Effect of moisture content on conveying characteristics of pulverized coal for pressurized entrained flow gasification

During the pneumatic conveying, pulverized coal with different moisture contents may develop substantial difference in flow characteristics, whose cause is not fully understood. This study focused on influence of moisture content on conveying characteristics in an experimental test facility with the conveying pressure up to 4 MPa. The experiments included soft coal and lignite with similar density and particle size. With the increase in moisture content, the mass flow rate decreased for lignite (3.24% < M < 8.18%) but increased at first and then decreased for soft coal (0.4% < M < 6.18%) at same operating parameters. The flowability of soft coal was worse than that of lignite at similar operating parameters and external moisture content. The extremal conveying moisture contents of two coal types were obtained. The particle charge and surface moisture content were investigated to indicate influence mechanism of moisture content on mass flow rate in pneumatic conveying at high pressure. Pressure drop of soft coal was greater than that of lignite for same test section. The conveying phase diagram of dense-phase pulverized coal at high pressure was obtained and the pressure drops through different test sections were compared and analyzed. The bend loss factor rose with the increase in moisture content and was independent of conveying velocity and solid-gas ratio in dense-phase pneumatic conveying at high pressure.     

An investigation into flow mode transition and pressure fluctuations for fluidized dense-phase pneumatic conveying of fine powders

This paper presents the results of an ongoing investigation into the fluctuations of pressure signals due to solids–gas flows for dense-phase pneumatic conveying of fine powders. Pressure signals were obtained from pressure transducers installed along different locations of a pipeline for the fluidized dense-phase pneumatic conveying of fly ash (median particle diameter 30 μm; particle density 2300 kg/m³; loose-poured bulk density 700 kg/m³) and white powder (median particle diameter 55 μm; particle density 1600 kg/m³; loose-poured bulk density 620 kg/m³) from dilute to fluidized dense-phase. Standard deviation and Shannon entropy were employed to investigate the pressure signal fluctuations. It was found that there is an increase in the values of Shannon entropy and standard deviation for both of the products along the flow direction through the straight pipe sections. However, both the Shannon entropy and standard deviation values tend to decrease after the flow through bend(s). This result could be attributed to the deceleration of particles while flowing through the bends, resulting in dampened particle fluctuation and turbulence. Lower values of Shannon entropy in the early parts of the pipeline could be due to the non-suspension nature of flow (dense-phase), i.e., there is a higher probability that the particles are concentrated toward the bottom of pipe, compared with dilute-phase or suspension flow (high velocity), where the particles could be expected to be distributed homogenously throughout the pipe bore (as the flow is in suspension). Changes in straight-pipe pneumatic conveying characteristics along the flow direction also indicate a change in the flow regime along the flow.     

Tandem fluidized bed elutriator—Pneumatic classification of coal particles in a fluidized conveyer

Coal moisture control (CMC) in coking process, which reduces coal moisture before loading the coal into the coke oven, allows substantial reduction in coking energy consumption and increase in coke productivity. The technology is seeking to integrate the coal classification, thus calling it the coal classifying moisture control (CCMC), to separate the fine and coarse coal fractions in the CMC process so that the downstream coal crushing can only treat the coarse fraction. CCMC adopts a reactor that integrates a fluidized bottom section and a pneumatic conveying top section. The present work investigates the pneumatic classification behavior in a laboratory CCMC reactor with such a configuration by removing the coal fraction below a given size (e.g., 3.0 mm) from a 0 to 20.0 mm coal feed. The results show that the coal classification were dominated by the gas velocity in the top conveying section, and the required gas velocity for ensuring the maximal degree of removing a fine coal fraction could be roughly predicted by the Richardson and Zaki equation. The effect of bottom fluidization on the performance of CCMC is also examined.     

