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Copyright, CSC Publishing, Powder and Bulk Engineering
Choosing an elbow for your pneumatic
conveying system
Jerry Paulson Pelletron Corp.
Selecting an elbow for your pneumatic conveying
system can be a tough job, especially considering
how many different types of elbows are on the mar-
ket. Yet a properly selected elbow can keep your sys-
tem 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.
S
everal types of elbows (also called bends or sweeps)
are available for pneumatic conveying lines, and
each type is suited to certain applications and has its
own set of advantages and disadvantages. The elbow you
choose will have a huge impact on your pneumatic con-
veying systems performance, whether the system oper-
ates in dense or dilute phase and under pressure or
vacuum. [Editors note: For more information on pneu-
matic conveying systems see the later section For further
reading or contact the author.]
How elbows affect conveying performance
What makes elbows so important to pneumatic conveying
system performance? Each elbow provides a change in the
conveying line direction, and every direction change adds
to the systems pressure loss (that is, kinetic energy loss or
pressure drop). The initial conveying air velocity required
to overcome flow resistance in the line increases as the
conveying distance increases, in turn increasing the sys-
tem pressure.
Several factors contribute to the pressure loss at each
elbow. For instance, in a dilute-phase system the factors
are centrifugal force (produced as the material moves
around the elbow), heat (created by material and air fric-
tion on the elbows surfaces), impact energy (from mate-
rial hitting the elbow walls and fracturing apart), and the
force required to reaccelerate the material after the elbow.
These pressure losses can really add up. The more elbows
your system requires, the more the system pressure in-
creases, and the more flow resistance the air velocity has
to overcome to convey your material, which can signifi-
cantly increase your energy costs. Careful elbow selection
is an effective way to keep these pressure losses low and
your system performance at peak levels. The right elbow
can also prevent other problems, such as material degrada-
tion, elbow wear, and plugging, as well as the maintenance
and lost production headaches that come with them.
Some elbow basics
Before discussing available elbows and how to choose one
for your application, lets look at how an elbow functions
in a pneumatic conveying system.
As material enters the elbow. As material in the pneu-
matic conveying line enters the elbows inlet, it typically
continues moving in a straight line until it impacts the
elbow in an area called the primary impact zone. The pri-
mary impact zone deflects the material at a known angle
l-Pelletron_48-57 4/25/05 3:25 PM Page 2
toward the elbows outlet. This deflection angle is deter-
mined by the elbows shape and the materials velocity and
mass. Often, the material will impact the elbow again in an
area called the secondary impact zone before exiting
through the elbow outlet.
Friction, collisions, pressure loss. Material striking the
primary and secondary impact zones causes friction,
which reduces the materials velocity and results in pres-
sure loss. Particle-on-particle collisions that occur in and
near the impact zones can fracture some of the particles,
also reducing the materials velocity and contributing to
pressure loss. The friction caused by particle-on-elbow
and particle-on-particle collisions creates heat that raises
the material, conveying air, and conveying line tempera-
tures and can degrade heat-sensitive materials such as
plastic pellets. Particle-on-elbow collisions also abrade the
elbows interior surface, creating holes that contribute to
pressure loss and material leakage. A dilute-phase system
typically experiences more friction and pressure loss than
a dense-phase system because the incoming materials ve-
locity is much higher in the dilute-phase system.
As material exits the elbow. The materials velocity de-
creases as the material moves toward the elbows outlet,
which creates a slurry-like mass of particles just before the
outlet in an area called the acceleration zone. Faster-moving
incoming particles continuously collide with the slower
moving particles in the particle mass, creating turbulence
that pushes the particles nearest the outlet out of the elbow.
This action can further damage the particles, elbow, and con-
veying line as well as contribute to pressure loss. As the ma-
terial exits the elbow, it disperses in the conveying line and
accelerates to a velocity greater than the initial conveying air
velocity. The more material being conveyed, the more likely
this particle mass in the acceleration zone will develop and
the greater your initial conveying air velocity will need to be
to overcome the flow resistance the mass creates.
