Chapter 5

Pneumatic Transport

• Dilute phase and dense phases transport

• Choking velocity and saltation velocity
• Design for dilute phase transport
• Dense phase transport
• Matching the system to the powder
Learning outcomes

 By the end of this session, student should be

able to:
 Differentiate between dilute and dense pneumatic
transport
 Determine the pressure loss in horizontal and
vertical pipelines.
Dilute Phase And Dense Phases
Transport
 Pneumatic Transport (sometimes referred to as
pneumatic conveying),which is the use of a gas to
transport a particulate solid through a pipeline.
 Classified into two flow regimes:
-dilute (or lean) phase flow
-dense phase flow.
Dilute phase flow
 Most recognizable form is characterized by:
-high gas velocities (greater than 20 m/s)
-low solids concentrations (less than 1% by volume)
-low pressure drops per unit length of transport line
(typically less than 5 mbar/m).
 Limited to short route, continuous transport of solids at
rates of less than 10 t/h.
 The only system capable of operation under negative
pressure.
 Solid particles behave as individuals, fully suspended in
the gas, and fluid-particle forces dominate.
Dense phase flow
 Two types :Continuous and Discontinuous flow pattern
 Characterized by :
-low gas velocities (1–5 m/s)
-high solids concentrations (greater than 30% by volume)
-high pressure drops per unit length of pipe (typically
greater than 20 mbar/m).
 Dense phase transport is described as the condition in
which solids are conveyed such that they are not entirely
suspended in the gas.
 The main advantages low gas requirements and low solids
velocities
The continuous dense phase flow

 The continuous dense phase flow pattern, in which the solids

occupy the entire pipe, is virtually extrusion. Transport in this
form requires very high gas pressures and is limited to
short straight pipe lengths and granular materials (which
have a high permeability).
Discontinuous dense phase flow pattern

 Discontinuous dense phase flow pattern can be divided

into three fairly distinct flow patterns:
-‘discrete plug flow’ of solids occupy the full pipe
cross-section
- ‘dune flow’ in which a layer of solids settled at the
bottom of the pipe move along in the form of rolling
dunes;
-a hybrid of discrete plug flow and dune flow in which
the rolling dunes completely fill the pipe cross-section
but in which there are no discrete plugs (also known as
‘plug flow’).
 Distinguishing dense phase flow
from dilute phase flow:
 Konrad (1986):
(a) on the basis of solids/air mass flow rates;
(b) on the basis of solids concentration;
(c) dense phase flow exists where the solids completely fill the cross section of
the pipe at some point;
(d) dense phase flow exists when, for horizontal flow, the gas velocity is
insufficient to support all particles in suspension, and, for vertical flow,
where reverse flow of solids occurs.
 Thus, the transition point between dilute and dense phase
transport is saltation for horizontal transport and choking
for vertical transport.
Flow patterns in horizontal pneumatic
conveying
Dense phase Dilute phase
Choking Velocity And Saltation
Velocity

General components of pressure drop across a

length of transport line:
 pressure drop due to gas acceleration;
 pressure drop due to particle acceleration;
 pressure drop due to gas-to-pipe friction;
 pressure drop related to solid-to-pipe friction;
 pressure drop due to the static head of the solids;
 pressure drop due to the static head of the gas.
Phase diagram for dilute-phase vertical
pneumatic transport

At the higher solids feed

rate, G2, the choking
velocity is higher.

The choking velocity, UCH, is the

lowest velocity at which this
dilute phase transport line can be
operated at the solids feed rate
Saltation velocity
 Further decrease in gas velocity results in rapid
‘salting out’ of solids and rapid increase in Δp=ΔL as
the area available for flow of gas is restrict
 The saltation velocity marks the boundary between
dilute phase flow and dense phase flow in horizontal
pneumatic transport.ed by settled solids.
The Saltation Velocity in Horizontal
Transport

curve GH
for a higher solids feed rate

CDEF for a solids flux, G1

the curve obtained for gas only in the line

Fundamental
Continuity
 Consider a length of transport pipe into which are
fed particles and gas at mass flow rates of Mp and
Mf, respectively. The continuity equations for
particles and gas are:
Gas to frictional wall
Bend
Horizontal

Vertical

Bend
Design for dilute phase transport

Involves :
 Selection of a combination of pipe size and
gas velocity to ensure dilute flow
 Calculation of the resulting pipeline pressure
drop
 Selection of appropriate equipment for
moving the gas and separating the solids
from the gas at the end of the line.
 Design for dilute phase transport

 Equipment

Dilute-phase transport:
positive pressure system
Design for dilute phase transport

 Equipment

Dilute-phase transport:
negative pressure system
Problem of plug formation is tackled in
three ways:
 Equipment:
 1. Detect the plug at its formation and take
appropriate action to either

Dense phase conveying system using a bypass line to break up plugs of solids
Problem of plug formation is tackled in
three ways:
 Equipment
 1. Detect the plug at its formation and take
appropriate action to either

Dense phase conveying system using

pressure-actuated valves to direct gas
Problem of plug formation is tackled in
three ways:
 Equipment
 2. Form stable plugs

Solid plug formation using

timer-operated air knife
Problem of plug formation is tackled in
three ways:
 Equipment
 2. Form stable plugs

Solid plug formation using alternating air valves

(valves 1 and 2 open and close alternately to
create plugs of solids in the discharge pipe)
 Problem of plug formation is tackled in
three ways:
 Equipment
 2. Form stable plugs

Solid plug creation using air-

operated diaphragm
Problem of plug formation is tackled in
three ways:
 Equipment
 3. Fluidization–add extra air along the
transport line in order to maintain the
aeration of the solids and hence avoid the
formation of blockages.
 All commercial dense phase transport systems
employ a blow tank which may be with
fluidizing element or without.

Blow tank without fluidizing element Dense phase transport blow tank with fluidizing
element
Therefore

 Dense phase transport is thus a batch

operation because of the high pressures
involved.
 Dilute phase transport can be continuous
because of the relatively low pressures and
the use of rotary valves.
The end