Experimental investigation into transient pressure pulses during pneumatic conveying of fine powders using Shannon entropy

This paper presents the results of an ongoing investigation into transient pressure pulses using Shannon entropy. Pressure fluctuations (produced by gas–solid two-phase flow during fluidized dense-phase conveying) are recorded by pressure transducers installed at strategic locations along a pipeline. This work validates previous work on identifying the flow mode from pressure signals (Mittal, Mallick, & Wypych, 2014). Two different powders, namely fly ash (median particle diameter 45 μm, particle density 1950 kg/m³, loosely poured bulk density 950 kg/m³) and cement (median particle diameter 15 μm, particle density 3060 kg/m³, loosely poured bulk density 1070 kg/m³), are conveyed through different pipelines (51 mm I.D. × 70 m length and 63 mm I.D. × 24 m length). The transient nature of pressure fluctuations (instead of steady-state behavior) is considered in investigating flow characteristics. Shannon entropy is found to increase along straight pipe sections for both solids and both pipelines. However, Shannon entropy decreases after a bend. A comparison of Shannon entropy among different ranges of superficial air velocity reveals that high Shannon entropy corresponds to very low velocities (i.e. 3–5 m/s) and very high velocities (i.e. 11–14 m/s) while low Shannon entropy corresponds to mid-range velocities (i.e. 6–8 m/s).     

Multi-scale analysis on the pulverized coal flow behaviors under high pressure dense-phase pneumatic conveying

To deeply knowledge of the flow behaviors of pulverized coal particles in dense gas–solid two-phase flow, a multi-scale analysis method based on electrostatic sensor array is applied for the multi-scale characterization of flow behaviors of dense gas–solid flow. The experimental results indicate that: for steady flow, with the increment of conveying pressure difference, the individual particles increase and the particle clusters decrease, the individual particle distribution is always inhomogeneous but the particle cluster distribution tends to be more homogeneous over the cross-section of pipe, while the average flow behavior of pulverized coal particles is always in the relatively static state. For unsteady flow, the average flow behavior of pulverized coal particles is dynamic, and the flow behaviors of the multi-scale flow structures over the cross-section of pipe are all significantly inhomogeneous. Moreover, the effect of particle size on flow behavior of pulverized coal is also investigated and validated.     

Transportation characteristics of gas–solid two-phase flow in a long-distance pipeline

In this study, experiments on fly ash conveying were carried out with a home-made long-distance positive-pressure pneumatic conveying system equipped with a high performance electrical capacitance tomography system to observe the transient characteristics of gas–solid two-phase flow. The experimental results indicated that solids throughput increased with increasing solids–gas ratio when the conveying pipeline was not plugged. Moreover, the optimum operating state was determined for the 1000 m long conveying pipeline with a throttle plate of 26 orifices. At this state the solids throughput was about 12.97 t/h. Additionally, the transportation pattern of fly ash gradually changed from sparse–dense flow to partial and plug flows with increasing conveying distance because of the conveying pressure loss. These experimental results provide important reference data for the development of pneumatic conveying technology.     

Energy loss at bends in the pneumatic conveying of fly ash

An accurate estimation of the total pressure drop of a pipeline is important to the reliable design of a pneumatic conveying system. The present paper presents results from an investigation into the modelling of the pressure drop at a bend in the pneumatic conveying of fly ash. Seven existing bend models were used (in conjunction with solids friction models for horizontal and vertical straight pipes, and initial acceleration losses) to predict the total pipeline pressure drop in conveying fly ash (median particle diameter: 30 μm; particle density: 2300 kg/m³; loose-poured bulk density: 700 kg/m³) in three test rigs (pipelines with dimensions of 69 mm inner diameter (I.D.) × 168 m length; 105 mm I.D. × 168 m length; 69 mm I.D. × 554 m length). A comparison of the pneumatic conveying characteristics (PCC) predicted using the seven bend models and experimental results shows that the predicted total pipeline PCC and trends depend on the choice of bend model. While some models predict trends that agree with the experimental results, other models predicted greater bend pressure drops for the dense phase of fly ash than for the dilute phase. Models of Pan, R. (1992). Improving scale-up procedures for the design of pneumatic conveying systems. Doctoral dissertation, University of Wollongong, Australia, Pan, R., & Wypych, P.W. (1998). Dilute and dense phase pneumatic conveying of fly ash. In Proceedings of the sixth International Conference on Bulk Materials Storage and Transportation (pp. 183–189), Wollongong, NSW, Australia and Chambers, A.J., & Marcus, R.D. (1986). Pneumatic conveying calculations. In Proceedings of the second International Conference on Bulk Materials Storage and Transportation (pp. 49–52), Wollongong, Australia reliably predicted the bend losses for systems conveying fly ash over a large range of air flows.     