Comparing the elbows
The following sections describe and illustrate some com-
mon elbow types. As you consider which elbow is right for
your pneumatic conveying system, keep these selection
factors in mind:
What conveying phase dense or dilute the elbow
must handle.
What application new installation, replacement, or
retrofit the elbow is for.
What conveying direction change (from horizontal to
vertical, or from vertical to horizontal) the elbow must
provide.
How much pressure loss the elbow will contribute to
your conveying system.
How well the elbow resists abrasion and how long its op-
erating life is likely to be in your application.
How well the elbow can prevent damage to your particles.
Copyright, CSC Publishing, Powder and Bulk Engineering
Whether the elbow is likely to produce cross-contamina-
tion in your application.
Whether the elbow is prone to plugging with material.
Long- and short-radius elbows
Long- and short-radius elbows are the two most common
elbows in pneumatic conveying systems. These elbows
consist of a curved pipe or tube section with the same diam-
eter as the conveying line. A long-radius elbow (LRE) typi-
cally has a radius thats 10 times the conveying line
diameter, and a short-radius elbow (SRE) typically has a ra-
dius thats 3 times the line diameter. For instance, an LRE
installed in a 4-inch-diameter line would have a 40-inch ra-
dius, and an SRE installed in the same line would have a 12-
inch radius. In both the LRE and SRE, particle-on-elbow
impact deflects and redirects flow to the elbow outlet, and
both elbows can be used in dense- and dilute-phase systems.
In an LRE or SRE that redirects flow from horizontal to
vertical, material enters the elbow at or above the initial
conveying air velocity. Then the material hits the elbows
interior surface at the primary impact zone, is deflected
upward to the acceleration zone, and exits the outlet, as
shown in Figure 1. Material striking the primary impact
zone causes friction, which creates heat. Particle-on-parti-
cle collisions occurring in the primary impact zone and ac-
celeration zone can fracture some of the particles.
In a dilute-phase system, the SREs sharp deflection angle
at the primary impact zone increases friction, particle
breakage, elbow wear, and pressure loss, whereas the
LREs shallow deflection angle reduces these effects. In a
dense-phase system, the SRE contributes less pressure loss
than the LRE because the SREs inlet-to-outlet distance is
Figure 1
Long-radius elbow in dense phase
Acceleration zone
Slurry
Incoming material
Primary impact zone
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much shorter, which reduces the time and pressure needed
to redirect the material flow. Because of this, the LRE is
best suited for dilute-phase systems handling free-flowing
nonfriable materials, and the SRE is best suited for dense-
phase systems handling free-flowing friable materials.
Advantages. Some LRE and SRE advantages are:
Either can be used in dense- and dilute-phase systems.
Material purges completely from either elbow at the con-
veying cycles end, preventing cross-contamination.
Either elbow installs horizontally or vertically to redirect
material in any direction.
An LRE in a dilute-phase system contributes low pres-
sure loss.
An SRE in a dense-phase system contributes low pres-
sure loss.
The SRE installs easily in cramped quarters for a new in-
stallation, replacement, or retrofit.
Disadvantages. Some LRE and SRE disadvantages are:
Both elbows wear when conveying mildly abrasive ma-
terials, resulting in a short operating life.
Friction-induced heat damages heat-sensitive materials
in both elbows.
Particle-on-elbow and particle-on-particle collisions
damage fragile materials in both elbows.
For both the LRE and SRE, excessive pressure loss leads
to interrupted material flow if multiple elbows arent in-
stalled at least 15 to 20 feet apart in the conveying line.
In both elbows, material plugging at the primary impact
zone causes high-pressure surges.
The LRE is difficult to install in cramped quarters be-
cause of its space requirements.
