Optimized Pressure Vessel Design for Reliable Multivessel Conveying Arrangement
Pneumatic Conveying System
At Rieco, we are continuously striving to enhance the performance of our Pneumatic Conveying Systems. Recently, we embarked on in-depth research to optimize blow tank designs for the reliable dense-phase conveying of ash, particularly for economizer hoppers and the 2nd & 3rd fields of the ESP (Electrostatic Precipitator).
Our goal was to ensure efficient and consistent ash feed into the pressure conveying pipeline, which requires blow tanks specifically designed for varying ash characteristics across different collection points.
The Challenge
Traditional blow tanks were designed for handling ash from ESP (Electrostatic Precipitator) first fields, which have high ash collection rates. However, for the finer ash collected in ESP second and third fields, as well as from air preheaters and economizers, standard blow tanks proved unnecessarily large and inefficient. The challenge was to optimize tank size and weight to handle lower ash discharge rates effectively, while ensuring reliable dense-phase conveying with minimal air consumption.
Methodology and Development
Our multi-phase approach involved several critical steps:
- Ash Characterization: We collected samples from economizers, ESP fields, and bag filters, assessing key properties like bulk density, particle size distribution, and angle of repose. These measurements provided valuable data for tailoring the blow tank design.
- CFD Simulations: Using computational fluid dynamics (CFD), we simulated multiple blow tank designs to evaluate flow characteristics and minimize wear on internal surfaces.
- Flow Visualization: Transparent conduits allowed us to visualize the flow behavior of ash under various conditions, confirming simulation data and helping fine-tune the design.
- Validation & Testing: Three blow tank prototypes were fabricated based on the simulations and tested under real conditions to ensure effectiveness across ash variations.
The following table shows the physical properties of ash samples.
| S. No. | Fly ash | Particle size range (µm) |
|---|---|---|
| 1 | Fabric Filter | 2 to 50 |
| 2 | Field 1 | 4 to 90 |
| 3 | Field 3 | 3 to 50 |
| 4 | Economizer | 100 to 400 |
Outcomes and Benefits
By optimizing the blow tank design and weight, we have developed a solution that:
- Reduces Air Consumption: Efficient dense-phase conveying reduces the air required for conveying, cutting energy costs.
- Enhances Reliability: Consistent discharge of both coarse and fine ash helps prevent blockages and ensures smooth operation.
- Increases Equipment Longevity: Lower wear on internal surfaces extends equipment life and reduces maintenance.
Conclusion
This optimization project has allowed Rieco to refine our blow tank designs to meet the demanding requirements of dense-phase pneumatic conveying systems for ash. Our solutions improve efficiency and reliability while reducing operational costs, reinforcing our commitment to delivering innovative, tailored solutions to clients.
Stay tuned for more advancements in pneumatic conveying technology from Rieco Industries! Curious to know more? Contact us at rieco@rieco.com.
