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		Saving energy and maintenance headaches by switching to pneumatic unloading Over the years, we've strived to show you how to optimize pneumatic conveying system performance. Several columns have presented tips for improving an existing pneumatic conveying system's operation. This month's column shows that we practice what we preach: A case study illustrates how we improved the operation of a bulk unloading system at a cement plant. Pneumatic Conveying: Conveying Difficult Materials 3/10 CD of live Broadcast 3/9/2010 Presenter(s): Paul E. Solt, PBE Editorial Advisory Board Member, Pneumatic Conveying Consultants Jack D. Hilbert, PE, Pneumatic Conveying Consultants Moderator: Robert Harkin, Associate Editor of Powder and Bulk Engineering DVD/CDs are non-returnable/non-refundable How to protect fragile materials during pneumatic conveying This article provides practical advice for preventing damage to your fragile material during pneumatic conveying. Information concentrates on preventing material degradation by controlling conveying velocity and properly designing the conveying line and material receiver. More ways to reduce power usage to improve conveying efficiency (March 2010) In this column, we'll continue our discussion from the November 2009 column on ways to reduce your pneumatic conveying system's power cost. This time, we'll look at how the system's feeding device, conveying line configuration, and air-material separation equipment affect the system's horsepower requirements. Information is provided on how to select, design, or operate this equipment to reduce your conveying system's power usage where possible. Pneumatic Conveying: Troubleshooting 12/09 CD of live Broadcast 12/08/2009 This webinar will address numerous aspects of troubleshooting the performance of a pneumatic conveying system.The presentation will include recommendations and guidelines for determining in which mode of conveying an existing system is operating; optimizing capacity; improving reliability; solving wear and product degradation problems.Individual components such as gas supplies, line chargers, conveying lines and accessories as well as receivers and dust collectors will be reviewed.The webinar is well suited for personnel involved in the operation and maintenance of pneumatic conveying systems, production personnel, system designers and those responsible for specifying pneumatic conveying systems and components. Reducing power usage to improve conveying efficiency (November 2009) In this column, we'll continue our discussion from the July 2009 column on ways to reduce your conveying system's power cost, including increasing the conveying line diameter and changing the pickup velocity. Pneumatic Conveying: Myth Busting Pneumatic Conveying Systems 6/09 CD of live broadcast 6/9/09 We will take many of the more common "myths" and "old wives tales" about Pneumatic Conveying Systems and explain if they are TRUE or FALSE. . . OR BOTH if certain conditions can make the difference . . .and we will also provide the technical background to support that position. Reducing power usage to improve your conveying efficiency (July 2009) During the first days and weeks after purchasing a new car, it's customary to test the vehicle's performance. If it turns out to have lower-than-expected fuel economy, you'd probably try to improve the vehicle's operating efficiency. So why doesn't the same apply to a pneumatic conveying system? Pneumatic Points to Ponder by Paul E. Solt CD Collection Essential pneumatic conveying information at your fingertips! All columns from 1989–2008…60 complete articles! Major savings over purchasing the articles individually! Pneumatic Conveying: Reducing Energy Requirements in Pneumatic Conveying 3/09 CD of live broadcast 3/10/09 Pneumatic conveying has various costs, including initial equipment investment, labor and maintenance costs, and energy costs. In this Webinar, we’ll look at energy costs and how you can improve your bottom line by controlling them. Your pneumatic conveying systems can experience many changes, large and small, that can affect the system’s operating energy requirement. We’ll explain how to identify and eliminate or control these changes to achieve cost savings. You can make changes to your existing pneumatic conveying system to reduce energy use, but these changes may require a financial investment. We’ll show how to evaluate the cost of energy-saving changes against potential cost savings. When you purchase or design a new pneumatic conveying system, there are many ways to design in energy-saving measures. We’ll review several of theses. CDs are non-returnable/non-refundable Abrasion-resistant pipe provides long operating life A foundry installs abrasion-resistant pipe and elbows in its conveying lines to increase pipe life and reduce downtime and maintenance. Slow-motion conveying system rapidly delivers positive results A synthetic-yarn manufacturer installs two new conveying systems to improve its resin pellet delivery operation. Answers to eight common questions about pneumatic conveying While pneumatic conveying is a common method of transferring powders, granules, and other dry bulk materials, understanding this conveying technology can be a challenge. This article addresses pneumatic conveying questions frequently asked by people in dry bulk materials processing and handling plants. How much air are you moving? (March 2009) When it seems that there isn't enough air in your pneumatic conveying system to move your material, you'd like to measure the system's air volume to help you identify the problem: Is there air leakage in the system? Is something worn? Was the system designed correctly? If you could check how much actual air volume the system is using, you'd know the answers! Pneumatic Conveying: A Primer in Troubleshooting Systems 10/08 CD of live broadcast 10/7/08 This Webinar will focus on the following types of problems: Air (gas) supply: high differential pressure, high temperature rise, low air volume and low differential pressure; Line chargers: excessive leakage, high temperature rise and low capacity; Transport line: excessive wear at elbows, frequent line plugs, product degradation and high pressure deferential; Filter receiver/cyclone/dust collector: pressure differential, wear and erosion, and poor material discharge Diagnosing and fixing material buildup problems in conveying lines (November 2008) Material buildup inside your pneumatic conveying line is usually caused by poor conveying air quality or by your material’s fineness or stickiness. While fixing the conveying air quality is usually easy, you probably have to live with your material's fineness or stickiness. But can you find ways to avoid buildup despite these material characteristics? Usually, yes. In this month's column, we'll look at each of these buildup sources and explore ways to prevent or minimize the problems they cause. Conveying line elbows provide maintenance-free operation A wastewater reclamation plant installs 17 specially designed elbows in its lime conveying systems to eliminate dust leaks and downtime caused by material abrasion. Six practical ways to handle rotary airlock valve leakage Because of the way a rotary airlock valve is designed, it's normal for a small amount of conveying air to leak back through the airlock as it feeds bulk solid material to a pressure pneumatic conveying system. But if you don't take steps to properly vent this leakage air from your equipment, it can create several problems. This article describes six practical ways of arranging your pneumatic conveying equipment to vent airlock leakage so you can avoid these problems. Vacuum loading system simplifies material-transfer process A toll processing plant installs a vacuum loading system to transfer dry ingredients from drums into a batch solution tank. Pneumatic Conveying: Simplified Calculation of Dilute Phase 6/08 CD of live broadcast 6/3/2008 This webinar will describe how the design of a pneumatic conveying system is based on many different parameters, including the material to be handled, the conveying system mode (i.e., dense phase versus dilute phase), and the geometry of the conveying line itself. This webinar will look at the various parameters, show how they interrelate with each other and propose a simplified methodology for designing basic dilute-phase vacuum or pressure conveying systems. CDs are non-returnable/non-refundable Conveying sugar: How sweet it is! (July 2008) Sure, sugar is sweet, except when you want to pneumatically convey it. In my mind, beautiful crystal-clear, granular sugar is the most challenging dry bulk material to transfer in a pneumatic conveying system. In this month’s column, we’ll concentrate on how to solve various problems with pneumatically conveying sugar. But rest assured: Even if you’re not handling sugar, you can apply most of the information to solving problems with conveying other materials. Troubleshooting a pneumatic conveying capacity problem (Jack D. Hilbert) (March 2008) This month's column addresses how I worked on solving a client's pneumatic conveying system problem. The information here can be applied to a range of pneumatic conveying applications. Customer-friendly test lab provides conclusive results A new test lab improves a pneumatic conveying equipment company’s demonstration and material-testing capabilities. New conveying system cleans up railcar unloading operation A detergent producer installs a semidense-phase conveying system to improve its railcar unloading operation. Protecting your pneumatic conveying system investment by hiring a startup technician Is this the year you'll install a new pneumatic conveying system in your plant? This article explains how a professional startup technician can supervise the system startup, ensure that the system runs smoothly, and train employees to run and troubleshoot the system with confidence. Pneumatic Conveying: Study of the Phase Diagram for Pneumatic Conveying 2/08 CD of live Broadcast 02/05/2008 This webinar takes a close look at a useful tool for analyzing any pneumatic conveying system. Webinar • Describes the System Phase Diagram and how to use it • Addresses the relationship between conveying line pressure and conveying velocity and how they interact to form the System Phase Diagram • Shows how the System Phase Diagram can help you determine whether the system is operating in dilute-, dense-, or two-phase mode Pneumatic Conveying: Troubleshooting 10/07 CD of live broadcast 10/2/07 This webinar will cover troubleshooting in the following areas: air (gas) supply (high differential pressure, high temperature rise, low air volume, and low differential pressure), line