PNEUMATIC CONVEYING SYSTEM PRODUCTION
Pneumatic transport production is the process of producing technical equipment which provides conveying of dry bulk materials or containers (piece load) under pressure of compressed air or diffused gas mixture. Nowadays, it is one of the most technologically advanced ways of automating transportation of powdered, granular, bulk and piece materials.
High capacity and feasibility of creating long-range systems enables the use of pneumatic transport and aspiration in various areas of industry. Pneumatic transport devices also occupy less space, prevent loss of bulk material during transportation, provide excellent hygiene and sanitary operating conditions, block contaminating factors and allow for a broad range of settings up to complete automation.
THE USE OF PNEUMATIC CONVEYING SYSTEM AND ASPIRATION
When the grain size of the dry bulk material is not too big, pneumatic conveying system has a great number of advantages in comparison with all other conveying methods. Pneumatic conveying systems have been used for a broad range of purposes in production and conveying.
- At construction material production;
- At chemical, refining and petrochemical enterprises for transportation of powders, fragmented materials, bulky stock, catalyst bulk and contact mass;
- Aspiration systems for disposal of production waste around machines (dust, shavings etc.);
- In wood-pulp and paper industry (to convey wood processed into chips and waste of wood processing (shavings, sawdust, dust));
- In various branches of food industry, including confectionery, milling, sugar and bread baking industries;
- Pneumatic conveying systems are used in brewing and alcohol industry for transportation of raw material (kerns, malt, yeast etc.) for alcoholic beverages;
- In canned foods industry, for automatic feed of dry ingredients.
- In the production of tea, coffee, tobacco products.
PRINCIPAL COMPONENTS OF PNEUMATIC CONVEYING SYSTEMS
Pneumatic conveying system production includes the following nodes:
- A feeder is a loading device for feed of material from a special container (silage) to be transported by the system or of production waste (in the case of aspiration); feeders of pressure units are also catered for air mixture optimization. Feeders can have various designs and sizes of nozzles.
- Discharging devices are specialized sealed bins, tanks and other containers (silages) that are meant to separate and remove waste and dust from the general flow.
- Metal pipelines for transportation of the materials. They provide sealing of the system and are characterized by durability and low friction resistance. Pipelines are produced from thin sheets of stainless steel or rough steel depending on their intended use.
- Air movers are the true “heart” of a pneumatic conveying system, selected specifically for the required characteristics of capacity, system scope and power.
- All pneumatic conveying systems fall into one of three categories based on how they transport materials: vacuum operation (such aspiration is effective for suction of chips, dust etc.), pressure operation (transportation of powders with the help of condensed air) and combined pressure-vacuum operation (the blower installed in the pipeline divides the system into two sections).
OLAND PROMTECHMONTAZH OFFERS THE FOLLOWING SET OF SERVICES WITHIN THE SCOPE OF PNEUMATIC TRANSPORT PRODUCTION WHEN THE SYSTEM IS USED IN THE CLIENT’S MANUFACTURING FACILITY:
- Professional design of an effective pneumatic conveying system and aspiration which will significantly reduce the expenses for manual labor as well as the risk of “human factor.”
- Time-efficient system installation.
- Equipment setting to ensure convenience of operating for the personnel.
- Ensuring high reliability and uninterrupted operation of pneumatic transports.
- Use of the most advanced technological solutions.
- Reduction of production contamination by product waste and increase in the level of safety.
- Full warranty of performance of pneumatic conveying systems and aspiration systems, warranty and post-warranty service.
Only professional support provided by OLAND PROMTECHMONTAZH, from the stage of development up to the start-up and adjustment of the system, can guarantee productive capacity and efficiency of the equipment.
|PIPELINES (PIPE)||A pipeline is one of the principal elements of a pneumatic conveying system. It consists of multiple pipes which are integrated into a single system with the help of shaped elements.
Metal pipes are the optimal choice for pneumatic conveying systems. They are highly reliable, resistant to humidity and rapid change of temperature as well as to other aggressive environmental influences.
There are pipelines that use clean air and those which use a combination of air and other materials.
