ТЕKA. COMMISSION OF MOTORIZATION AND ENERGETICS IN AGRICULTURE – 2014, Vol. 14, No.
2, 20-25
Pressue losses design while bulk solids pneumatic conveying
Mіkhail Chaltsev
Automobile and Highway Institute of State Higher Educational Establishment
«Donetsk National Technical University»,
51, Kirova Street, Horlivka city, Donetsk region, 84646, Ukraine, e-mail:
[email protected] Received May 26.2014: accepted June 17.2014
S u m m a r y . A new theoretically justified technique of conducted with unreasonably high margins.
the hydraulic design of aerodispersed flows in The compressed air overconsumption and its
horizontal pipes is developed. The existing techniques
are of empiric nature and are correct only for a limited
pressure lead to the increase of power intensity
range of conditions that are close to the experiment of units, primary equipment wear. It makes the
conditions. The new technique is developed on the basis air cleaning process complicated and leads to
of the solution of the Bernulli's equation for two phase the conveying pipeline falling.
flows considering the latest researches in the sphere of
hydraulic conveying.
The revised designs by the new technique show their RESEARCH AND PUBLICATIONS
conformity to the results of the experimental researches
within the wide range of characteristics of pneumatic
ANALYSIS
conveying systems and conveyed materials.
K e y w o r d s : pneumatic conveying, aerodispersed flow, The most important task of the bulk
hydraulic design, bulk solids solids pneumatic conveying hydraulic design
is the correct evaluation of pressure losses
along the pipeline that enable the least power
INTRODUCTION
consumption at steady conveying process with
Under the conditions of the increasing the specified efficiency.
use of pneumatic conveying systems in the The well known techniques of the
different fields of industry there arises the pressure losses hydraulic design can be
necessity of further researches of divided into two types, differing in the main
aerodispersed flows. Problems of engineering formulas structure. The Gastershtadt formula
and using of pneumatic conveying systems are can be referred to the first type. The formula
solved mostly by conducting labor-intensive takes the form [12]:
and expensive experiments. At that, the
ΔP ΔP
obtained dependences as a rule are applicable = (1 + K μ) a , (1)
for the limited range of systems, meeting the L L
experiment conditions. The generalization of
results of other experimental researches where: ΔP and ΔPa – pressure losses at
conducted under different conditions leads to the pipeline segment of the L length,
considerable design errors. The designs are µ – mixture mass concentration,
PRESSUE LOSSES DESIGN WHILE BULK SOLIDS PNEUMATIC CONVEYING 21
K – Gastershtadt empirical coefficient. use of the experimental data have been
As different researchers say the suggested [2-4, 8, 9]. This fact does not
dependence (1) can be considered as general provide the required accuracy of design. [10,
and the numerical values of the coefficient K 11, 13, 14, 16, 17, 19-22].
should be experimentally determined for every Thus by now a generalized technique of
individual case. pneumatic conveying settled flows hydraulic
Upon carefully conducted experiments design suitable for a wide range of pneumatic
formula (1) provides the results that are conveying conditions has not been developed
sufficient for engineering practice. It is simple yet.
and convenient for engineering designs yet all
practical attempts for K coefficient
justification have been unsuccessful. WORK PURPOSE
The techniques of hydraulic design,
The work purpose is the creation of
having the Darcy – Weisbach formula for
scientifically based engineering techniques of
homogeneous liquids as their base (second
hydraulic design of settled flows in horizontal
type) are widely used in the practice of
pipes for industrial pneumatic conveying
pneumatic conveying systems engineering.
systems engineering with the purpose of their
One of the variants of this formula suggested
reliability and operation efficiency control.
by G. Zegler [Zegler 1937] is as follows:
ΔP ρU
= λm a a , (2) MATHEMATIC MODEL
L 2D
Hydraulic equations of continuity,
where: λ m – coefficient of hydraulic energy balance (analogue of the Bernoulli's
resistance to the motion of the air and equation), hydraulic resistances and gas
conveyed material mixture, equations serve as basic equations for solving
ρa and U a – density and air motion tasks of gas suspension flow in the pipe at
velocity, D – pipeline diameter. hydraulic design of pneumatic conveying
The coefficient λ m in formula (2) is systems. While writing them down we assume
that the gas expansion process is isothermal
determined experimentally. The modified and the flow is one dimensional, i. e. the
variant of formula (2) suggested by V. Bart mixture temperature during the conveying
[Bart 1960]: process is permanent and its density and
concentration change while going from one
ΔP ρU 2 pipe section to another one.