chargers (excessive leakage, high temperature rise, and low capacity); transport line (excessive wear at elbows, frequent line plugs, product degradation, and high pressure deferential; and filter receiver/cyclone/dust collectors (pressure differential, wear and erosion, and poor material discharge). CDs are non-returnable/non-refundable Troubleshooting rotary airlock valve performance (Guest writer Jack D. Hilbert) (November 2007) This month's column addresses a PBE reader's question about improving a rotary airlock valve's throughput capacity. In fact, this question is fairly common among pneumatic conveying users. Because any of several problems can be behind poor rotary airlock valve performance, the information here will detail eight potential sources of this problem and how to investigate them. This information can be applied to a range of pneumatic conveying applications. Pneumatic Conveying: Controls and Instrumentation 6/07 CD of live Broadcast 6/5/2007 Usually when planning a new system, the last items to be considered are the controls and instrumentation. Today's PLC and DCS systems have brought virtually unlimited capabilities for control of the system operations as well as a mechanism to collect operating data on a real-time basis. The presenters will discuss what you should know to optimize your system's capabilities. CDs are non-returnable/non-refundable Pneumatic Conveying: Selecting a Gas Mover 10/06 CD of live Broadcast 10/25/2006 These four main topics were covered: Gas mover types Principles of operation Advantages and disadvantages of various types Other selection criteria CDs are non-returnable/non-refundable Using supplementary air in dense-phase pneumatic conveying (Guest writer Jack D. Hilbert) (July 2007) In past columns, we've discussed pneumatic conveying topics including system design, operation, equipment, and applications. Many of the columns have concentrated on one area of a pneumatic conveying system, such as the air (or other gas) mover, material supply vessel, material feeder (line charger), conveying line, or air-material receiver (or receiving bin). In this column, we'll focus on a topic related to the conveying line: introducing supplementary air to help aerate the conveyed material and prevent line plugs in dense-phase conveying systems. Determining which system and components will best meet your needs I (November 1998) Building on the information in his first four series of columns, Paul E. Solt -- a private consultant with more than 41 years experience installing and troubleshooting pneumatic conveying systems -- presents a fifth series of columns on the general application of pneumatic conveying. In a separate section, Solt also answers your pneumatic conveying questions. Venturi eductors, regenerative blowers reliably transport limestone dust at mine When a limestone mine in Mexico installed dust collectors to contain limestone dust, low-maintenance venturi eductors and regenerative blowers were chosen to convey the dust from the collectors. How to dry conveying air for smoother pneumatic conveying Removing moisture from a pneumatic conveying system's conveying air can prevent problems with contaminating, spoiling, or caking the conveyed material. This article explains dew point and pressure dew point, then discusses equipment for cooling and drying conveying air and describes an example application in which installing such equipment solved moisture problems in a food plant's operation. Using a pellet-cleaning system to separate the good from the bad and the ugly A company installed a pelletcleaning system in each of its polypropylene pellet production lines to maximize production efficiencies and guarantee product quality for its customers. Everything’s coming up fufu A tropical foods company installs a vacuum conveying system to improve its production process and increase powder conveying efficiency. Facing conveying challenges (July 2002) In this thirteenth column on the general application of pneumatic conveying, we'll discuss both old and new challenges users face in applying pneumatic conveying systems. We'll also consider a way to bring US suppliers and users together to address these and other pneumatic conveying issues. Using an aero conveyor to solve some common conveying problems Concerned about the cost of your drag conveyor's high horsepower and maintenance requirements, or the conveyor's tendency to degrade friable particles? Is dust from your bucket elevator or belt conveyor clouding your workplace air? And are you hesitating to switch to a pneumatic conveying system, with its air mover and filtering equipment costs and headroom requirements? An aero conveyor may be the answer you need for a single-run conveying span between about 10 and 120 feet. The conveyor requires low horsepower and little maintenance, gently handles particles, controls dust, and requires no separate air mover or filtering equipment and minimal headroom. This article describes how the aero conveyor works, how the conveyor reduces particle degradation, and conveyor limitations and future developments. Respecting your system's safety hazards (March 2002) In this twelfth column on the general application of pneumatic conveying, we'll discuss some of the safety hazards associated with pneumatic conveying systems. Although these systems don't have a lot of moving parts and, in fact, appear to be fairly harmless, every year people are injured or killed as a result of working with them. Treating your system with respect and following safe practices when working near it can help you avoid many pneumatic conveying safety hazards. The following sections describe and explain how to avoid these hazards, including material bridges and buildup, system air pressure, system vacuum, safety switches and moving parts, and inert gas. [Editor's note: This column doesn't cover explosion prevention techniques. Find articles on explosion prevention and protection listed under "Safety" in Powder and Bulk Engineering's comprehensive "Index to articles," in the December 2001 issue or at www.powderbulk.com.] Designing a robust pneumatic conveying system to handle future expansion - Part I Today's slow business climate is making efficient, reliable pneumatic conveying in dry bulk materials handling plants more important than ever. The trouble is, we often expect more out of our pneumatic conveying systems than they're designed to provide, creating a host of new problems. This two-part article explains how you can design a robust pneumatic conveying system that will handle afterinstallation system changes. Part I covers testing your material and designing the system, and Part II[to appear in April 2004] covers choosing system hardware, controlling and monitoring the system, and complying with noise and air quality requirements. Pneumatic conveying: Basic design and component options This article introduces the primary components of dilute- and-dense-phase pneumatic conveying systems. Air gravity conveying to efficiency A wallboard manufacturer installs air gravity conveyors to minimize power consumption and maintenance. Determining which system and components will best meet your needs III (July 1999) Building on the information in his first four series of columns, Paul E. Solt, a private consultant with more than 42 years experience installing and troubleshooting pneumatic conveying systems, presents a fifth series on the general application of pneumatic conveying. In a separate section, Solt also answers your pneumatic conveying questions. Conveying system successfully transfers carbon black prills from railcars to silos A rubber hose producer installs a dense-phase conveying system to improve its plant's railcar unloading operation. Dense-phase conveying system moves coal without particle degradation and dusting When dilute-phase pneumatic conveying degraded fuel coal for boilers and emitted dust at outdoor stockpiles, a nuclear weapons waste-recovery facility installed a discontinuous dense-phase pneumatic conveying system. Tests help customers solve difficult pneumatic conveying problems MAC Equipment's test center shows a plastics processor how to efficiently convey tacky plastic pellets and kaolin clay. Rotary valve return on investment: Doing the math Should you buy a low-cost, replaceable rotary valve or a high-cost, heavier-duty version that can be rebuilt? Calculating a rotary valve´s return on investment is a good place to start. After describing available rotary valves, this article explains how running a series of cost calculations can help you choose the most cost-efficient valve for your application. Pneumatic Conveying: Using Line Chargers 7/06 CD of live broadcast: July 25, 2006 These main topics were covered: Types of line chargers and how they operate What kinds of line charges work best for vacuum and pressure systems How to select an effective line charger for your system Important information you will need to know to size your line charger Options and accessories that can assist you meet specific needs CDs are non-returnable/non-refundable Designing a pressure system fed by a venturi (July 2001) In this tenth column on the general application of pneumatic conveying, we'll apply information from previous columns to designing a pressure pneumatic conveying system fed by a venturi. As you read this month's column, it may be helpful to review related topics in previous columns. Growing your bulk handling system to handle growing production (November 2003) In this column, we'll cover pneumatic unloading systems for materials received in bulk bags or bulk truck trailers or railcars.1, 2 Find related information in these previous "Pneumatic points to ponder.." columns: March 1991, November 1994, November 1995, March 1999, and July 1999. Dust-free vacuum-loading system transfers powder safely A company specializing in battery technology needs to find a dust-free way to transfer a hazardous powder. Take a Load Off! A company works with a supplier to design a vacuum system for unloading cement and other powdered materials from river barges. Computer simulation: An aid to upgrading your dilute-phase pneumatic conveying system Choosing the best way to upgrade your dilute-phase pneumatic conveying system to transport dry material at a faster rate is a complex process. This article explains how software can simulate your system's conveying characteristics to help you assess how effective each upgrade option will be. After discussing upgrade steps, the article describes a computer simulation of an example conveying system. This information covers facts about the existing conveying system installation, then describes simulating and modifying the conveying system. Related information provides tips for choosing software to