Numerical evaluation of turbulence models for dense to dilute gas–solid flows in vertical conveyor

A two-fluid model (TFM) of multiphase flows based on the kinetic theory and small frictional limit boundary condition of granular flow was used to study the behavior of dense to dilute gas–solid flows in vertical pneumatic conveyor. An axisymmetric 2-dimensional, vertical pipe with 5.6 m length and 0.01 m internal diameter was chosen as the computation domain, same to that used for experimentation in the literature. The chosen particles are spherical, of diameter 1.91 mm and density 2500 kg/m³. Turbulence interaction between the gas and particle phases was investigated by Simonin's and Ahmadi's models and their numerical results were validated for dilute to dense conveying of particles. Flow regimes transition and pressure drop were predicted. Voidage and velocity profiles of each phase were calculated in radial direction at different lengths of the conveying pipe. It was found that the voidage has a minimum, and gas and solid velocities have maximum values along the center line of the conveying pipe and pressure drop has a minimum value in transition from dense slugging to dilute stable flow regime. Slug length and pressure fluctuation reduction were predicted with increasing gas velocity, too. It is shown that solid phase turbulence plays a significant role in numerical prediction of hydrodynamics of conveyor and the capability of particles turbulence models depends on tuning parameters of slip-wall boundary condition.     

CFD–DEM simulation of the pneumatic conveying of fine particles through a horizontal slit

Fine particles play a significant role in many industrial processes. To study the dynamic behavior of fine particle and their deposition in rock fractures, the pneumatic conveying of fine particles (approximately 100 μm in diameter) through a small-scale horizontal slit (0.41 m × 0.025 m) was studied, which is useful for the sealing technology of underground gas drainage in coal mining production. The CFD–DEM method was adopted to model the gas-particle two-phase flow; the gas phase was treated as a continuum and modeled using computational fluid dynamics (CFD), particle motion and collisions were simulated using the DEM code. Then, the bulk movement of fine particles through a small-scale horizontal slit was explored numerically, and the flow patterns were further investigated by visual inspection. The simulation results indicated that stratified flow or dune flow can be observed at low gas velocities. For intermediate gas velocities, the flow patterns showed pulsation phenomena, and dune flow reappeared in the tail section. Moreover, periodic flow regimes with alternating thick and sparse stream structures were observed at a high gas velocity. The simulation results of the bulk movement of fine particles were in good agreement with the experimental findings, which were obtained by video-imaging experiments. Furthermore, the calculated pressure drop versus gas velocity profile was investigated and compared with relative experimental findings, and the results showed good agreement. Furthermore, the particle velocity vectors and voidage distribution were numerically simulated. Selected stimulation results are presented and provide a reference for the further study of fine particles.     

Validated scale-up procedure to predict blockage condition for fluidized dense-phase pneumatic conveying systems

