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.     

Investigation of influence of coal properties on dense-phase pneumatic conveying at high pressure

Experiments of dense-phase pneumatic conveying of pulverized coal using nitrogen were carried out in a test facility at pressures of up to 3.7 MPa to study the effects of coal type, particle size and moisture content on flow characteristics. The Jenike shear test and scanning electron microscopy (SEM) were employed to provide a better understanding of effects of the material properties on flow characteristics. Two kinds of pulverized coals, Yanzhou and Datong, with similar particle size, moisture content and density, were used in the test. Pressure drop increases with increasing the particle size at similar solid–gas ratio, superficial velocity and pressure in the receiving hopper, and pressure drops through different test sections decrease firstly and then rise with increasing the conveying velocity for the same particle size, mass flow rate and pressure in the receiving hopper. The flowability of pulverized coal decreases with increasing the moisture content in the range from 3.24% to 8.18%. Unconfined yield strength (UYS) increases and flow function (FF) decreases with increasing the moisture content. Results of the shearing tests are consistent with the results of the conveying study. Pressure drops through different test sections are discussed and analyzed.     

Flow characterization of high-pressure dense-phase pneumatic conveying of coal powder using multi-scale signal analysis

Flow characterization of high-pressure dense-phase pneumatic conveying of coal powder is not fully understood. To further reveal the dynamic behavior of coal particles in dense-phase pneumatic conveying pipelines, a method for the scale decomposition of particle motion based on empirical mode decomposition and Hurst analysis of experimental electrostatic signals is reported. This allows the multi-scale motion characteristics of single coal particles and particle clusters to be determined. Micro-, meso-, and macro-scale subsets were reconstructed, which reflected the different behaviors of the coal particles: specifically, dynamic features of the micro-scale subset represented features of single particle collisions and frictional interactions; dual fractal characteristics of the meso-scale subset described the motion of coal particle clusters; and features of the macro-scale subset reflected persistent dynamic behavior of the entire pneumatic conveying system. Motion behavior of single particles and particle clusters could be respectively investigated by considering the relative energies of the micro- and meso-scale contributions to the electrostatic signal. This was verified both by theoretical analysis and experiment.     

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.     

水平管道气固两相分层流动过程的研究

以空气作为输送动力、粉煤灰及玻璃微珠作为输送物料,对气力输送管道中气固两相流的流动特性进行了系统的试验研究.对管路系统的特性、操作条件、物料和气体的性质等影响气固两相流压力损失的主要因素进行了探讨.并在实验的基础上对两相流动的沉积速度、经济速度进行了确定.同时在对粉体受力分析的基础上建立了分层流动的物理及数学模型,通过对比数学模型计算值与试验值得出该数学模型具有一定的计算精度,能够用于指导分层流动的研究及应用.     

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 sol ids 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.     

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.     

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.     

A qualitative study on the pulsatile flow phenomenon in a dense fly ash pneumatic conveyor

Understanding of the dynamic particulate flow structures within a dense gas-fly ash pneumatic conveyor must be improved in order to better aid its design guidance.The complex pulsatile movement of the gas-fly ash mixture dominates the flow performance within the pipeline,and historically,non-invasive measurement devices such as the electrical capacitance tomography（ECT） were often used to sufficiently capture the flow dynamics.However,inadequate studies have been conducted on the pulsatile flow phenomenon,which directly relate to the gas-fly ash two-phase flow performance.This paper aims to investigate the pulsatile flows using an ECT device.Initially,pulsatile flow patterns under various experimental conditions were obtained through ECT.Pulses within a flow were then characterised into pulse growth and decay segments,which represent the superficial fluidisation and deaeration processes during conveying.Subsequently,structural and statistical analyses were performed on the pulse growth and decay segments.Results suggested that the increasing air mass flow rate led to the decrease of the superficial fluidisation/deaeration magnitude,however,the increase of the superficial fluidisation/deaeration durations.Also,the air mass flow rate was indicated as the dominant factor in determining the pulsing statistical parameters.This research provides fundamental insights for further modelling the dense fly ash pneumatic flows.     