= (λ a + μ λ s ) a a , (3)
L 2D We assume the carrying medium as
incompressible while considering the problem
where: λ s – additional coefficient of of specific pressure losses in the pipeline, i. e.
resistance, reflecting the presence of solids in at its short parts. under these conditions
the mixture, determined experimentally. hydraulic equations of continuity and gas
There are known attempts of creating suspension motion are as following:
analytical techniques of design [6, 7, 15, 24]
but they are true for flows of low ρS SU S = GS , (4)
concentration (up to 5 kg/kg) only therefore
are of not wide spread. The biggest part of ρa (1 − S )U a ω = Ga , (5)
industrial pneumatic conveying systems
operate at the concentrations of 15–25 kg/kg
U m2
and above. ρm + P + ΔP = const , (6)
2
In most commonly known works the
semi-empirical design methods based on the
22 MІKHAIL CHALTSEV
where: ρS , ρa , ρm – solids density, air the beginning of solids falling on the pipe low
density, air and solids mixture density wall,
respectively, Re S – Reynolds number expressed
GS , Ga – mass consumption of material through the free falling velocity wS and solids
and air, mean diameter, i. e.
P – pressure,
ΔP – pressure losses at the pipeline part wS d S
Re S = ,
of L length. vg
The expression (6) is the Bernulli's
equation for the gas suspension. The equation where: vg – gas kinematic viscosity.
(6) is transformed, taking into account the
respective dependencies, given in the works Taking into account the fact that gas
[21] and [8]: suspension volume concentrations are not big
as a rule we assume that the Coriolis
1− S ρS S3 U2 coefficient for the gas phase is 1, i.e. β a ≈ 1 .
[ ⋅βa + ⋅ 2 ⋅β S ] ⋅β a ⋅ a + , (7)
(1 − C ) 2 ρa C ⋅ (1 − S ) 2 2 Furthermore the values S <<1 and
+ P + ΔP = const C <<1 of the first summand in the square
brackets can be neglected as the value of the
where: βa and βS – non-dimensional summand is much less than the second
coefficients, being analogues of Coriolis summand in these brackets. Taking into
coefficient for the carrying agent flow. If account the above mentioned and after some
however βa takes the values 1.04÷1.1 for transformations the equation (7) can be
carrying agent, βS may differ considerably reduced to the following form:
from 1. 2
⎡ ⎛ρ ⎞ ⎤
The equation (7) includes volume flow ⎢ μ3 ⎜ a ⎟ ⎥
concentration S equal to the ratio of solids ⎢ ⎝ ρS ⎠ ⎥ U a2
volume flow rate QS to the gas suspension ⎢1 +
ρ
β S ⎥ ρa 2 + P + ΔP = const , (11)
⎢ C 2 (1 − μ a )2 ⎥
QS ⎢ ρS ⎥
Q = QS + Qa volume flow rate, i. e. S = ⎣ ⎦
QS + Qa
and the mean volume concentration C , taking GS
into account the velocity fields asymmetry and where: µ= – mixture mass
Ga
concentrations in the pipe cross section. The concentration.
concentration S and C functional connection As it is known in hydraulics specific
obtained from the results of pipeline ΔP
conveying [18] hydraulic research: pressure loss in the pipeline determined by
L
the friction of the incompressible liquid is
⎡ 2,16 ⎤
⎛ C ⎞ ⎛ ucr ⎞ proportional to the specific (per the volume
S = C ⎢1 − f ( Re S ) ⎜1 − ⎟ ⎜ ⎟1, 66 ⎥ , (8)
⎢ ⎝ Cmas ⎠ ⎝ u ⎠ ⎥ U2
⎣ ⎦ unit) kinematic energy of the flow ρ which
2
is expressed with the first summand of the left
f (Re S ) = 0, 45 ⎡1 + SignX ⋅ th 0, 967 X
⎣⎢ ( 0,6
)⎤⎦⎥ , (9) side of the Bernulli's equation (6) and
determined by the Darcy – Weisbach formula:
X = lg Re S − 0,88 , (10)
ΔP 1 U2
=λ ρ , (12)
where: Cmas – limit volume concentration L d 2
of solid material,
ucr – critical velocity of pneumatic
where: λ – hydraulic friction coefficient,
d – pipe drift diameter.