This paper presents results of an ongoing investigation into modelling fluidized dense-phase pneumatic conveying of powders. For the reliable design of dense-phase pneumatic conveying systems, an accurate estimation of the blockage boundary condition or the minimum transport velocity requirement is of sig- nificant importance. The existing empirical models for fine powder conveying in fluidized dense-phase mode are either based on only a particular pipeline and product or have not been tested for their accuracy under a wide range of scale-up conditions. In this paper, a validated test design procedure has been devel- oped to accurately scale-up the blockage boundary with the help of a modelling format that employs solids loading ratio and Froude number at pipe inlet conditions using conveying data of two different samples of fly ash, electro-static precipitation （ESP） dust and cement （particle densities： 2197-3637 kgJm3; loose poured bulk densities： 634-1070kg/m3; median size： 7-30 l~m）. The developed models （in power func- tion format） have been used to predict the blockage boundary for larger diameter and longer pipelines （e.g. models based on 69 mm I.D. ~ 168 m long pipe have been scaled up to 105 mm I.D. and 554 m length）. The predicted blockage boundaries for the scale-up conditions were found to provide better accuracy compared to the existing models.     

Cold flow experiments in an entrained flow gasification reactor with a swirl-stabilized pulverized biofuel burner

Short particle residence time in entrained flow gasifiers demands the use of pulverized fuel particles to promote mass and heat transfer, resulting high fuel conversion rate. The pulverized biomass particles have a wide range of aspect ratios which can exhibit different dispersion behavior than that of spherical particles in hot product gas flows. This results in spatial and temporal variations in temperature distribution, the composition and the concentration of syngas and soot yield. One way to control the particle dispersion is to impart a swirling motion to the carrier gas phase. This paper investigates the dispersion behavior of biomass fuel particles in swirling flows. A two-phase particle image velocimetry technique was applied to simultaneously measure particle and gas phase velocities in turbulent isothermal flows. Post-processed PIV images showed that a poly-dispersed behavior of biomass particles with a range of particle size of 112–160 µm imposed a significant impact on the air flow pattern, causing air flow decelerated in a region of high particle concentration. Moreover, the velocity field, obtained from individually tracked biomass particles showed that the swirling motion of the carrier air flow gives arise a rapid spreading of the particles.     

Thermal and friction characteristics of laminar flow through rectangular and square ducts with transverse ribs and wire coil inserts

The heat transfer and the pressure drop characteristics of laminar flow of viscous oil (195 < Pr < 525) through rectangular and square ducts with internal transverse rib turbulators on two opposite surfaces of the ducts and with wire coil inserts have been studied experimentally. Circular duct has also been used. The transverse ribs in combination with wire coil inserts have been found to perform better than either ribs or wire coil inserts acting alone. The heat transfer and the pressure drop measurements have been taken in separate test sections. Heat transfer tests were carried out in electrically heated stainless steel ducts incorporating uniform wall heat flux boundary conditions. Pressure drop tests were carried out in acrylic ducts. The flow friction and thermal characteristics are governed by duct aspect ratio, coil helix angle and wire diameter of the coil, rib height and rib spacing, Reynolds number and Prandtl number. Correlations developed for friction factor and Nusselt number have predicted the experimental data satisfactorily. The performance of the geometry under investigation has been evaluated. It has been found that on the basis of constant pumping power, up to fifty per cent heat duty increase occurs for the combined ribs and wire coil inserts case compared to the individual ribs and wire coil inserts cases in the measured experimental parameters space. On the constant heat duty basis, the pumping power has been reduced up to forty per cent for the combined enhancement geometry than the individual enhancement geometries.     

Effect of coal particle swarm properties on the fluidization characteristics and coal beneficiation in a dense-phase gas–solid fluidized bed

This paper analyzes the influence of different coal mass fraction in an air dense medium fluidized bed (ADMFB). The effect of the low density particles layer on heavy sedimentation increased with increasing material layer thickness. The thickness of the low density particles layer also affected the final settling time of the high density particles. Increasing the thickness of the low density particles layer by Δh provoked an increase in the settling of high density particles that was related to their diameter (Δh/D). The pressure gradient across the bed was lower than that observed for the control experiment, which had only the dense material, owing to a decrease in the pressure gradient in Zones 1 and 5 (at the top and bottom of the bed, respectively). Introducing different coal sizes resulted in different fluidization environments, particle accumulation layers, and changes to the surrounding zone. However, the influence of the coal particles on the local bed characteristics was related to its concentration. The feeding mass fraction of 6–13 mm size and 13–25 mm size coal should be limited to10% and 13%, respectively. The ranges of possible deviation were found to be 0.08–0.15 and 0.07–0.10 for the respective samples.     