help you upgrade your dilute-phase pneumatic conveying system. Valve solves problems in space-restricted applications A company installs a flat rotating-disc valve in a dense-phase conveying system to increase conveying capacity and decrease the vertical space required for installation. Options for preventing and predicting wear in pneumatic conveying lines Materials such as coal dust, cement, and sand quickly wear through pneumatic conveying lines that are not protected. Asphalt producer waits two years for pneumatic pump to fail -- it's still waiting For many years, Western Paving, Inc., an asphalt production company located in Denver, Colo., had a serious problem. The granite dust collected by its dust collector was so abrasive that every 25 to 35 working days it destroyed the rotary airlock that moved the dust from the collector to a pneumatic air line and back into production. Active muffler helps solve bulk transfer company's baffling noise problem When a portable pneumatic conveyor with a baffled industrial silencer is too noisy for workers and neighbors, a bulk transfer company installs an innovative noise reduction system. Using inert gases for pneumatic conveying Using compressed air as the conveying medium in pneumatic conveying pipelines can create explosive or unstable conditions for some materials and in some applications. In many cases, you can safely use inert gases that don't support combustion as substitutes for air. This article profiles three inert gases -- nitrogen, argon, and carbon dioxide -- as media for pneumatic conveying applications, provides some examples of pneumatic conveying applications using inert gases, and discusses the equipment you'll need for conveying with inert gases. Design criteria — Selecting rotary valves and pressure vessels for a pressure system (July 1994) Building on the information presented in his first and second series of columns, Paul E. Solt -- a private consultant with more than 37 years experience installing and troubleshooting pneumatic conveying systems -- presents a third series of columns discussing design criteria for a pneumatic conveying system. In a new section premiering with this month's column, Solt also answers your pneumatic conveying questions. Pneumatic conveying elbows fit in tight space When sweep elbows wouldn't fit in the space available for a new pneumatic piping arrangement, Miller Brewing used more compact elbows. Pneumatic unloading: Staying ahead of the surge If your plant uses a pneumatic unloading system to transfer material from pressure differential railcars and trucks, you're probably concerned about a phenomenon called the "surge." This is a large surge of air that can overwhelm your unloading system's receiving vessel and lead to other problems as well. This article discusses safe, reliable, and robust methods you can use to control surge effects. How to write a request for quotation (Guest writer Jack D. Hilbert) (July 2005) Accurate communication with potential vendors before you buy your new pneumatic conveying system will ensure that the system you purchase operates well in your application. Guest writer Jack D. Hilbert details how to write a request for a quotation that will get you what you need. What’s a bearing isolator? The bearing isolator is a long-lasting, reliable alternative to conventional bearing protection devices.. Directing pneumatic conveying traffic At a single keystroke, computer-controlled diverter valves route powder through pneumatic conveying system multiple destinations. How to evaluate vendor bids II (Guest writer Jack D. Hilbert) (July 2006) In this column, we pick up where we left off in the March 2006 column with more information on how to evaluate vendor bids for a pneumatic conveying system. Designing a dust collector for your pneumatic conveying system This article explains how you can configure a dust collector for your pneumatic conveying system to provide efficient, cost-effective dust collection. Three major sections cover these topics for pneumatic conveying systems: common dust collection problems; ways to reduce dust collection a complexity, headroom requirements, and cost; and choosing a baghouse or cartridge dust collector for your pneumatic conveying system. Related information provides tips on cleaning cartridge dust collectors and vacuum pneumatic conveying systems. Metal powder processor loses weight, breathes easier with automated handling Labor-intensive production and safety concerns led processor to install three pneumatic conveying lines. Comparing pneumatic conveying system types (July 2003) In this column, we'll return to a topic covered in the March 1991 column: types of pneumatic conveying systems. The types include vacuum, pressure, and combination vacuum-pressure systems. We'll describe each, along with its advantages and disadvantages, to help you understand what each system includes and how systems of each type are designed. Classification of pneumatic conveying systems -- Part II, Material conveying phase At present, no industry standards exist for classifying pneumatic conveying systems. As a result, the systems shown throughout engineering literature and in equipment suppliers' brochures are described by various terms -- vacuum, negative pressure, positive pressure, low pressure, medium pressure, high pressure, low velocity, high velocity, dilute phase, dense phase, and medium phase. To aid your understanding of basic pneumatic conveying terms, Part I [March 1989] of this article classified pneumatic systems by the type of airstream used to convey material -- vacuum, pressure, or combination vacuum/pressure. Part II classifies pneumatic systems by the degree of material concentration in the conveying phase. Venturi eductor successfully conveys high temperature abrasive material A cement manufacturer installs a venturi eductor and blower system to solve a powderhandling problem. Dilute-phase conveying: Saving air means saving money Are you using more air -- or a higher pickup velocity -- in your dilute-phase conveyor than you really need? If so, your conveyor could be consuming a lot of extra power and raising your operating costs. This article describes pickup velocity and the problems that result from using an unnecessarily high pickup velocity, then explains how reducing this high velocity can save energy costs. How to manage impact forces in your dense-phase pneumatic conveying system Low-velocity plug flow is a method of dense-phase pneumatic conveying that handles granules or pellets of fairly uniform shape and size. System throughput over 50,000 lb/h and conveying distances over 1,000 feet are becoming more common for this conveying method. And when equipped with high-pressure rotary valves, a plug-flow system can operate continuously without using a pressure vessel. Pneumatic Conveying: The Pipeline & Receivers 2/07 CD of live Broadcast 2/6/2007 Paul and Jack will discuss the importance of pipelines and how the product receivers must be properly applied and designed or they can have a significant contribution (usually negative) on the system's performance. Also covered: The DOs and DON'Ts of pipeline routing Pipe construction material options and recommendations Receiver options and recommendations Venturi eductor achieves maintenance victory A nickel producer replaces a glycol-cooled screw conveyer and rotary airlock with a venturi eductor to successfully convey high-temperature, abrasive dust without constant equipment repairs. Mobile pneumatic conveyor keeps food supplement company's operation flowing smoothly A food supplement capsule manufacturer installs a mobile pneumatic conveyor that eliminates manual mixer loading, conveys without degrading the product or decreasing its flowability, and permits a production increase. Tests help customers from various industries find pneumatic conveying solutions Ducon's test center offers customers several options for conveying materials ranging from fluidizable powders to dense pellets. Vacuum conveying system is nothing to sneeze at A company installs a dilutephase vacuum conveying system to convey salt and pepper to four packaging machines. Bend location and pressure drop — An in-depth study (November 2006) In this column, we'll look at the effect of bend location on pressure drop in a pneumatic conveying system. Compact pneumatic conveyor cleanly transfers detergent dust After a flexible screw conveyor inefficiently moved a cleaning products manufacturer's detergent dust, a compact pneumatic conveyor improved transport of the reusable dust. How to minimize particle degradation in pneumatic conveying systems Particles transported in a pneumatic conveying system can degrade either as they pass through the feeder or as the particles flow through the system and impact other particles, the pipeline walls, or pipeline fittings. This article discusses some ways to minimize particle degradation in pneumatic conveying systems, including choosing a dilute- or dense-phase system, stepping pipeline diameter, and simplifying pipeline configurations and selecting pipeline bend geometries and materials. Performance of a venturi eductor as a feeder in a pneumatic conveying system The venturi eductor has long been used as a pipeline feeding device in pneumatic conveying systems. The early ejector patents of 1870 and 1936 even suggested, in nebulous language, their ability to "convey dusts and powders." No substantive analysis of a venturi eductor's ability to convey particulates was found in the technical literature. Consequently, a joint research project was undertaken in 1985 by Fox Valve, Dover, N.J., and Thames Polytechnic, London, to investigate the factors affecting the performance of a system fed by a venturi eductor. Key dilute-phase equations IV — Zenz and Othmer (December 1992) Building on the information presented in his first series of columns, Paul E. Solt -- a private consultant with more than 35 years experience installing and troubleshooting pneumatic conveying systems -- presents a second series of columns discussing pneumatic conveying basics and how to apply them when designing a pneumatic conveying system. Engineering study: Solving a bin vent problem in a pneumatic unloading system Are your pneumatic unloading system's operating conditions stressing your bin vent and reducing its efficiency? Instead of installing a whole new dust collector system, an engineer at a casting foundry solved such a problem at moderate cost with components that are relatively simple to design and install. This article covers the engineer's analysis of the problem, his solution, and advice for applying a similar solution to your own bin vent problems. Eight common signs of rotary valve problems: A troubleshooting guide Air leakage, lack of material