FLUIDCON - FICEMficem.org/boletines/boletines2014/BOLETIN_DE_RESULTADOS_CT_2014... · Bucket elevator & air slide Solution B: Pneumatic pipe transport . The Solution FLUIDCON •

FLUIDCON

Pneumatic conveying with FLUIDCON Operating experience and results

by Claudius Peters

The Problem

• Raw Meal from Silo to Preheater Tower

Preheater

tower Raw meal silo

Solution A: Bucket elevator

& air slide

Solution B: Pneumatic pipe transport

The Solution

FLUIDCON

• The pneumatic conveying system with the advantages of pipe and air slide transport

• Developed and patented by Claudius Peters

FLUIDCON

View inside the FLUIDCON pipe What means FLUIDCON

• The system is a combination of air slide transport and pneumatic pipe conveying

FLUIDCON

Air Slide Transport Features:

• Fluidisation of material

• Material flow by gravity

• Need of height difference

• Only inclined arrangement

• Low conveying velocity

• Low wear / abrasion

• Low energy consumption

FLUIDCON

Conventional conveying pipe Features:


• Material flow by air stream

• Various conveying routing: Up, down, horizontal, inclined

• Flexible routing

• High energy consumption

• High wear / abrasion

• High conveying velocity

FLUIDCON

Claudius Peters FLUIDCON Features:


• Various conveying routing: Up, down, horizontal

• Inclinded transport with inclination up to 30 %

• Flexible routing

• Lower conveying velocity

• Lower wear / abrasion

• Lower energy consumption

FLUIDCON Design

Fluidcon pipe Aeration pad

• Homogeneous aeration • Dust tight • One socket for aeration & fastening • Exchange separately

FLUIDCON Design

Aeration pad within the pipe Dust tight design

Fabric

Fasteners

Air socket Fabric

Fasteners

Air socket

Optional: Wear protection

by perforated plate

Suitable Materials

for FLUIDCON

Evaluation of the material with the bulk material

classification in groups according to Geldart

• A) Fluid and expanded under aeration

• B) Fluid but no expansion under aeration

• C) Small particle size / cohesive,

difficult to aerate

• D) Larger particle size / difficult to aerate,

high aeration velocity is requested

A Langley Holdings Company Claudius Peters Projects GmbH

Proved Materials for FLUIDCON

Average particle diameter dS,50 [µm]

Dif

fere

nce o

f d

en

sit

ies ρ

S -

ρF [

kg

/m³]

Group D Group B

Iron-II-Sulphate

Petcoke

Hydrated Alumina

Hydrated Alumina

Alumina

Cement

Titanium Ore

Gypsum

Fly Ash

FGD-Gypsum

Cement

Kiln Dust

Group A Group C

FLUIDCON

• The system is suitable for wide ranges of

materials

• Especially typical building materials and

additives are within this range

• Cement, raw meal, lime, gypsum, blasted

furnace slag

• Critical materials are to be tested in the

technical center of Claudius Peters

FLUIDCON

Principle of design

Feeding device Pump

Pressure vessel

Rotary lock

Double pendulum flap

FLUIDCON- conveying pipe

Pressure generator

Blower

Compressor

Network

Separator

Cyclone

Troughed filter

Bin mounted filter

Conveying air

Bulk material

Bulk material

FLUIDCON

Feeding devices

Suitable with all industry feeders • X-Pump • Pressure vessel • Star feeder

• Double pendulum flap

FLUIDCON Various feeding devices

X-Pump Star feeder

FLUIDCON Various routings

FLUIDCON Various routing

FLUIDCON

Flow sheet of a system

Pressure

generator

Air flow for fluidization

Feeding device

Aerated FLUIDCON- pipe

Receiving bin

PIC

M

Air flow for

conveying

FIC FIC FIC FIC


FLUIDCON

Comparison of pulsation

Conveyance with FLUIDCON:

• Continuous massflow

• Reduced pulsation

Time t V

Weig

ht

G

Pre

ssu

re p

We

igh

t G

S

Pre

ssu

re p

R

Time t V

Conveyance of Titanium Ore

with conventional pipe

S


FLUIDCON

Comparison of a cement conveyance

DESIGN DATA:

Bulk Material: Cement 1

Mass Flow: 100 t/h

Conveying Distance: 200 m

Conveying Height: 25 m at the end of conveying line

Pipe Diameter: DN 250

Feeding Device: Claudius Peters pump X-250

+ 117 % 45,1 20,8 SOLID/AIR RATIO [kg(S)/kg(F)]

82.400

10,8

2,5

0,77

1.990

33

FLUIDCON

- 78% 11,5 INITIAL VELOCITY [m/s]

- 54 % 23,3 FINAL VELOCITY [m/s]

- 52% 172.000 OPERATION COST [EURO/a]*

- 26% 1,04 PRESSURE DROP [barü]

- 52% 4.140 AIR VOLUME FLOW [Nm³/h]

- 35% 51 POWER AT COUPLING [kW]

Comparison Conventional

*1 kWh = 0,010 €


P (Pneumatic)

P (Belt)`

FLUIDCON

Comparison of power consumptions

0,1

1

10

100

0 200 400 600 800 1000

1,3

6,5

32

Conveying

distance [m]