Blind-tee elbow
The blind-tee elbow looks like the letter T and resembles
the SRE in that it has a sharp material deflection angle, as
shown in Figure 2. The elbow consists of two straight pipe
or tube sections with the same diameter as the conveying
line that have been joined together at a 90-degree angle. The
inlet section has a capped end opposite the inlet, and the out-
let sections open end is connected to the inlet sections side
a few inches in front of the capped end, forming a pocket. In
the blind-tee elbow, which can be used in both dense- and
dilute-phase systems, particle-on-particle and particle-on-
elbow impacts deflect and redirect material flow.
In a blind-tee elbow that redirects flow from horizontal to
vertical, material enters the elbow at or above the initial
conveying air velocity and fills the pocket. Additional in-
coming material hits the static material mass formed in the
pocket at the primary impact zone and is deflected upward
at about a 45-degree angle toward the acceleration zone
(Figure 2). The material contacts the elbow at the sec-
Copyright, CSC Publishing, Powder and Bulk Engineering
ondary impact zone, is deflected through the acceleration
zone, and exits the outlet.
In the primary impact zone, particle-on-particle impact de-
flects the material, which protects this part of the elbow
from abrasive wear. In the secondary impact zone, parti-
cle-on-elbow impact deflects the material, causing friction
that abrades the elbow and creates heat.
In a dilute-phase system, the blind-tee elbows sharp de-
flection angle at the primary impact zone increases parti-
cle breakage and pressure loss. In a dense-phase system,
nonfree-flowing material can bridge at the primary impact
zone and stop material flow, which leads to high-pressure
surges and makes the system unstable. However, the
blind-tee elbow is best suited for dense-phase systems
handling friable or abrasive materials because the low ini-
tial conveying air velocity reduces material attrition,
elbow wear, and friction-induced heat.
Advantages. Some advantages of a blind-tee elbow are:
Its suited to both dense- and dilute-phase systems.
The elbow is less subject to wear, extending its operating
life.
It installs easily in cramped quarters for a new installa-
tion, replacement, or retrofit.
It installs horizontally or vertically to redirect material in
any direction.
Disadvantages. Some disadvantages of a blind-tee elbow
are:
The elbow contributes high pressure loss (relative to the
LRE) in both dense- and dilute-phase systems.
Material becomes impacted in the elbow pocket, causing
cross-contamination.
Figure 2
Blind-tee elbow in dilute phase
Acceleration zone
Slurry
Secondary impact
zone
Incoming material
Primary impact zone
Pocket
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Material bridges at the primary impact zone, causing
high-pressure surges.
High-velocity particle-on-particle impact in dilute-phase
systems causes particle attrition.
Spherical chamber elbow
The spherical chamber elbow1 is shaped like the SRE, ex-
cept that it has a spherical vortex chamber opposite the
inlet, as shown in Figure 3. In the spherical chamber
elbow, which can be used in both dense- and dilute-phase
systems, particle-on-particle and particle-on-elbow im-
pacts deflect and redirect material flow.
In a spherical chamber elbow that redirects flow from hor-
izontal to vertical, material enters the elbow at or above the
initial conveying air velocity and fills the vortex chamber.
The inlet section is sloped slightly downward so that the
vortex chambers center is somewhat below the incoming
conveying lines centerline. The chambers shape and lo-
cation force the material to rotate in the chamber. A small
kick-up area at the chambers bottom forces the material
back to the chambers top, creating a counter-rotating ball
of fluidized material. Incoming material impacts the flu-
idized material at the primary impact zone and is deflected
upward at about a 45-degree angle toward the acceleration
zone. The material contacts the elbow at the secondary im-
pact zone, is deflected through the acceleration zone, and
exits the outlet. The fluidized material in the vortex cham-
ber eventually discharges back into the material stream
and is replaced by new material and air entering the elbow.
Since in the spherical chamber elbows primary impact zone
particle-on-particle impact deflects the material, this zone is
protected from abrasive wear. However, in the secondary im-
pact zone particle-on-elbow impact deflects the material,
which causes friction that abrades the elbow and creates heat.
The spherical chamber elbow is best suited for systems
handling abrasive or friable materials.