through horizontal pipeline, corresponding to
PRESSUE LOSSES DESIGN WHILE BULK SOLIDS PNEUMATIC CONVEYING 23
Passing from the fluid flow to the gas Кe – relative roughness of the pipe inner
suspension flow and taking into account the walls.
expression in the round brackets of the left The value λ m is determined by the same
side of the Bernulli's equation (11) we write by formula (10) but taking into account the
analogy with (12): Uad
Reynolds number Re a = , where the
νm
⎡ 2 ⎤
⎛ρ ⎞ mixture viscosity can be determined by the
⎢ μ3 ⎜ a ⎟ ⎥
ΔP ⎢ ⎝ ρS ⎠ ⎥ ρa U a 2 formula:
= ⎢1 + 2
β S ⎥ λ m . (13)
L ⎢ d 2
2⎛ ρa ⎞ ⎥
⎢ C ⎜1 − μ ρ ⎟ ⎥ 1 + 3,5С
⎣ ⎝ S ⎠ ⎦ νm = νa . (18)
⎛ρ ⎞
1 + ⎜ S − 1⎟ С
The expression (10) can be introduced ⎝ ρa ⎠
the following way:
The functional dependency of the
ΔP ΔP Coriolis coefficient βS for a solid body from
=ϕ a , (14)
L L the determining parameters is deduced by
processing the experimental data of measuring
where:
ΔPa
– specific pressure losses the specific pressure losses due the friction in
L the horizontal pipe.
while clean air movement: λm
If we assign ≈1 that is correct for the
λa
ΔPa ρ U 2 flows of low concentration and introduce the
= λa a a , (15)
L d 2 notation:
ϕ coefficient – ⎡ ρg ⎤
2
⎢ μ ⎥
ρS
⎡ ⎤ K=⎢ ⎥ ⋅β ,
S (19)
⎛ρ ⎞ ⎢ ρg ⎥
⎢ μ3 ⎜ a ⎟ ⎥ ⎢ С (1 − μ ) ⎥
⎢ ⎝ ρS ⎠ ⎥ λm ⎣ ρS ⎦
ϕ = ⎢1 + β
2 S⎥
. (16)
⎢ 2⎛ ρa ⎞ ⎥ λa
⎢ С ⎜1 − μ ρ ⎟ ⎥ ϕ = 1 + Kµ in this case formula (16) is
⎣ ⎝ S ⎠ ⎦
transformed to the Gastershtadt empiric
For the practical application of formula formula (1).
(11) we determine the parameters λ a , λ m and The crucial significance of formula (16)
βS . As for the coefficients of hydraulic
is in its theoretical justification of the
coefficient K dependence from its determining
resistance λ a and λ m their values are equal in parameters.
the quadratic realm of resistance as they do not The checking evaluation by formula (11)
depend upon Rea number. In case of pre has shown their almost full coincidence with
quadratic realm of the hydraulic resistance the the experimental data. The design error is no
value λ a is determined by Altschul formula: more than 10 %.
0,25
⎡ 68 Кe ⎤ CONCLUSIONS
λ a = 0,11⋅ ⎢ + ⎥ , (17)
⎣ Rea d ⎦
1. The scientifically-based technique of
Uad the pneumatic conveying parameters design,
where: Rea = – the Reynolds number, based on the aerodynamic equations of
νa
νa – air kinematic viscosity, continuity is suggested for the steady air
disperse flow as a compressible medium.
24 MІKHAIL CHALTSEV
2. The scientifically-based technique for using a comprehensive kinetic theory with
determining and analyzing the coefficient turbulence modulation, Powder Technology,
included into the Geisterstadt formula is № 150 (1), 42-55.
suggested. 9. Cowell A., McGlinchey D., Ansell R., 2005.:
3. The suggested formula (14) can be Determination of pneumatic transport
capabilities of dry pulverised coal suitable for
recommended for the hydraulic design of entrained flow processes, Fuel, № 84 (17),
steady air disperse flows in the horizontal 2256-2266.
pneumatic conveying line. 10. Datta B.K., Ratnayaka C., 2005.: A possible
scaling-up technique for dense phase
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аэродисперсных потоков в горизонтальном
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344. (in Russian). новейших исследований в области гидротранспорта.
Проверочные расчеты по новой методике
показывают соответствие результатам
экспериментальных исследований в широком
диапазоне характеристик пневмотранспортных
систем и транспортируемых материалов.
Ключевые слова: пневматическое
транспортирование, аэродисперсный поток,
гидравлический расчет, сыпучий материал
