Clyde Bergemann Presentation MD PUMP

Lean or Dense Phase?
Selecting the
most suitable pneumatic conveying
system for handling Fly Ash”
© CBW Clyde Bergemann Wesel 10.2007 - Rev. 5
Pneumatic Conveying Basic Principles
Conveying System Components
Material
Air Feeder Air & Product Separator Air
Types of Conveying System

Material
 Continuous
 Batch
Principles of Pneumatic Conveying 2

© Clyde Bergemann Materials Handling , Doncaster - All rights reserved
Positive Pressure Conveying System
Product
Blower /
Air Feeder Air & Product Separator Air
Compressor
Product

Vacuum Conveying System
Product
Air Feeder Air & Product Separator Exhauster Air
Product

Modes of Conveying
Lean Phase / Dilute Phase
▪ Fully Suspended Flow

▪ Entrains the material in a high velocity air flow
▪ Can either be positive pressure or vacuum
▪ Pipe diameters must be large to achieve reasonable transfer rates
▪ Component and pipe wear is high because of the high transfer velocities
▪ Lower capital costs
▪ Energy consumption can be high

Modes of Conveying
Dense Phase
▪ Material is transferred through the pipe in discrete plugs with pockets

of compressed air in between
▪ Mostly positive pressure systems
▪ Velocity is much lower resulting in lower air demand & reduced pipe
wear
▪ Pipes are much smaller than lean-phase
▪ Higher capital costs
▪ Energy consumption is low and usually directly proportional to the
actual transfer rate

Modes of Conveying

Ash Transfer System
▪ Multiple options available depending on transfer

capacity and conveying distance
▪ Wide range of vessels utilising the same key
components
▪ Systems are bespoke designs targeted at customers
specific requirements
▪ Robust design capable of conveying a wide range of
particle distribution and composition
▪ Conveying aids available for problematic materials
Before we can select the right

technology we need to take into
account
Capability Presentation the
~ Tractebel ~ Feb 2017 Fly Ash properties.
8
Flyash properties
▪ Fuel Type ( Solid, Liquid, Gas)

▪ Boiler Type (PFB, CFB)
▪ Bulk Density
▪ Particle Size Distribution
▪ Moisture Content
▪ Flow Characteristics
▪ Chemical Composition
Name of presentation 9
Flyash properties Particle Size Distribution
Fine Flyash d50 = 30 – 50 mic

Course
d50 = 70 – 90 mic
Flyash
Fine Grit d50 = 130 – 160 mic
Coarse Grit d50 = 580 – 620 mic
Geldart Classification
Dense-Phase Pneumatic Conveying 11

Flyash properties Particle Shape
Fine Fly Ash Sand
Coarse Fly Ash Grit Fly Ash

Selection Criteria
Selection criteria should include:
▪ Material Properties
▪ Pipe wear
▪ Energy consumption at all operating conditions
▪ Lifetime operating costs over at least 10 years
▪ Capital Cost

Dense Phase Options
Used for short to medium distance conveying on multi collection

hopper applications
CLYDE Bergemann
Ash Vessel
Incorporates the World renowned

Clyde Bergemann Dome Valve

Clyde Bergemann Ash Vessel
▪ Cast Vessel
▪ Low Cost
▪ Capable of conveying most Fly Ash & Grits
▪ Max conveying distance <500m
▪ Conveying rate <= 25tph at 200m.

Used for long distance conveying on multi collection hopper
applications
CLYDE Bergemann
MD-Pump
Incorporates the World renowned Dome Valve

Clyde Bergemann MD-Pump
▪ Fabricated Vessel
▪ Capable of conveying Fine Fly Ash
▪ Max conveying distance <1000m

Used for long distance high capacity conveying applications
CLYDE Bergemann
D-Pump
Incorporates the World renowned Clyde Bergemann

Dome Valve

Clyde Bergemann Double D-Pump – Operating
Cycle
Start conveying
Stop conveying
Balance Vent valve

valve open open
Vessel 1
conveying Vessel 2
filling
Continuous
air supply

Clyde Bergemann D-Pump – Intelligent Dome
Valve
▪ Discharge Dome Valve fitted with valve positioner

▪ Partially open position controlled and modulated by logic controls based on attaining pipeline
pressure set-point
▪ Pressure too high
Valve ~ valve partially closes
Positioner ▪ Pressure too low
PLC Logic ▪ ~ valve partially opens
▪ If blockage forms (causing
Control pressure to continue to rise)
Panel ▪ ~ valve fully closes
Pressure set-point
Pressure
Time
Used for single and multi outlet fly ash handling and intermediate
transfer systems
CLYDE Bergemann
PD-Pump
Dome Valve

Clyde Bergemann PD-Pump
PD-Pump for high efficiency, single or multi outlet fly ash handling
▪ For conveying dry, fluidisable materials
▪ High transfer rates over medium to long

distances
▪ High material : air ratio low air and power

consumption
High Volume Batch Transfer System

Used to Transport Fine Ash from the Intermediate Silo to the Ash
Storage Facility
CLYDE Bergemann
TD-Pump

Dome Valve

Lean Phase Positive Pressure system
Eductors
Benefits Material
▪ Cheap and Cheerful.