Effect of particle degradation on electrostatic sensor measurements and flow characteristics in dilute pneumatic conveying

Vigorous particle collisions and mechanical processes occurring during high-velocity pneumatic conveying often lead to particle degradation. The resulting particle size reduction and particle number increase will impact on the flow characteristics, and subsequently affect the electrostatic type of flow measurements. This study investigates this phenomenon using both experimental and numerical methods. Particle degradation was induced experimentally by recursively conveying the fillite material within a pneumatic pipeline. The associated particle size reduction was monitored. Three electrostatic sensors were embedded along the pipeline to monitor the flow. The results indicated a decreasing trend in the electrostatic sensor outputs with decreasing particle size, which suggested the attenuation of the flow velocity fluctuation. This trend was more apparent at higher conveying velocities, which suggested that more severe particle degradation occurred under these conditions. Coupled computational fluid dynamics and discrete element methods (CFD–DEM) analysis was used to qualitatively validate these experimental results. The numerical results suggested that smaller particles exhibited lower flow velocity fluctuations, which was consistent with the observed experimental results. These findings provide important information for the accurate application of electrostatic measurement devices in pneumatic conveyors.     

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.     

An experimental investigation into modeling solids friction for fluidized dense-phase pneumatic transport of powders

Results are presented of an ongoing investigation into modeling friction in fluidized dense-phase pneumatic transport of bulk solids. Many popular modeling methods of the solids friction use the dimensionless solids loading ratio and Froude number. When evaluated under proper scale-up conditions of pipe diameter and length, many of these models have resulted in significant inaccuracy. A technique for modeling solids friction has been developed using a new combination of dimensionless numbers, volumetric loading ratio and the ratio of particle free settling velocity to superficial conveying air velocity, to replace the solids loading ratio and Froude number. The models developed using the new formalism were evaluated for accuracy and stability under significant scale-up conditions for four different products conveyed through four different test rigs (subject to diameter and length scale-up conditions). The new model considerably improves predictions compared with those obtained using the existing model, especially in the dense-phase region. Whereas the latter yields absolute average relative errors varying between 10% and 86%, the former yielded results with errors from 4% to 20% for a wide range of scale-up conditions. This represents a more reliable and narrower range of prediction that is suitable for industrial scale-up requirements.     

Predicting the mode of flow in pneumatic conveying systems-- A review

An initial prediction of the particulate mode of flow in pneumatic conveying systems is beneficial as this knowledge can provide clearer direction to the pneumatic conveying design process. There are three general categories of modes of flow, two dense flows： fluidised dense phase and plug flow, and dilute phase oniy. Detailed in this paper is a review of the commonly used and available techniques for predicting mode of flow. Two types of predictive charts were defined： basic particle parameter based （e.g. particle size and density） and air-particle parameter based （e.g. permeability and de-aeration）. The basic particle techniques were found to have strong and weak areas of predictive ability, on the basis of a comparison with data from materials with known mode of flow capability. It was found that there was only slight improvement in predictive ability when the particle density was replaced by loose-poured bulk density in the basic parameter techniques. The air-particle-parameter-based techniques also showed well-defined regions for mode of flow prediction though the data set used was smaller than that for the basic techniques. Also, it was found to be difficult to utilise de-aeration values from different researchers and subsequently, an air-particle-based technique was developed which does not require any de-aeration parameter in its assessment.     

Predicting the mode of flow in pneumatic conveying systems-A review

An initial prediction of the particulate mode of flow in pneumatic conveying systems is beneficial as this knowledge can provide clearer direction to the pneumatic conveying design process.There are three general categories of modes of flow,two dense flows:fluidised dense phase and plug flow,and dilute phase only.Detailed in this paper is a review of the commonly used and available techniques for predicting mode of flow.Two types of predictive charts were defined:basic particle parameter based (e.g.particle size and density) and air-particle parameter based (e.g.permeability and de-aeration).The basic particle techniques were found to have strong and weak areas of predictive ability,on the basis of a comparison with data from materials with known mode of flow capability.It was found that there was only slight improvement in predictive ability when the particle density was replaced by loose-poured bulk density in the basic parameter techniques.The air-particle-parameter-based techniques also showed well-defined regions for mode of flow prediction though the data set used was smaller than that for the basic techniques.Also,it was found to be difficult to utilise de-aeration values from different researchers and subsequently,an air-particle-based technique was developed which does not require any de-aeration parameter in its assessment.     