Hydrodynamics and energy consumption studies in a three-phase liquid circulating three-phase fluid bed contactor

The hydrodynamics and energy consumption have been studied in a cold flow, bubbling and turbulent, pressurized gas–liquid–solid three-phase fluidized bed (0.15 m ID × 1 m height) with concurrent gas–liquid up flow is proposed with the intention of increasing the gas hold up. The hydrodynamic behaviour is described and characterised by some specific gas and liquid velocities. Particles are easily fluidized and can be uniformly distributed over the whole height of the column. The effect of parameters like liquid flow rate, gas flow rate, particle loading, particle size, and solid density on gas hold up and effect of gas flow rate, solid density and particle size on solid hold up, energy consumption and minimum fluidization velocity has been studied. At the elevated pressures a superior method for better prediction of minimum fluidization velocity and terminal settling velocities has been adopted. The results have been interpreted with Bernoulli’s theorem and Richardson–Zaki equation. Based on the assumption of the gas and liquid as a pretend fluid, a simplification has been made to predict the particle terminal settling velocities. The Richardson–Zaki parameter n′ was compared with Renzo’s results. A correlation has been proposed with the experimental results for the three-phase fluidization.     

Experimental study of the blockage boundary for dense-phase pneumatic conveying of powders through a horizontal slit

The estimation of the blockage boundary for pneumatic conveying through a slit is of significant importance. In this paper, we investigate the characteristics for blockage of powder (48 μm average diameter) through a horizontal slit (1.6 m × 0.05 m × 0.002 m). The results show that the required critical solid mass flow rate increases as the superficial air velocity increases superficial air velocity. The solid loading ratio and superficial air velocity displayed a decreasing power law relationship. This finding agrees with existing theory and experimental results. However, a minimum inlet solid loading ratio exists. When the air velocity is greater than the corresponding air velocity of the minimum solid loading ratio, the solid loading ratio exhibits an increasing trend in power law. We also found that when the inlet conveying pressure increased, the critical solid mass flow rate required for blockage, the inlet solid loading ratio, and the minimum inlet solid loading ratio increased.     

Thermohydraulics of turbulent flow through rectangular and square ducts with axial corrugation roughness and twisted-tapes with and without oblique teeth

The heat transfer and the pressure drop characteristics of turbulent flow of air (10,000 < Re < 100,000) through rectangular and square ducts with combined internal axial corrugations on all the surfaces of the ducts and with twisted-tape inserts with and without oblique teeth have been studied experimentally. The axial corrugations in combination with twisted-tapes of all types with oblique teeth have been found to perform better than those without oblique teeth in combination with axial corrugations. The heat transfer and the pressure drop measurements have been taken in separate test sections. Heat transfer tests were carried out in electrically heated stainless steel ducts incorporating uniform wall heat flux boundary conditions. Pressure drop tests were carried out in acrylic ducts. The flow friction and thermal characteristics are governed by duct aspect ratio, corrugation angle, corrugation pitch, twist ratio, space ratio, length, tooth horizontal length and tooth angle of the twisted-tape, Reynolds number and Prandtl number. Correlations developed for friction factor and Nusselt number have predicted the experimental data satisfactorily. The performance of the geometry under investigation has been evaluated. It has been found that on the basis of constant pumping power, up to 55% heat duty increase occurs for the combined axial corrugation and regularly spaced twisted-tape elements inserts with oblique teeth case compared to without oblique teeth twisted-tape inserts cases in the measured experimental parameters space. On the constant heat duty basis, the pumping power has been reduced up to 47% for the combined enhancement geometry than the individual enhancement geometries. However, full-length and short-length twisted-tapes with oblique teeth in combination with axial corrugations show only marginal improvements over the twisted-tapes without oblique teeth.     