Advantages. Some advantages of a spherical chamber
elbow are:
It can be used in both dense- and dilute-phase systems.
The primary impact zone provides soft particle-on-parti-
cle impact, which reduces material attrition.
The elbows design reduces abrasion and elbow wear,
extending the elbows operating life.
It installs easily in cramped quarters for a new installa-
tion, replacement, or retrofit.
Multiple elbows can be installed a short distance apart
and still provide uninterrupted material flow.
The elbow installs horizontally or vertically to redirect
material in any direction.
Disadvantages. Some disadvantages of a spherical cham-
Copyright, CSC Publishing, Powder and Bulk Engineering
ber elbow are:
The elbow contributes moderate pressure loss (relative to
the LRE) in both dense- and dilute-phase systems.
Material may not always purge completely from the vor-
tex chamber, causing cross-contamination.
Multitransition elbow
The multitransition elbow2 resembles the LRE, except that
its fabricated from both flat and round pieces. The
elbows inlet and outlet are the same diameter as the con-
veying line, its inner radius is round, and its outer radius
consists of multiple flat-plate segments that are wider than
the inlet and outlet, as shown in Figure 4. In this elbow,
particle-on-elbow and particle-on-particle impacts deflect
and redirect material flow to the elbow outlet. This elbow
is for dilute-phase systems conveying plastic pellets,
where it prevents streamers from forming.
In a multitransition elbow that redirects flow from hori-
zontal to vertical, material enters the elbow at or above the
initial conveying air velocity. Because the flat-plate sec-
tions are wider than the inlet and outlet, the material slows
down and spreads out before hitting the primary impact
zone. The primary impact zone is on a flat plate thats an-
gled 30 degrees from vertical away from the inlet and de-
flects material upward to the acceleration zone (Figure 4).
The deflected material slows and forms a slow-moving
slurry below the acceleration zone that prevents material
from rubbing against the elbow interior. The secondary
impact zone is within the slurry, where incoming material
continuously impacts the slurry and moves material near-
est the outlet out of the elbow. The elbow diameter con-
tracts to match the conveying line diameter near the outlet,
and as the material exits the elbow, it accelerates to a ve-
locity greater than the initial conveying air velocity.
Figure 3
Spherical chamber elbow in dilute phase
Secondary Acceleration zone
impact
zone
Vortex chamber Primary impact zone
Incoming material
Material
rotation
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In the primary impact zone particle-on-elbow impact de-
flects the material, which causes some minor friction and
elbow wear. In the secondary impact zone particle-on-par-
ticle impact deflects the material and minimizes streamer
formation and material attrition.
Advantages. Some advantages of a multitransition elbow
are:
The elbow reduces streamer formation and particle attri-
tion in dilute-phase systems conveying plastic pellets.
Material purges completely from the elbow at the con-
veying cycles end, preventing cross-contamination.
The elbow installs easily in tight spaces for a new instal-
lation, replacement, or retrofit.
Disadvantages. Some disadvantages of a multitransition
elbow are:
The elbow is used only in dilute-phase systems convey-
ing plastic pellets.
Particle-on-elbow impact at the primary impact zone
causes elbow wear.
The elbow contributes moderate pressure loss (relative to
the LRE).
It installs only horizontally to redirect material vertically.
Phase-transition elbow
The phase-transition elbow3 resembles an SRE with a large
expanded chamber between the inlet and outlet, which are
the same diameter as the conveying line, as shown in Figure
5. After the inlet, a small step (called a Bernoulli step) drops
the elbows outer radius below the conveying lines bottom
and the elbows outer radius and adjoining sides flare out to
Figure 4
Multitransition elbow in dilute phase
Acceleration
zone
Slurry
Incoming material
Secondary
impact
zone
Primary impact zone
expand its interior area, much like the multitransition elbow.
Copyright, CSC Publishing, Powder and Bulk Engineering
The phase-transition elbow contracts toward the outlet to
match the conveying lines diameter. In the elbow, which
can be used in both dense- and dilute-phase systems, parti-
cle-on-particle impact and a conveying-phase transition de-
flect and redirect material flow to the elbow outlet.