flow, and noisy operation are all signs of rotary valve problems that can disrupt your pneumatic conveying or other processing or handling system's operation. While the signs are usually obvious, identifying the underlying valve problems isn't always easy. By listing eight common trouble signs and explaining what's behind them, this article provides and easy-to-follow guide for troubleshooting your rotary valve. Dense-phase pneumatic conveying: Improving efficiency A dense- phase pneumatic conveying system's efficiency can be reduced by major air losses, which can result from the way air is supplied to the system or the way the system uses air. This article's first section discusses basic information about dense-phase pneumatic conveying efficiency. The next two sections discuss ways of modifying a dense-phase pneumatic conveying system to minimize air supply losses and air usage losses. The last section summarizes the system modification results. How system capacity affects conveying line pressure I (March 1990) In a series of quarterly columns, Paul E. Solt -- a private consultant with more than 35 years experience in installing and troubleshooting pneumatic conveying systems -- looks at pneumatic conveying through the computer eye to analyze the relationships among several operating parameters. How to choose a bin vent for your pneumatic conveying system Bulk solids processors typically spend a lot of time designing and selecting major components for a pneumatic conveying system. But choosing a bin vent for the receiving bin at the system's end often gets short shrift. This article explains how a bin vent functions in a pneumatic conveying system, what types of bin vents are available, and how to choose a bin vent that will help your system perform to your specifications. Pneumatic conveyor for calcined coke sparks electrode supplier's interest An electrode supplier's experience conveying calcined coke with a bucket elevator leads to the installation of a dilute-phase pneumatic conveyor. Getting the information you need to troubleshoot your pneumatic conveying system -- Part II Problems with a pneumatic conveying system are easier to diagnose if you have good information about the system's operating variables. This two-part article explains how you can obtain, store, and analyze this data so that you can successfully troubleshoot your conveying system. Part I (March) covered the measurements you need and described transducers for monitoring system variables. Part II concludes the article with information on portable data acquisition systems for sampling and storing system data and a case study showing how system data was used to troubleshoot a pneumatic conveying system plagued by intermittent line blockages. A kinder, gentler railcar unloading system A low-pressure pneumatic railcar unloading system reduces fines and angel hair when unloading plastic pellets. New valve liner performs in a pinch Pinch valves with two-piece liners provide a cement terminal's pneumatic conveying system with the consistent service life one-piece liners failed to give. Design criteria — The conveying line (July 1993) Building on the information presented in his first and second series of columns, Paul E. Solt -- a private consultant with more than 36 years experience installing and troubleshooting pneumatic conveying systems -- presents a third series of columns discussing design criteria for a pneumatic conveying system. Increasing unloading rates from pressure-differential truck trailers and railcars (March 2007) In this column, we'll look at different methods for increasing the unloading rate from any self-unloading pressure-differential (PD) bulk carrier -- a truck trailer or railcar. We'll also discuss how to evaluate the economics of each method. Eductor adds fumed silica to make waxes flow freely at Deurex Low-melt waxes become sticky as particle size decreases. Equipment solutions for storing and feeding a hard-to-handle material Do you handle a fine, lightweight material that's dusty, explosive, and floods or compacts easily? Is your material abrasive and hard on pneumatic conveying elbows? Or have you found that the material doesn't readily form a dust cake on your dust collector media, preventing efficient filtering? Read this article for information on how one hard-to-handle material, powder activated carbon, can be stored and fed in both dry and slurry forms with the right equipment. You can apply many of the principles to your own hard-to-handle material. Making tougher turns to convey pellets Pneumatic conveying line elbows resist wear from a plastic producer's abrasive materials. Dense-phase pneumatic conveying reduces product degradation at Perstorp New system reduces conveying velocity, cutting fines content in half. Elbows solve wear problem A wastewater treatment facility installs five new specially designed elbows in its lime conveying system to reduce dust leaks and downtime caused by material abrasion. Material wear and equipment degradation (March 1997) Building on the information presented in his first three series of columns, Paul E. Solt -- a private consultant with more than 40 years experience installing and troubleshooting pneumatic conveying systems -- presents a fourth series of columns on troubleshooting pneumatic conveying systems. In a separate section, Solt also answers your pneumatic conveying questions. Filling railcars to the brim Pneumatically driven loaders increase a plant's railcar fill rate and efficiency. Classification of pneumatic conveying systems -- Part I, System type At present, there are no industry standards for classifying pneumatic conveying systems. The systems shown throughout engineering literature and in equipment suppliers' brochures are de- scribed by various terms -- vacuum, negative pressure, positive pressure, low pressure, medium pressure, high pressure, low velocity, high velocity, dilute phase, dense phase, and medium phase. Some terms describe the type of airstream the system uses to convey material, other terms describe the degree of material concentration in the system's conveying phase. Turnkey system accurately weighs, conveys, and blends dry powder ingredients A specialty chemicals company installs a fully automated turnkey system to make a new product. Pneumatic conveying gives coffee production a lift By eliminating tote bins, a coffee factory increases production capacity while preserving coffee quality. Design criteria — How air (gas) movers affect the conveying system (July 1995) Building on the information presented in his first and second series of columns, Paul E. Solt -- a private consultant with more than 38 years experience installing and troubleshooting pneumatic conveying systems -- presents a third series of columns discussing design criteria for a pneumatic conveying system. In a separate section, Solt also answers your pneumatic conveying questions. Valves take the heat, handle the pressure By finding the right valves, a pneumatic conveying equipment supplier builds a system that transports fly ash 2,000 feet from a power plant to a cement company's storage terminal. Seal of approval A flame-retardant additive producer replaces its rotary valves' leaky shaft packing with gas-purged solid-metal seals. How to evaluate vendor bids I (Guest writer Jack D. Hilbert) (March 2006) In this column, we follow up on the July 2005 topic (how to write a request for a pneumatic conveying system quotation) with information on how to evaluate vendor bids. [Editor's note: See past "Pneumatic points to ponder..." columns for information on a range of topics, including pneumatic conveying theory, design principles, system types, system components, applications, and troubleshooting. Increasing system capacity II (November 1996) Building on the information presented in his first three series of columns, Paul E. Solt -- a private consultant with more than 39 years experience installing and troubleshooting pneumatic conveying systems -- presents a fourth series of columns on troubleshooting pneumatic conveying systems. In a separate section, Solt also answers your pneumatic conveying questions. Plastic products manufacturer saves money with dual-purpose vacuum system A plastic products manufacturer switches from manually handled bags of resin to bulk loads, reducing batching labor and material costs with a pneumatic conveying system that doubles as a central vacuum cleaning system. Full-scale pneumatic blending and conveying tests help determine equipment needs Whirl-Air-Flow's test center shows a food processor and a cat litter manufacturer how their products work in pneumatic blending and conveying equipment. Choosing an elbow for your pneumatic conveying system Selecting an elbow for your pneumatic conveying system can be a tough job, especially considering how many different types of elbows are on the market. Yet a properly selected elbow can keep your system operating at peak performance levels, decrease maintenance costs, and minimize material attrition and elbow wear. After outlining factors you should consider when selecting an elbow for your system, this article provides descriptions of commonly used elbows and their advantages and disadvantages. Dilute- and dense-phase pneumatic conveying system basics (July 1991) Building on the information presented in his fist series of columns, Paul E. Solt -- a private consultant with more than 35 years experience in installing and trouble shooting pneumatic conveying systems -- presents a second series of columns discussing pneumatic conveying basics and how to apply them when designing a pneumatic conveying system. It's OK to be a little dense when conveying salt A food manufacturer installs a dense-phase pressure conveying system to prevent problems while conveying salt. Solving problems in the cement, chemical, paper, and power industries By making its complete line of equipment available for testing, Fuller assures that all testing options are explored. Screening fine powders in tight places A low-profile circular vibratory screener fit into existing space when an auger conveyor was replaced with a pneumatic conveyor. Selecting a pneumatic system A pneumatic material handling system is one of the most innovative and versatile plant improvements available. W e manual or mechanical systems generally have higher convey rates and lower horsepower usage than pneumatic systems, they do not offer the same degree of flexibility, efficiency, and economical operation. Because of the enormous potential of pneumatic systems, it is very important to select the proper equipment. By gathering all the necessary facts and application requirements at the start, you can select a pneumatic system designed to exactly meet your material handling