Gas–liquid pressure drop in vertical internally wavy 90° bend

Experiments of air water two-phase flow pressure drop in vertical internally wavy 90° bend have been carried out. The tested bends are flexible and made of stainless steel with inner diameter of 50 mm and various curvature radiuses of 200, 300, 400 and 500 mm. The experiments were performed under the following conditions of two-phase parameters; mass flux from 350 to 750 kg/m² s. Gas quality from 1% to 50% and system pressure from 4 to 7.5 bar. The results demonstrate that the effect of the above-mentioned parameters is very significant at high ranges of mass flow quality. Due to the increasing of two-phase flow resistance, energy dissipations, friction losses and interaction of the two-phases in the vertical internally wavy 90° bend the total pressure drops are perceptible about 2–5 times grater than that in smooth bends. Based on the mass and energy balance as well as the presented experimental results, new empirical correlation has been developed to calculate the two-phase pressure drop and hence the two-phase friction factor of the tested bends. The correlation includes the relevant primary parameter, fit the data well, and is sufficiency accurate for engineering purposes.     

Experimental study on local characteristics of oil–water dispersed flow in a vertical pipe

The local flow characteristics of oil–water dispersed flow in a vertical upward pipe were studied experimentally. The inner diameter and length of the test section are 40 mm and 3800 mm, respectively. A double-sensor conductivity probe was used to measure the local interfacial parameters, including interfacial area concentration, oil phase fraction, interfacial velocity, and oil drops Sauter mean diameter. The water flow rates varied from 0.12 m/s to 0.89 m/s, while the oil flow rates ranged from 0.024 m/s to 0.198 m/s. Typical radial profiles of interfacial area concentration, oil phase fraction, interfacial velocity, and oil drops Sauter mean diameter are presented. An interesting phenomenon is that the local and cross-section-averaged interfacial area concentrations display concave change with water flow rate under constant oil flow rate. The physical mechanism of such a variation is discussed in details.     

Flow fields and packing states in the discharge flow of noncircular particles—A SIPHPM simulation

Although the discharge flow of spherical materials has been extensively explored, the effect of particle shape on discharge is still poorly understood. The present work explores the two-dimensional discharge flow fields of noncircular particles using the soft-sphere-imbedded pseudo-hard particle model method. Rectangular particles having different aspect ratios (R_a = 1, 1.5, 2–5) and regular polygonal particles having different numbers of sides (N_s = 3–8, 10) are discharged through hopper beds having different orifice widths (D_i = 40, 70.77, 99.13, 125.74, 151.13 mm). The discharge rates of differently shaped particles in different beds are consistent with Beverloo’s relation. Moreover, the flow fields are computed and evaluated to study the effects of R_a, N_s, and D_i on particle discharge. The characteristics of particle–particle connections in the discharge process are evaluated according to the temporal evolution and spatial distribution of the contact points. Additionally, the effect of the initial packing on the discharge profile is investigated. The findings help clarify the discharge of noncircular particles.     

Electrostatic beneficiation of fly ash in a free-falling system

A systematic study of fly ash electrostatic beneficiation in a free-falling separation system was carried out to provide fundamental understanding of the separation efficiency for the design of a suitable process for industrial applications. The parameters investigated included feeding position, electric field strength, particle size and moisture content. Particles larger than 105 μm presented the best separation efficiency among four different size fractions, whereas particles smaller than 44 μm showed minimal separation. However, sonication treatments helped separation by liberating more carbon from ash particles, although particle sizes were reduced as well. Experiments also showed that exposure to moisture significantly altered charging behavior of fly ash and its subsequent separation due to more free mobile ion-induced charge exchanges. The optimal feeding position was found to be slightly on the side of the negative electrode, leading to a 30% reduction in loss-on-ignition (LOI) and a 45% recovery in a single pass. A simplified mechanical model based on trajectory analysis for charged particles in an electrical field was in reasonable agreement with experimental results.