In a phase-transition elbow that redirects flow from hori-
zontal to vertical, material enters the elbow at or above the
initial conveying air velocity. As the material passes over
the Bernoulli step into the expanded chamber, it slows
down and changes conveying phases, creating a fluidized
slurry. The primary impact zone is within the slurry, and
incoming material continuously impacts and moves the
slurry upward toward the acceleration zone at about a 90-
degree angle (Figure 5). The Bernoulli step creates a low-
pressure zone that draws material from the primary impact
zone back across the elbows bottom to the inlet and back
up into the incoming material stream. As the material exits
the elbow, the elbow diameters reduction to the convey-
ing line diameter changes the materials conveying phase
back to its original phase and accelerates the material to a
velocity greater than the initial conveying air velocity.
In a dilute-phase system, the material changes from dilute
to dense phase and then back to dilute phase. In a dense-
phase system, the material changes from dense phase to a
more intense dense phase (which increases the particle
density in the slurry) and then back to dense phase.
In the primary impact zone particle-on-particle impact de-
flects the material, which reduces friction and elbow wear.
The conveying-phase transition slows the material to mini-
mize material attrition caused by particle-on-particle impact.
Figure 5
Phase-transition elbow in dilute phase
Acceleration Conveying-phase
zone transition zone
Incoming material
Slurry
Primary
impact zone
Bernoulli step
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The phase-transition elbow is best suited for systems han-
dling friable or abrasive materials.
Advantages. Some advantages of a phase-transition
elbow are:
The elbow can be used in both dense- and dilute-phase
systems.
The primary impact zone provides soft particle-on-parti-
cle impact, reducing material attrition.
The elbow is subject to less abrasion and wear, extending
its operating life.
It installs easily in cramped quarters for a new installa-
tion, replacement, or retrofit.
Multiple elbows can be installed a short distance apart
and still provide uninterrupted material flow.
Material purges completely from the elbow at the con-
veying cycles end, preventing cross-contamination.
The elbow installs horizontally or vertically to redirect
material in any direction.
Disadvantages. The disadvantage of using a phase-transi-
tion elbow is that it contributes moderate pressure loss
(relative to the LRE).
Making your final choice
Before making a final decision about which elbow to in-
stall in your pneumatic conveying system, make a list of
the elbow features that are most important in your applica-
tion. This will allow you to compare the features of vari-
ous elbows to determine which elbow is best for your
application. Also insist that the elbow supplier provide ref-
erences to support the suppliers elbow performance
claims. Before purchasing an elbow, youll also want to
talk with people who have a system similar to yours and
Copyright, CSC Publishing, Powder and Bulk Engineering
have installed the same elbow that youre considering.
PBE
References
All elbows are available from multiple suppliers unless
theyre listed here.
1. Smart Elbow, manufactured by HammerTek, Landisville, Pa., 800-
505-9665 (www.hammertek.com).
2. Gamma Bend, manufactured by Coperion, Ramsey, N.J., 201-327-
6300 (www.coperion.com).
3. Pellbow, manufactured by Pelletron, Lancaster, Pa., 717-293-4008
(www.pelletroncorp.com).
For further reading
Find more details on elbows and pneumatic conveying
system design and operation in articles listed under Pneu-
matic conveying in Powder and Bulk Engineerings
comprehensive article index at www.powderbulk.com
and in the December 2004 issue.
Jerry Paulson is vice president of research and development
at Pelletron Corp., 499 Running Pump Road, Lancaster, PA
17601-2208; 717-293-4008, fax 717-293-4011 (jerrypaul-
son@mac.com, www.pelletroncorp.com). He has a BS in me-
chanical engineering from the University of Minnesota,
Minneapolis, and has more than 50 years experience in the
bulk solids handling industry. This article is adapted from the
authors paper Moving in circles, which includes detailed
information on pneumatic conveying system operation and
design calculations; for more information, contact the author.