Conventional pipe

FLUIDCON

Aeroslide

FLUIDCON Price advantages

In comparison with conventional pipe conveying

• Marginally higher installation costs

• Modification of existing piping systems available

• Considerable lower operating costs

– Equal/higher throughput

– Less repairs and replacements

– Considerable lower power consumption

CASE STUDIES Operational FLUIDCON systems

Cement conveying

in Russia Bulk Solid Cement

Conveying gas Air

Type of Solid Feeder X-Pump

Type of Conveying System Conventional FLUIDCON

Solid mass flow [t/h] 135 135

Total conveying distance [m] 153 153

Including: Total height [m] 9 9

Total gas volume flow at 1 bar 20°C

[m³/h] 4364 2237

Gas Velocity at pipe inlet [m/s] 10.2 3

Gas Velocity at pipe outlet [m/s] 22.7 11.2

Solid/air ratio at pipe inlet [kgs/kgf] 27.2 32

Pipe pressure difference [bar] 1.3 1.1

Total pressure difference [bar] 1.6 1.4

Power consumption of Compressor

[kW] 173 86

Power consumption of X-pump

[kW] 87 70

Total power consumption [kW] 260 156

Total specific power consumption

[kWh / (t·100 m)]

1.259 0.755

Power Consumption relative to conventional conveying

% 100 60

• Lower velocity

• Lower Pressure

• 40 % of the original power consumption.

• Assuming electricity costs of X €/kWh total savings of Y €/year.

Blast-furnace slag meal

conveying in Germany Bulk Solid Ground blast surface slag Conveying gas Air Type of Solid Feeder X-Pump

Type of Conveying System Conventional FLUIDCON Solid mass flow [t/h] 100 100

Total conveying distance [m] 300 300

Including: Total height [m] 22 22 Total gas volume flow at 1 bar 20°C

[m³/h] 7.088 3.622

Gas Velocity at pipe inlet [m/s] 11.3 2.8

Gas Velocity at pipe outlet [m/s] 24.2 12.8

Solid/air ratio at pipe inlet [kgs/kgf] 12 56

Pipe pressure difference [bar] 1.18 0.84

Total pressure difference [bar] 1.48 1.14

Power consumption of Compressor

[kW] 305 114

Power consumption of X-pump

[kW] 77 44

Total power consumption [kW] 382 158

Total specific power consumption

[kWh / (t·100 m)]

1.273 0.527

Power Consumption relative to conventional conveying

% 100 41

Return to Problem

• Raw Meal from Silo to Preheater Tower

Preheater

tower Raw meal silo

Solution A: Bucket elevator

& air slide

Solution B: Pneumatic pipe transport

CASE STUDIES

Wietersdorfer & Peggauer Zementwerke GmbH Plant Wietersdorf, Austria


Wietersdorfer & Peggauer A -

Factory survey

Homosilo

Raw meal mill 4 Preheater- elevator

Bulk loader

Cement mill



Variations

Homosilo

Elevator with

aeroslides

• Pressure vessel conveyor

• Pump conveyor

• Pipe belt conveyor

Preheater- elevator



Decision matrix

Power

consumption Reliability

Maintenance

cost Flexibility

Environmental

behaviour

Capital

expenditure

Type of

Conveyance general

Clocking

risk

Power

failure

behaviour

Bucket elevator

and aeroslides + + + + + - + -

Pressure vessel

without bypass % - % % % + + %

Pressure vessel

with bypass % % % % - + +

-

Pump conveyor

- % - - % + + +

Belt conveyor

+ + + + - - - -

Pipe belt

conveyor + + + + - - % -

FLUIDCON

% + + + % + + %

neutral positiv negativ



Technical design

Conveying data

Conveyance Capacity horizontally vertically Bends

Raw Meal [t/h] [m] [m] [Pcs.]

Basic design

(Conveyance to BE- inlet) 125 194 0 2 x 90

Conveyance to BE- head + 100m 90 194 100 3 x 90

Conveyance into cement mill 40 344 0



Feeding

Silo discharge

of homo silo

FLUIDCON feeding

with X-Pump

X- Pump



Pipe routing



Visualisation



Summary und forecast

With kind support and approval by Mr. Dipl.-Ing. Peter Schwei (W&P),

extracts from the presentation held on the FLUIDCON-Open-Day, May 10-12, 2006, Buxtehude

• All expectations have been met

• No risk factor has occured

• Optimum operating behaviour

• Opimum flexibility regarding further

factory planning

• 2 additional plants are ordered

FACTS & DATA

FLUIDCON Facts & Data

• Claudius Peters References: 90 all over the world

• Realised mass troughput: up to 300 t/h

• Realised conveying distances: up to 480 m

• Wide range of materials

• Restart time: Below 1 minute

• Flexible pipe routing

• Various feeders

FLUIDCON Facts & Data

• Less amount of conveying air: approx. 40 % (depending on actual data)

• Less operating velocity: approx. 50 % (at outlet depending on actual data)

• Less power consumption: approx. 40 % (depending on actual data)

• Less operating pressure

• Less wear on system

• Less maintenance

• Reduced pulsation

Conclusion

• FLUIDCON protects environment

• FLUIDCON offers flexible conveying path

• FLUIDCON reduces wear

• FLUIDCON reduces energy consumption

• FLUIDCON reduces operating costs

• FLUIDCON improves profitability

Documents

FLUIDCON - FICEMficem.org/boletines/boletines2014/BOLETIN_DE_RESULTADOS_CT_2014... · Bucket elevator & air slide Solution B: Pneumatic pipe transport . The Solution FLUIDCON •