needs. This article focuses on the kinds of application information you'll need to gather when selecting a pneumatic system. Chemical producer shifts course with automated diverter valves Conveying line plugging and maintenance costs lead a producer to retire their manual diverter valves. Finding and fixing common rotary airlock valve problems A rotary airlock valve is one of the most important components in your pneumatic conveying system. But do you know how to troubleshoot valve problems? After describing rotary airlock valve selection and operation, this article explains how you can find and fix common valve problems. Related information covers preventive maintenance. Key dilute-phase equations III — Fine-tuning pressure (July 1992) Building on the information presented in his first series of columns, Paul E. Solt -- a private consultant with more than 35 years experience installing and troubleshooting pneumatic conveying systems -- presents a second series of columns discussing pneumatic conveying basics and how to apply them when designing a pneumatic conveying system. Unit works good, like a diverter valve should An international tobacco products manufacturer smokes out a new way to reliably divert the flow of tobacco from its pneumatic conveying lines. Closed-loop pneumatic conveying: Simple ways to troubleshoot your system without shutting it down Troubleshooting your closed-loop pneumatic conveying system doesn't always require a costly system shutdown. This article outlines some simple tests you can use to diagnose problems while your system is running. Although this article focuses on closed-loop, dilute-phase pneumatic conveying systems, much of the information can be applied to other pneumatic conveying systems as well. Tests help resin producer choose pneumatic conveyors for difficult-to-handle material Waeschle's test center, located in West Germany, uses a variety of equipment and pipeline lengths to duplicate production conditions in pneumatic conveying tests. Reducing your dense-phase pneumatic conveying system's demand on plant compressed air The goal for any plant compressed-air system is to supply air at the right pressure for all air-powered applications in the plant. But a dense-phase pneumatic conveying system's short-term, high-volume demands on the air system can cause the air pressure to fluctuate and lead to plantwide problems -- low production throughput, frequent downtime for air-powered equipment, and poor product quality, not to mention higher energy costs when a standby air compressor has to kick in. This article outlines ways you can reduce your dense-phase conveying system's use of plant compressed air. The article ends with general advice for improving plant air system performance by stabilizing the system's pressure level. Conveyor and blower system unloads positive results A ready-mix concrete producer installs a semidense-phase conveyor and blower system to improve its production plant's railcar cement unloading operation. Determining which system and components will best meet your needs IV (November 1999) Building on the information in his first four series of columns, Paul E. Solt, a private consultant with more than 42 years experience installing and troubleshooting pneumatic conveying systems, presents a fifth series on the general application of pneumatic conveying. In a separate section, Solt also answers your pneumatic conveying questions. Engineering study: Solving a plugging problem in pneumatic conveying lines Is your sticky material plugging your plant's pneumatic conveying lines? An engineer at a cellophane-manufacturing plant analyzed his sticky line plugging problem and came up with a low-cost solution that involved replacing steel lines with flexible hose. The solution eliminated the plugs, saved labor, and reduced downtime. This article covers the engineer's analysis of the problem, the solution, and advice for applying a similar solution to your own line plugging problems. Centrifugal compressors blow away roofing manufacturer's conveying troubles When a roofing manufacturer's pneumatic conveyor failed to perform adequately, the manufacturer installed two conveying lines, one using centrifugal compressors. Determining if pneumatic conveying is the best option (July 1998) Building on the information in his first four series of columns on pneumatic conveying topics, Paul E. Solt -- a private consultant with more than 41 years' experience installing and troubleshooting pneumatic conveying systems -- presents a fifth series of columns on the general application of pneumatic conveying. In a separate section, Solt also answers your pneumatic conveying questions. Dense-phase conveyor solves problem of adding dry chemicals to holding tanks Conveying system replaces a venturi-based system that never worked right. Ethanol research center toasts new production line equipment An ethanol research center installs a supplier's feeding and conveying equipment to ensure accurate and reproducible production results. Portable pneumatic conveyor moves plastic pellets at bulk transfer facility A portable conveyor transfers material between hopper railcar and dry-bulk trailers. Design criteria — System components (November 1993) Building on the information presented in his first and second series of columns, Paul E. Solt -- a private consultant with more than 36 years experience installing and troubleshooting pneumatic conveying systems -- presents a third series of columns discussing design criteria for a pneumatic conveying system. Proper air management pulls the plug on pneumatic conveying line blockage Kaolin clay repeatedly plugged dense-phase conveying lines until a minerals producer found a retrofit solution. Troubleshooting basics (March 1996) Building on the information presented in his first three series of columns, Paul E. Solt -- a private consultant with more than 39 years experience installing and troubleshooting pneumatic conveying systems -- presents a fourth series of columns on troubleshooting pneumatic conveying systems. In a separate section, Solt also answers your pneumatic conveying questions. Bulk handling system replaces company's manual bag-handling method The automatic weighing and conveying of limestone improves batching accuracy and reduces the cost of producing bolt resin. Comparing dilute- and dense-phase conveying (March 2003) In this column, we'll return to a topic last covered in the July 1991 column and compare dilute- and dense-phase pneumatic conveying systems. A dilute-phase system is commonly called a stream-flow system; a dense-phase system can be one of several types. To help you understand how each system works, this column describes and illustrates each system and provides a table comparing each system's typical performance under various operating conditions. Vacuum conveying system washes away the competition A company installs a vacuum conveying system to maintain a facial cleansing powder’s particle size, density, and composition during conveyance. A practical approach to improving your pneumatic unloading rate Time is money. If your plant receives or ships truck trailer or railcar loads of dry bulk materials that are pneumatically unloaded, improving your unloading rate can save time and cut costs. This article outlines a practical approach to speeding pneumatic unloading, with sections on predicting the unloading rate, determining optimum air volume, and overcoming problems in determining the unloading rate. The article also explains how a cement plant sped up its pneumatic unloading operation. Pneumatic system conveys problems away A paint manufacturer's new pneumatic weigh/batching system reduces the dirt, downtime, and expense that was caused by the old mechanical system. How conveying line length affects system capacity (March 1989) Changing one operating parameter of a pneumatic conveying system affects other operating parameters. In a plant environment, however, you don't have the luxury of studying the effects of these system changes. In a series of quarterly columns, Paul E. Solt -- a private consultant with more than 34 years experience in installing and troubleshooting pneumatic conveying systems -- will look at pneumatic conveying systems through the computer eye to analyze the relationships among several operating parameters. Dense-phase pneumatic conveying: Applications, system design, and troubleshooting The use of dense-phase pneumatic conveying is growing in bulk solids plants because the method's low velocity provides gentler handling for some materials and causes less conveying line wear than dilutephase conveying. After describing applications for the method, this article explains how to decide if dense-phase conveying is right for your application, how to avoid some common problems when designing your own dense-phase conveying installation, and how to troubleshoot the system. Decisions, decisions: Automated versus manual batching Should you replace your hand scoops with feeders? Deciding whether to switch from manual to automated batching can be difficult. Typical batch sizes can range from grams to tons, and each batch can involve hundreds of ingredients. Ingredients can be delivered to your plant in bags, bulk bags, drums, rigid intermediate bulk containers, trucks, and other containers and can be transported to your batching station by hand, pneumatic conveying, or mechanical conveying. Rather than tell you that automated batching is better than manual, this article outlines a step-by-step approach to helping you decide whether automated batching is really the better choice for your plant. Emerging technology: Low-velocity pneumatic conveying of carbon black Low-velocity system conveys carbon black without plugging or producing high levels of fines. Using heat exchangers to solve temperature and humidity problems in pneumatic conveying systems Pneumatic conveying systems are used in many different applications with a diverse range of products. However, with some products the temperature or moisture content of the conveying gas causes problems. Heat exchangers designed specifically for use in pneumatic conveying systems can effectively and efficiently change the conveying gas's temperature, moisture level, or both to prevent degradation of the conveyed product. This article discusses the advantages and disadvantages of heat exchangers commonly used in pneumatic conveying systems. Problems solved by heat exchangers are also discussed. Key dilute-phase equations II — Pressure and pressure drop (March 1992) Building on the information presented in his first series of columns, Paul E. Solt -- a private consultant with more than 35 years experience installing and troubleshooting pneumatic conveying systems -- presents a second