Steel sheets or aluminium are the materials most often used in pipeline production. Material conveying requires weldless or hot-rolled steel pipes. The pipes are connected by welding or special flanges.
|SHAPED ELEMENTS OF A PHEUMATIC CONVEYING SYSTEM (FLANGE BEND)||Flange bend is used to change the air pipe direction at the right angle. This element allows to ensure reliable connection, preserving the optimal velocity and correct direction of air flow.
This element is easy to install as it is equipped with flanges on both sides to fix it to the principal element of th pipeline. When installed correctly, this shaped element preserves sealing capacity and can be used for an appreciable length of time. Special screws and nuts are used for its installation, with rubber pads preventing air leaks.
Flange bends vary in diameter and are selected depending on pipe characteristics. All the sizes are standardized, which makes it easy to select this shaped element for any pipeline.
|SHAPED ELEMENTS OF A PHEUMATIC CONVEYING SYSTEM (BEND)||Bends are shaped elements used during pneumatic conveying system installation to change the direction of air flow.
Bends vary in diameter and bend radius. The latter is standardized and equals 1.5D. It is the perfect size for optimization of air flow velocity. In some instances, bends of non-standardized bend radius can be used.
The number of bend segments can vary depending on the smoothness of the flow and the angle of air flow turn.
The bends have to be made from steel of the same grade as the steel used for production of the principal air ducts.
There are bends both round and rectangular in section. It allows to select shaped elements for the pneumatic conveying system regardless of the configuration.
|SHAPED ELEMENTS OF A PHEUMATIC CONVEYING SYSTEM (PIPE REDUCER)||The absolute majority of air filtration systems consist of pipelines of various diameters and section shapes. Pipe reducers are shaped elements used to connect different segments of the system.
There are pipe reducers which connect pipes of the same shape as well as those which connect round and rectangular pipes.
The sizes and aspect ratios of reducers are standardized, which facilitates correct air distribution in the system. There are shaped elements for various pipes of standard sizes on the market.
Pipe reducers are made from high-quality galvanized steel which ensures their durability and long service lifetime. These elements help to shape a system of any configuration, making optimal use of the available space.
|SHAPED ELEMENTS OF A PHEUMATIC CONVEYING SYSTEM (SUPPORTING FRAME)||The bearing parts of the pneumatic conveying system are supporting frames that serve as a bearing and fixing member. These shaped elements come in a large variety depending on their intended use.
Air movers are installed in the pneumatic conveying system with special frames that provide reliable connection and facilitate the installation process. The frames can be made from galvanized steel, which provides corrosion resistance. Supplementary materials can be used to ensure sealing of the system and prevent moisture penetration in case of special requirements for the system.
To stabilize the pneumatic conveying system, the supporting frames can be made from durable metal, which allows to fix the air ducts in one place.
There are also special frames that connect heat-insulated air ducts with ventilation equipment, such as roof ventilators. They have a heat-insulating soundproof layer made from rock wool.
|SHAPED ELEMENTS OF A PHEUMATIC CONVEYING SYSTEM (SYMMETRICAL AND ASYMMETRICAL PIPE FITTINGS)||Fittings are used to connect air ducts of different sizes and shapes of section into a single system. There are symmetrical and asymmetrical pipe fittings.
A symmetrical pipe fitting is used when the center line of the two connected air ducts coincides. If the center lines are different, this fitting is called asymmetrical.
Shaped elements for installation of fittings vary in their type, shape of pipe section as well as sizes. All the elements are standardized according to the National State Standard, which means that as long as the characteristics of the pipe is clear, there is no problem with finding fittings for any air cleaning system.
Fittings are in high demand for installation of air ducts, because there is always a need to connect pipes of different diameters and shapes.
|SHAPED ELEMENTS OF A PHEUMATIC CONVEYING SYSTEM (SQUARE SYMMETRICAL TUBING TEE)||One of the shaped elements used for installation of a pneumatic conveying system is a square symmetrical tubing tee. This element is used for dividing or combining air fluxes.
The principal part of a tubing tee is the shaft which coincides with the guiding axle of the air duct. The branch makes an angle with the shaft.
