
The material volume is ignored to compensate for the periods
of inconsistent material loading that occur during start-up and
shut-down. However, the material content of the overall
airstream mixture cannot be ignored when calculating system
resistance or when sizing the fan.

Figure 4

Sufficient velocities must be maintained throughout the

conveying system to avoid material settling. All airborne
materials, except the finest of dusts or fumes, can settle in a
system or even in the fan itself. When settling occurs in the
horizontal plane, it is known as salt ation. When settling occurs
in the vertical plane, it is called choking.
Saltation is probably the most difficult to avoid because even
the smallest ridge or duct seam can begin the process.
Whenever possible, it is advantageous to employ the aid of
gravity to minimize potential build-up by designing the piping
or ductwork with a downward slope. This is particularly true
with fine granular materials.
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 poses additional problems. If
enough material is forced back into the fan where it
recirculates, the fan will exhibit premature wear due to
excessive loading.
To minimize the potential for saltation or choking, it is
recommended that some provision be included in the system
for bleeding in excess air through adjustable vents or dampers.
See Figure 3. This excess air will effectively increase
velocities in the system to assist material transportation. It is
important to remember that the fan selection must account for
the maximum potential excess air, and that handling more air
then the minimum system requirements will result in increased
power consumption.

Fans are constant volume machines that discharge a fixed

volume of air at a fixed speed. If a fan is required to handle a
given volume of air and a given volume of material, it should
be sized to handle the combined volume. Using the previous
example, 1800 lbs./hr. of sawdust at an average bulk density of
3
3
11 lbs./ft. results in 164 ft. /hr. or nearly 3 CFM. The fan
should be selected to handle 803 CFM (800 + 3). In this
example the 3 CFM is negligible. However, in situations
where greater material volumes are being handled or when the
bulk material density is much lighter, the volume cannot be
ignored.

The effects of the material on system resistance must be

considered. Since most materials usually exhibit a lower
coefficient of friction than air, a simple density correction
based on the combined weight and volume of the air/material
mixture would result in an unnecessarily high correction. No
dependable methods of determining the flow resistance of
air/material mixtures have been proven, so only reasonable
estimates are available. Some researchers have theorized that
the bulk material content merely acts to reduce the effective
area of the pipe or duct and so ignore the density effect by
calculating air resistance through the resulting smaller pipe
diameter. The best method for determining the resistance of
the air/material mixture is through pilot-plant testing or
experimentation. Figure 5 provides correction factors that can
be used as reasonable starting points for estimating resistance.

FRICTION
MULTIPLIER

MULTIPLY FRICTION
FOR CLEAN AIR
BY MULTIPLIER

CUBIC FEET OF AIR PER MINUTE PER POUND OF MATERIAL

Figure 5 Resistance Factors

Page 3

Even though the air/material mixture does not follow the

traditional laws of fluid flow as they apply to friction or
resistance, it is suggested that the fan brake horsepower (BHP)
will increase according to the bulk density of the mixture. The
combined weight and total volume can be used to determine
the maximum airstream density for selecting a motor that will
handle the fan BHP at the bulk density.
Where,
1800 lbs./hr. material + 3600 lbs./hr. air =
5400 lbs./hr.
5400 60 = 90 lbs./min.
90 803 CFM = .112 lbs./ft.3 bulk density
To determine the approximate BHP for this example, multiply
the rated BHP at standard density of .075 lbs./ft.3 by 1.5.
(.112 .075) = 1.5

Either positive pressure or vacuum can be used to move the

containers. In a pressurized system, air is directed through a
drilled or slotted surface, where the air is discharged at a slight
angle in the direction of flow. The greater the discharge angle,
the higher the velocity from one station to the next. Vacuum
elevators are used to raise or lower containers to different
levels in the system by holding them to a moving, perforated
belt. Vacuum transfer devises allow fallen or damaged product
to drop out of the system, thereby reducing downtime and
maintaining efficient high-speed processing. Both techniques
may be employed in different portions of complex conveying
systems.
The benefits of air film conveying over conventional mechanical
conveying include:

Increased process speed.

Lower maintenance costs (fewer moving parts).
Reduced energy consumption.
Reduced noise and safety hazards.
Reduced downtime from jamming.
Gentler handling of the product.

It is sometimes thought that a larger fan is naturally better than a

smaller one. This is far from correct since material is just as
liable to settle in a fan as in a duct. If the inlet and outlet
velocities of a fan are at least as high as the minimum conveying
velocity, no settling should occur in the fan. This is true for
both dust collection and conveying.

Many companies in the packaging industry use a combination of

air and mechanical conveying systems in their manufacturing
processes.

AIR-FILM CONVEYING

CONCLUSION

This method of pneumatic conveying uses a film or cushion of

air to move items such as cans, boxes, or plastic containers
through a plant. Used primarily in the packaging industry, air
film conveying usually requires fan static pressures of no more
than 8" WG. In most cases, the system utilizes several smaller
fans as opposed to one large fan. Because the air is clean,
various fan types can be used in these systems, including
backwardly inclined and radial-bladed designs. Selection is
based on pressure and flow, but configuration is equally
important.

Pneumatic conveying systems have limitations, and alternate

manual or mechanical means cannot be ruled out. However,
pneumatic conveying systems usually require less plant space,
can be easily installed in the available or wasted space, can be
easily automated, can usually be easily altered for future
change, and usually carry a lower capital cost. Beyond these
economic advantages, pneumatic conveying systems can also
be useful in controlling or minimizing product loss, improving
dust control, and thus improving overall plant conditions.
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