series of columns discussing pneumatic conveying basics and how to apply them when designing a pneumatic conveying system. Let’s talk velocities (July 2004) Gas velocity changes at different points in a pneumatic conveying system, and when we talk about pneumatic conveying, we use different terms for velocities. So when designing a conveying system, it’s critical to understand what these velocity terms mean. Clean, dry compressed air: The secret to efficient filter cleaning Have you had filtering efficiency problems with your pulse-jet baghouse or reverse-pulse cartridge dust collector? Or is the collector frequently down for service or repairs? Moist, oily, or dirty compressed air in the collector's cleaning air system is often at the root of such problems. After a brief discussion of how filters are cleaned with compressed air, this article details the importance of clean, dry compressed air for filter cleaning, discusses types of air dryers, and explains how to select one for your application. Power plant's centrifugal compressors provide motive air for pneumatic conveying of fly ash A power plant needed to pneumatically convey fly ash 500 feet from an electrostatic precipitator to silos, so the plant chose centrifugal compressors to provide the motive air. Cleaning contaminants from your pneumatic conveying air with an in-line filter In this article, an environmental biology researcher reports results from studying how an in-line, high-pressure filter removes contaminants in dilute-phase pressure pneumatic conveying systems equipped with a positive-displacement blower. The data are from tests of unloading systems but can be applied to in-plant systems. King of the bin: Rotary paddle point level indicator A point level indicator indicates a material's presence or absence in a vessel, typically at a high or low point. Some of the point level indicator's most common applications are maintaining a predetermined material level in a vessel, preventing vessel overflow, and indicating plugging in a conveyor or pneumatic conveying line. This article looks at one indicator type -- the rotary paddle point level indicator -- whose simple electromechanical design, low cost, and other advantages make it one of today's most popular point level indicators. Chemical plant develops new method to gently load fragile prills into large bulk containers A customer's higher demand affects shipment need, prompting a chemical plant to install a dense-phase conveyor with mobile filling lance to efficiently load 20-metric-ton containers. Portable vacuum makes a clean sweep A glass panel manufacturer acquires a portable industrial vacuum to eliminate airborne dust. Troubleshooting pneumatic conveying systems A pneumatic conveying system's capacity or throughput is usually the most important factor in measuring the success of an installation. In varying degrees, noise, spillage, material carryover, component life, reliability, and contamination are also contributing factors. Capacity, however, is the most common and perhaps the most sensitive element. This article focuses on troubleshooting capacity- related problems. Its scope is limited to the common dilute system or saltated flow system. Dense- phase systems are not addressed here because many of their different design techniques are vendor specific; each dense- phase system is unique enough to require its own troubleshooting guidelines. Signed, sealed, and reduced maintenance delivered A cement production company removes a leaky diverter valve and replaces it with two new bulk material valves for reduced maintenance and increased production. Adventures in pneumatic conveying (March 2004) A reader recently commented that in my columns it appears that all pneumatic conveying systems turn out perfectly and convey materials without problems. When I responded that I've witnessed plenty of problematic conveying tests and some total system failures, he suggested that I share some of them with readers so you can learn from others' mistakes. So in this column, we'll cover some of these adventures in pneumatic conveying, most of them for transporting unusual materials, and discuss the hard-won successes along with some spectacular failures. Conveying system packages success New contract packaging operation expands Hayes Dockside's markets. Three steps to keep your hose working When you've selected the right industrial hose for a given application and you use the hose properly, it seldom fails. Hose failures usually come from misuse and abuse -- subjecting the hose to materials, temperatures, and stresses it wasn't designed to handle. This article describes how to protect your plant's hose investment by how you select, assemble, and use the hose. Selecting a flapper blade or plug diverter valve for your pneumatic conveying system Diverter valves can help you cost-effectively deliver material from one pickup point in your pneumatic conveying system to multiple destinations. Two commonly used diverter valves are the flapper blade and plug types. Read this article for information about the components and operation of both valves and for tips on choosing a diverter valve for your application. Center works to pneumatically convey difficult products The Macawber test center's solution to a food processor's product breakage problem prove to be worth more than peanuts. Dilute-phase pneumatic conveyor or flexible screw conveyor: How to choose Two versatile bulk solids conveyors that provide enclosed conveying, handle a range of materials, and convey them over a variety of paths are the dilutephase pneumatic conveyor and the flexible screw conveyor. Each of these conveyors has its pros and cons, however. This article explains what factors you need to weigh in determining which conveyor is better suited for your application. Reducing streamers and fines when conveying plastic pellets (Guest writer Amrit [Tim] Agarwal) (November 2002) In this column, we'll discuss how to handle streamers and fines formed when you pneumatically convey plastic pellets, such as polyethylene and polymer pellets. [Editor's note: Find more information on this topic in Solt's March 1998 column.] Selecting a system to convey a difficult material (March 2000) Building on the information in his first four series of columns, Paul E. Solt, a private consultant with more than 43 years experience installing and troubleshooting pneumatic conveying systems, presents a fifth series, on the general application of pneumatic conveying. In a separate section, Solt also answers your pneumatic conveying questions. Preventing and solving some common pneumatic conveying problems If your pneumatic conveying system has problems -- such as being unable to convey multiple materials at the desired capacity, degrading your material, or creating safety hazards -- the cause is probably a flawed system design. This article's first section details how you can prevent such problems by running conveying tests on your materials during the system design process. The remaining sections explain how you can diagnose and solve problems in a poorly designed existing pneumatic conveying system. Design criteria — How conveyed material affects the conveying system (March 1995) Building on the information presented in his first and second series of columns, Paul E. Solt -- a private consultant with more than 38 years experience installing and troubleshooting pneumatic conveying systems -- presents a third series of columns discussing design criteria for a pneumatic conveying system. In a separate section, Solt also answers your pneumatic conveying questions. How to minimize electrostatic discharge hazards in your pneumatic conveying system Sparks can initiate catastrophic dust explosions in pneumatic conveying systems that operate with air. To safeguard your conveying system from such electrostatic discharge hazards, you need to understand and identify the hazards and find ways to minimize them. This article first reviews some pneumatic conveying system basics, then explains how to analyze electrostatic discharge mechanisms and how to minimize electrostatic discharge hazards in your conveying system. Designing and using pneumatic conveyors A pneumatic conveyor that operates successfully in one application won't necessarily operate successfully in another. This article can help you gather the information you need to design and use a pneumatic conveyor that works successfully in your application. It describes what you need to know about the conveyed material's characteristics and the conveyor's purpose and operating conditions. Dense-phase pneumatic system conveys hydrated lime to treat sewer sludge Conveying dry, hydrated lime with a dense-phase pneumatic system and adding the dry lime directly to sewer sludge eliminates the problems incurred by injecting the sludge with a hydrated lime slurry. When oil and powder don't mix A dry vacuum pump allows an absorbent manufacturer to lower pneumatic conveying operating costs, reduce vacuum pump maintenance, and eliminate downtime. Emerging technology: Combining pneumatic conveying, blending, and storage in one operation A new technology called the pneumatic blender has proven to be a money- and energy-saving solution to blending materials such as plastic powders and pellets. How air density affects vacuum pump performance Perhaps you use a vacuum pump to power process equipment, such as a pneumatic conveyor. If so, then you should be aware that air density -- the number of air molecules per volume of air -- affects the vacuum level your pump can generate. But what factors influence air density? And how can you select a vacuum pump that performs well in the air density at your site? How system capacity affects conveying line pressure II (July 1990) In a series of quarterly columns, Paul E. Solt -- a private consultant with more than 35 years experience in installing and troubleshooting pneumatic conveying systems -- looks at pneumatic conveying through the computer eye to analyze the relationships among several operating parameters. Pneumatic Conveying Components Desktop Reference Published as a supplement to January 2001 issue, this is a 64 page concise reference on pneumatic conveying components. It includes: Columnist providing perspective on the past 50 years of pneumatic conveying advances Pneumatic points to ponder Case history on rotary valves Information on selecting a flapper blade or plug diverter valve for your system Tips on what not to forget when buying pneumatic conveying components And more! No one involved in pneumatic conveying should be without this valuable reference. Pneumatic loader speeds shipment of plastic pellets Company meets demand of overseas customers by quickly loading large containers. Using rubber hose to enhance