The choice of a tubing tee is based on the peculiarities of construction of the air duct. A wrong choice of this shaped element can reduce the efficiency of the entire air cleaning system.
A square symmetrical tubing tee carries out two functions at once: it connects elements of a pipeline and enables adding a supplementary brunch to the major pipeline.
|SHAPED ELEMENTS OF A PHEUMATIC CONVEYING SYSTEM (FLANGES)||A pneumatic conveying system is a system of pipes that are connected with shaped elements. Flanges are fastening elements that are used for connecting the ducts between themselves and to air cleaning equipment.
Flange connection is insulated and reliable. With proper mounting and timely maintenance, it can serve its purpose for a long time. Flanges enable the pipeline to be unmounted and mounted again multiple times, which allows to upgrade the cleaning system, replace individual broken-down elements.
Flange sizes are standardized in accordance with the National State Standard, which means that these shaped elements are easy to find for all types of pipelines. Flanges vary in sizes, shapes and type of fastening.
|CYCLONES (ЦР)||The ЦР modification falls into the category of discharge cyclones that are widely used for removing particles of medium and large sizes from the air: shavings, cuttings, coarse dust. This equipment is indispensable at grain mills, woodworking enterprises and facilities working with dry goods. These devices are often used in peumatic transport systems for primary cleaning of the air. Finer purification is done with the help of other types of equipment.
There are many modifications of ЦР cyclones depending on their efficiency. A device capable of cleaning 200-250 m3 of air per hour will be enough for a small space, while large production facilities need to use more powerful equipment that would be five to ten times as efficient.
|CYCLONES (4БЦШ)||4БЦШ cyclones are designed for removing medium-sized suspended particles from the air. This equipment is widely used at enterprises working with agriculture, grain processing, food industry. This type of air purifiers can be used for discharge of non-sticky matter.
The 4БЦШ modification is a group of в БЦ or ЦР cyclones put together into one apparatus. Such a device can remove up to 98% of suspended matter from the air.
For efficient air purification 4БЦШ are mounted as battery systems that can include two to eight cyclones, with the number always even.
When cyclones are mounted, a fan providing adequate inflow of air should be installed. It can be installed both before and after the purifying device.
|CYCLONES (СЦН-40)||Cyclones of the СЦН-40 modification are designed for discharge of fine and medium particles from the air. They are highly efficient and are characterized by low power consumption.
Thanks to an increased intensity of gas rotation inside the СЦН-40 cyclone, this device manages to remove almost all suspended particles from the air. This is also aided by the reduced speed of air flow moving towards the exhaust pipe.
СЦН-40 is made from high-quality stainless steel and are highly durable. They almost do not get clogged with dust particles, therefore this type of devices does not require special maintenance.
The СЦН-40 modification can be used in a group consisting of 4 cyclones. It allows to increase the efficiency and purify air in large spaces.
|CYCLONES (ЦП-2)||The ЦП-2 cyclone is a type of air purifiers much needed in facilities working in metal, oil, chemical and power industries. It is capable of entrapping particles after drying systems or fuel pulverization of solid fuel steam generators. For operation under hazardous production conditions, there is an explosion-proof modification.
ЦП-2 bins have rather small dimensions, which prevents accumulation of large volumes of explosive matter. The equipment is designed for spaces where suspended particle concentration in the air does not exceed 1500 g/m3.
ЦП-2 can be used as general industrial equipment. It should not be used for removing sticky dust or lint.
|CYCLONES (ЦРК)||ЦРК cyclones are catered for grain mills and remove medium-sized dust particles from the air. This equipment can also be used at woodwork facilities to remove shavings.
ЦРК are characterized by low energy consumption, high efficiency and a small size. They are best suited for production that does not need high efficiency and the space for mounting is limited.
ЦРК cyclones are made from stainless steel of high quality, which gives them excellent operation characteristics. The equipment can have clockwise or counterclockwise air rotation.
This type of cyclones allows to remove up to 90% of suspended matter from the air. The capacity is about 2500 m3/hour.