栓状流密相气力输送

首先介绍了气力输送的实验设备.评述了水平栓流气力输送的压力降计算方法,用3种不同的方法计算了压力降并与实验数据进行比较.此外评述了用特征线方法进行水平管的数值模拟,倾斜管的压力降计算和长距离的栓流气力输送.最后展望了该领域的发展方向.      

Characterization of the gas pulse frequency, amplitude and velocity in non-steady dense phase pneumatic conveying of powders

Current modelling techniques for the prediction of conveying line pressure drop in low velocity dense phase pneumatic conveying are largely based on steady state analyses.Work in this area has been on-going for many years with only marginal improvements in the accuracy of prediction being achieved.Experimental and theoretical investigations undertaken by the authors suggest that the flow mechanisms involved in dense phase conveying are dominated by transient effects rather than those of steady state and are possibly the principal reasons for the limited improvement in accuracy.This paper reports on investigations on the pressure fluctuation behaviour in dense phase pneumatic conveying of powders.The pressure behaviour of the gas flow in the top section of the pipeline was found to exhibit pulsatile oscillations.In particular,the pulse velocity showed variation in magnitude while the frequency of the oscillations rarely exceeded 5 Hz.A wavelet analysis using the Daubechie 4 wavelet found that the amplitude of the oscillations increased along the pipeline.Furthermore,there was significant variation in gas pulse amplitude for different types of particulate material.     

PNEUMATIC CONVEYING OF BIOMASS PARTICLES. A REVIEW

Processes involving biomass are of growing interest, but handling and conveying biomass particles are challenging due to the unusual physical properties of biomass particles. This paper reviews recent work on pneumatic conveying of biomass particles, especially agricultural particles and pulp fibres. Experimental work has been mainly carried out to determine a range of parameters, such as pressure drop, particle velocity, flow regime and electrostatic charging for both horizontal and vertical conveying. Models ranging from empirical to CFD models are also being developed. Difficulties in representing turbulence and interactions among biomass particles and between the particles and fluid have so far limited the success of advanced modeling. Further work is needed to improve understanding of multiphase biomass pneumatic conveying and to assist in the development of biomass energy and conversion processes.     

PNEUMATIC CONVEYING OF BIOMASS PARTICLES: A REVIEW

Processes involving biomass are of growing interest, but handling and conveying biomass particles are challenging due to the unusual physical properties of biomass particles. This paper reviews recent work on pneumatic conveying of biomass particles, especially agricultural particles and pulp fibres. Experimental work has been mainly carried out to determine a range of parameters, such as pressure drop, particle velocity, flow regime and electrostatic charging for both horizontal and vertical conveying. Models ranging from empirical to CFD models are also being developed. Difficulties in representing turbulence and interactions among biomass particles and between the particles and fluid have so far limited the success of advanced modeling. Further work is needed to improve understanding of multiphase biomass pneumatic conveying and to assist in the development of biomass energy and conversion processes.     

Characterization of the gas pulse frequency,amplitude and velocity in non-steady dense phase pneumatic conveying of powders

Current modelling techniques for the prediction of conveying line pressure drop in low velocity dense phase pneumatic conveying are largely based on steady state analyses. Work in this area has been on-going for many years with only marginal improvements in the accuracy of prediction being achieved. Experimental and theoretical investigations undertaken by the authors suggest that the flow mechanisms involved in dense phase conveying are dominated by transient effects rather than those of steady state and are possibly the principal reasons for the limited improvement in accuracy. This paper reports on investigations on the pressure fluctuation behaviour in dense phase pneumatic conveying of powders. The pressure behaviour of the gas flow in the top section of the pipeline was found to exhibit pulsatile oscillations. In particular, the pulse velocity showed variation in magnitude while the frequency of the oscillations rarely exceeded 5 Hz. A wavelet analysis using the Daubechie 4 wavelet found that the amplitude of the oscillations increased along the pipeline. Furthermore, there was significant variation in gas pulse amplitude for different types of particulate material.