your pneumatic conveying process Rubber hose is widely used in pneumatic conveying systems for both conveying line and bends in systems that require some natural flexibility. Its properties also make it ideal for handling abrasive, friable, or cohesive conveyed materials. This article focuses on how to apply rubber hose in pneumatic conveying lines. Information on steel pipe is provided for comparison. Key dilute-phase equations I — Saltation velocity (November 1991) Building on the information presented in his first series of columns, Paul E. Solt -- a private consultant with more than 35 years experience installing and troubleshooting pneumatic conveying systems -- presents a second series of columns discussing pneumatic conveying basics and how to apply them when designing a pneumatic conveying system. Solving airflow problems (November 1997) Building on the information presented in his first three series of columns, Paul E. Solt -- a private consultant with more than 40 years experience installing and troubleshooting pneumatic conveying systems -- presents a fourth series of columns on troubleshooting pneumatic conveying systems. In a separate section, Solt also answers your pneumatic conveying questions. How conveying line diameter (area) affects system capacity (November 1989) Changing one operating parameter of a pneumatic conveying system affects other operating parameters. In a series of quarterly columns, Paul E. Solt -- a private consultant with more than 34 years experience in installing and troubleshooting pneumatic conveying systems -- looks at pneumatic conveying through the computer eye to analyze the relationships among several operating parameters. Venting your way to better rotary valve performance -- Part I This two-part article explains how to use venting to improve the rotary valve feedrate to your pneumatic conveying system. Part I discusses how leakage occurs in a rotary valve, how to predict leakage flow, and how to determine your venting needs. Part II, scheduled for the November 1997 issue, covers types of rotary valve vents, discusses selecting a passive or active vent system, explains how to troubleshoot vent system problems, and describes venting solutions in several case studies. Rotary sifter mounts in food processor's pneumatic conveying line To improve product quality, a food processor installs a rotary sifter in a pneumatic conveying line for cocoa powders. Conveying fluidizable materials (November 2000) Building on the information in his first four series of columns, Paul E. Solt, a private consultant with more than 43 years experience installing and troubleshooting pneumatic conveying systems, presents a fifth series, on the general application of pneumatic conveying. In a separate section, Solt also answers your pneumatic conveying questions. Venturi eductors convey dust from baghouse to dumpster, leaving old dumping method in the dust Dumping baghouse dust left plant grounds dirty, so a foundry switched to pneumatic conveying. Unwanted agglomeration: How it happens and how to prevent it When the topic of agglomeration comes up, it's natural to think first of the unit operation of size enlargement -- causing particles to adhere to each other -- and the benefits this process provides for many dry bulk products. Yet agglomeration isn't always a positive thing. Unwanted agglomeration is a natural phenomenon that can occur under certain conditions during many bulk solids processing and handling operations, causing a host of problems. This article looks at the sources of unwanted agglomeration in some common operations and describes ways to prevent it. Design criteria — Selecting a feeding device (March 1994) Building on the information presented in his first and second series of columns, Paul E. Solt -- a private consultant with more than 37 years experience installing and troubleshooting pneumatic conveying systems -- presents a third series of columns discussing design criteria for a pneumatic conveying system. Plastics additives plant pneumatically conveys soft, waxy pastilles Plastics plant modifications include switching from a bucket elevator that frequently clogged to a pneumatic conveyor that consistently transfers paraffin-wax-based pastilles. Venting your way to better rotary valve performance -- Part II This two-part article explains how to improve the rotary valve feedrate to your pneumatic conveying system with proper venting. Part I, which appeared in October 1997, discusses how leakage occurs in a rotary valve, how to predict leakage flow, and how to determine your venting needs. Part II covers types of rotary valve vents, discusses selecting a passive or active vent system, explains how to troubleshoot vent system problems, and describes venting solutions in several case studies. Choosing a pneumatic conveying system: Pressure or vacuum, dense or dilute phase? A pneumatic conveying system is efficient and inherently dust-tight, making it the most practical equipment for moving large quantities of many dry powders, granules, and pellets. The system uses an airstream to push or pull material through a fully enclosed horizontal or vertical conveying line (pipe or tubing). This article provides basic information to help you determine what kind of pneumatic conveying system will work best for your application. Rotary valves keep on turnin A rotary valve increases a mineral company's productivity by standing up to abrasive particle wear. Oat processor's reduced maintenance expenses hinge on elbow's unique design Using the Vortice Ell® elbow, National Oats has eliminated elbow repair and replacement, cut energy costs, and increased the vacuum conveying rate. Dealing with plastic residue when conveying plastic pellets (March 1998) Building on the information presented in his first three series of columns, Paul E. Solt -- a private consultant with more than 41 years experience installing and troubleshooting pneumatic conveying systems -- presents a fourth series of columns on troubleshooting pneumatic conveying systems. In a separate section, Solt also answers your pneumatic conveying questions. When is it desirable to step (increase) conveying line diameter? (November 1990) In a series of columns, Paul E. Solt -- a private consultant with more than 35 years experience in installing and troubleshooting pneumatic conveying systems -- looks at pneumatic conveying through the computer eye to analyze the relationships among several operating parameters. Let’s talk temperatures (November 2004) This article covers temperature and what role it plays in designing and operating a pneumatic conveying system. Noise treatment methods for rotary-lobe positive displacement vacuum pumps Reducing noise from your pneumatic conveying system's rotary-lobe positive displacement vacuum pump will help you improve worker comfort, meet safety requirements, and extend equipment life. This article discusses general noise information, vacuum pump package noise sources, and noise treatment equipment, then explains how to apply noise treatment equipment and techniques and how to specify the equipment. The final section discusses how to evaluate the equipment's effectiveness. In-line crushing device for pneumatic conveying system solves material flow problem A kaolin clay company installs an in-line crushing device to break lumps, promoting material flow to bag packers. Getting the information you need to troubleshoot your pneumatic conveying system -- Part I Problems with a pneumatic conveying system are easier to diagnose if you have good information about the system's operating variables. This two-part article explains how you can obtain, store, and analyze this data so that you can successfully troubleshoot your conveying system. Part I covers the measurements you need and describes transducers for monitoring system variables. Part II (April) covers portable data acquisition systems for sampling and storing system data and concludes with a case study showing how system data was used to troubleshoot a pneumatic conveying system plagued by intermittent line blockages. Increasing system capacity I (July 1996) Building on the information presented in his first three series of columns, Paul E. Solt -- a private consultant with more than 39 years experience installing and troubleshooting pneumatic conveying systems -- presents a fourth series of columns on troubleshooting pneumatic conveying systems. In a separate section, Solt also answers your pneumatic conveying questions. Portable pneumatic conveyors unload ship's large grain cargo When a lightering contractor needed equipment that could first transfer a large ship's grain cargo to smaller ships and then unload the grain in port, portable pneumatic conveyors did both jobs. Factors to consider when selecting a diverter valve Selecting a diverter valve for your pneumatic conveying system can be a tough job, especially when you consider how many diverter valves are on the market. Yet a properly selected diverter valve can keep your operation running smoothly, cut maintenance costs, and improve your conveying system's efficiency. After outlining factors you should consider to select a diverter valve for your system, this article provides descriptions of commonly used diverter valves, how they work, how they're applied, and their pros and cons. New elbows help company's conveying system turn corner toward improvement A ceramic-bead manufacturer installs specialty elbows in its conveying system to eliminate leaks caused by material abrasion. Clarifying confusing pneumatic conveying terms (November 2001) In this eleventh column on the general application of pneumatic conveying, we'll review the meaning of some commonly used pneumatic conveying terms. The terms, loading, saltation velocity, pickup velocity, terminal velocity, and unstable conveying zone, are sometimes used in different ways by pneumatic conveying authors and practitioners, which can be confusing. As we review what these terms mean, it may be helpful to arm yourself with previous columns discussing them, including July 1991, November 1991, March 1993, and November 1997. Pneumatic system cuts handling and batching costs of making hummingbird food When Perky-Pet wanted to reduce ingredient and labor costs at its plant by switching from manual handling and batching, the company chose a vacuum pneumatic system and used silos for storage. Test facility delivers positive results on time every time A company uses a supplier's test facility to determine the best pneumatic conveying system to install in its plant. Filters — the unseen heroes of pneumatic conveying (March 2005) The unseen heroes of any pneumatic conveying system are the filters. A conveying system typically has several of them, but many of them go unnoticed and, hence, aren’t maintained, which can lead to serious conveying problems. This column discusses inlet and discharge filters for vacuum and pressure pneumatic conveying systems, with tips on where to locate the filters, how to choose them, and how to maintain them. Engineering project: Modifying a foundry's material handling system to recycle 350 tons of sand and dust per day If you're planning to hire an engineering firm to help modify your plant or build an addition, you can take several steps to ensure the project goes smoothly. The first three sections in this article describe how to work with an engineering firm. The final section is a case study that shows how a foundry worked with one such firm to solve a large-scale handling problem. Solving compressed air problems for the long term Compressed air is a major expense in many plants, costing directly for equipment and power and indirectly through reduced productivity and scrap product. When your compressed air costs become too high, or when the air system doesn't seem to be operating as efficiently as it could, finding the right solution may mean going outside your plant for expert help. Partnering with a compressed air consultant to do a plantwide air system audit can provide you with concrete data and an action plan that can save your plant hundreds of thousands of dollars a year. This article describes how such a consultant works and uses one cement plant's story to show how working with a consultant improved the company's bottom line. Paint factory automates production and raises efficiency Automation also increases flexibility and improves working conditions. Dual-phase pneumatic conveying system averages 100 t/h Combination dense- and dilute-phase pneumatic conveying system unloads coal from railcars, meets steel producer's blast furnace demand. Pneumatic conveying system cures hide-processor's problems Excel's hide-processing operation saves money, time, and space by replacing bagged salt with a pneumatic bulk salt system. Designing a robust pneumatic conveying system to handle future expansion - Part II This two-part article explains how you can design a robust pneumatic conveying system that will handle after-installation system changes. Part I appeared in March 2004; Part II concludes the article with details about choosing system hardware, controlling and monitoring the system, and complying with noise and air quality requirements. Improving your system’s operation (March 2001) Building on the information in his first four series of columns, Paul E. Solt, a private consultant with more than 44 years experience installing and troubleshooting pneumatic conveying systems, presents a fifth series, on the general application of pneumatic conveying. In a separate section, Solt also answers your pneumatic conveying questions. Design criteria — How the conveying system affects conveyed material (November 1994) Building on the information presented in his first and second series of columns, Paul E. Solt -- a private consultant with more than 37 years experience installing and troubleshooting pneumatic conveying systems -- presents a third series of columns discussing design criteria for a pneumatic conveying system. In a separate section, Solt also answers your pneumatic conveying questions. How air volume (velocity) affects system capacity (July 1989) Changing one operating parameter of a pneumatic conveying system affects other operating parameters. In a series of quarterly columns, Paul E. Solt -- a private consultant with more than 34 years experience in installing and troubleshooting pneumatic conveying systems -- looks at pneumatic conveying through the computer eye to analyze the relationships among several operating parameters. Pneumatic Conveying Design Guide, Second Edition This detailed guide provides indispensable practical information for both designers and users of pneumatic conveying systems. Designing a vacuum conveying system to handle feedrate changes (November 2005) Columnist Paul E. Solt explains how to design a vacuum conveying system to handle feedrate changes. Compact conveyor bends for magnesium oxide require little elbow room When standard stainless steel conveying elbows frequently wore out, a coal-fired power-generating facility installed compact, durable elbows. Four steps to a successful pneumatic conveying system startup Are you faced with getting a pneumatic conveying system up and running? Defining system requirements and functions with input from others in your plant can help you design a pneumatic conveying system and get it started without costly delays. This article discusses four steps for a successful system startup, including designing the system, installing the system, planning the startup, and initiating the startup. The conclusion includes information about training plant workers to operate and maintain the system. Pneumatic conveying test setups simulate plant conditions Tests prove that expensive line boosters can be eliminated in dense-phase pneumatic conveying of polymer. Pneumatic conveying pipe bend with raised-diamond interior pattern works like a gem After trying many pipe bend styles, a plastic resin manufacturer finds one that's lightweight, durable, and that reduces plastic pellet degradation. Safely handling your powder with a closed-loop pneumatic conveying system Although users have found ways to apply pneumatic conveying in many industries over the years, some applications have presented problems. One example is pneumatically conveying a combustible or explosive powder. This article explores how you can select components for a closed-loop pneumatic conveying system that can safely handle such a powder in your plant. The Best of Pneumatic Conveying Every article relating to pneumatic conveying published from 1987 through 1991. How to choose a reliable, long-lasting rotary valve Selecting a rotary valve used to be a matter of matching the valve's feeding capacity, based on your product's bulk density, to your required process or pneumatic conveying system capacity. Today this is only the beginning. Now valve selection involves a combination of materials testing, computer-aided design engineering, high-quality raw materials, advanced casting and certified fabrication procedures, accurate machining, and high-quality bearings and shaft seals. As this article explains, the result is a rotary valve engineered to match your application and provide reliable, long-lasting service. Venturi eductors improve conveying of dense, abrasive, and fine materials When rotary airlocks for a recycler's furnace slag and slag dust wore quickly, leaked air, and reduced conveying efficiency, the recycler installed venturi eductors, which improved conveying. Test results: How bend types influence pneumatic conveying system performance A conveying line bend is just one of several components you must select for a pneumatic conveying system, but the bend type you choose will have a strong effect on the system's performance. The bend should generate a low pressure drop to minimize the system's energy consumption, and the bend should also minimize particle degradation and wear on the bend walls. Read this article to see how results of a test program at the University of Greenwich and an equation for predicting pressure drop due to bends can help you select a bend for your conveying system. Pneumatic injectors evenly feed fuel and sorbent to power plant boilers To meet strict emissions requirements, promote efficient operation, and minimize downtime, a power plant equipment supplier chose pneumatic injectors to convey fuel and sorbent to fluidized bed boilers. Pneumatic conveying system types — vacuum, pressure, and combination (March 1991) Building on the information presented in his first series of columns, Paul E. Solt -- a private consultant with more than 35 years experience in installing and troubleshooting pneumatic conveying systems -- presents a second series of columns discussing pneumatic conveying basics and how to apply them when designing a pneumatic conveying system. How a pressure system can be used for either dilute- or dense-phase (July 2000) Building on the information in his first four series of columns, Paul E. Solt, a private consultant with more than 43 years experience installing and troubleshooting pneumatic conveying systems, presents a fifth series, on the general application of pneumatic conveying. Troubleshooting control equipment problems (July 1997) Building on the information presented in his first three series of columns, Paul E. Solt -- a private consultant with more than 40 years experience installing and troubleshooting pneumatic conveying systems -- presents a fourth series of columns on troubleshooting pneumatic conveying systems. In a separate section, Solt also answers your pneumatic conveying questions. Key calculations for designing a combined dense- and dilute-phase system (March 1993) Building on the information presented in his first series of columns, Paul E. Solt -- a private consultant with more than 36 years experience installing and troubleshooting pneumatic conveying systems -- presents a second series of columns discussing pneumatic conveying basics and how to apply them when designing a pneumatic conveying system. Comparison of blower types used in pneumatic conveying systems At the heart of every pneumatic conveying system is the air-moving device or blower. This article compares two basic blowers used in dilute-phase pneumatic conveying systems: the positive displacement blower and the fan-type turbo blower. By applying a few basic principles of pneumatic conveying and analyzing the relationship between the characteristics of each blower and the conveying line, some general guidelines for selecting the proper blower for an application can be established. Determining which system and components will best meet your needs II (March 1999) Building on the information in his first four series of columns, Paul E. Solt -- a private consultant with more than 42 years experience installing and troubleshooting pneumatic conveying systems -- presents a fifth series of columns on the general application of pneumatic conveying. In a separate section, Solt also answers your pneumatic conveying questions. Design criteria — Methods for separating the conveyed material from the air (gas) (November 1995) Building on the information presented in his first and second series of columns, Paul E. Solt -- a private consultant with more than 38 years experience installing and troubleshooting pneumatic conveying systems -- presents a third series of columns discussing design criteria for a pneumatic conveying system. In a separate section, Solt also answers your pneumatic conveying questions. New Search