▪
Compressed Air
No fancy controls required.

▪ Low headroom requirement.
Drawbacks
▪ No Cooling Water Requirement
▪ High conveying velocity, 15-30m/s.
▪ No Density Stablisers or Boosters
▪ High wear of pipes & bends.
▪ Low capital cost.
▪ Large bore pipes / large volume of low
pressure transport air.
▪ Each Pickup point requires dedicated
conveying line
▪ Close coupled dedicated blower.
▪ Very limited conveying distance.
Eductors
APH Grit Handling System

Air Lock Vessels
▪ Low Pressure System Usually run from a 1

barg Roots Blower
▪ Non Coded vessels (cannot be used in EU)
▪ Can convey up to 500m @ 70-100 tph.
▪ Uses Hardened Cast chrome alloy pipes and
bends with compression coupling.
▪ Capable of handling wide range of ash. (One
system can handle ECO, APH & Flyash).
▪ No Cooling Water Requirement
▪ No Density Stablisers
▪ Lower capital cost.
▪ Very mature technology.
▪ Very Common in US & Asia
▪ Preferred choice of Korean EPC’s
▪ Much Cheaper than Dense Phase systems.
Lean Phase Vacuum system
Combination
Collector/Filter
An airlock is needed to transfer

material from the vacuum system
into the silo.
Airlock
SILO
SILO
BAGHOUSE
Vacuum
Blower
32
Disc Swings Open

(out of the ash flow stream)
Type “HC” Material Handling Valve

Swing Disc Closed
33
This valve works on the same,

“vacuum high” and “vacuum low”
principle as the swing valve but, it
is specially designed for fine
fluidisable materials.
TYPE “E” Valve
"Hg "Hg
0" 18" 0" 18"
34
Typical Advantages:
▪ Economical for one destination with many pick-up points.

▪ Vacuum systems leak inward (clean).
▪ Low headroom requirements at pick-up points.
▪ Capable of handling wide range of ash. (One system can
handle ECO, APH & Flyash).
▪ Single pneumatic valve under each hopper.
▪ One I/O per valve
Typical Disadvantages:
▪ limited to 200m distance max.

▪ Costly for multiple destination requirements.
▪ Vacuum is limited (~ 22”Hg/ 745 mbar), unlike pressure
systems.
▪ Collector filter media limits ash temperatures to ~ 200 C .
35
Conclusions
▪ Dense Phase conveying has edge on high conveying rates and long
distances.
▪ Capital cost is higher
▪ Maintenance cost is lower
▪ Running cost is lower
▪ Lean Phase conveying can handle most of the modern fly ash
handling applications
▪ Capital cost is lower
▪ Maintenance cost is higher
▪ Power industry is price driven.

▪ Lean Phase conveying always has advantage on cost.
www.cbpg.com
Thank You for Listening
Dense-Phase Pneumatic Conveying 37


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Lean or Dense Phase?

Conveying System Components

Air Feeder Air & Product Separator Air

Types of Conveying System

Principles of Pneumatic Conveying 2

Positive Pressure Conveying System

Principles of Pneumatic Conveying 3

Vacuum Conveying System

Air Feeder Air & Product Separator Exhauster Air

Principles of Pneumatic Conveying 4

Lean Phase / Dilute Phase

▪ Fully Suspended Flow

Principles of Pneumatic Conveying 5

▪ Material is transferred through the pipe in discrete plugs with pockets

Principles of Pneumatic Conveying 6

Principles of Pneumatic Conveying 7

▪ Multiple options available depending on transfer

Before we can select the right

▪ Fuel Type ( Solid, Liquid, Gas)

Fine Flyash d50 = 30 – 50 mic

Coarse Grit d50 = 580 – 620 mic

Dense-Phase Pneumatic Conveying 11

Fine Fly Ash Sand

Coarse Fly Ash Grit Fly Ash

Selection criteria should include:

Principles of Pneumatic Conveying 13

Used for short to medium distance conveying on multi collection

Incorporates the World renowned

Principles of Pneumatic Conveying 14

Principles of Pneumatic Conveying 15

Incorporates the World renowned Dome Valve

Principles of Pneumatic Conveying 17

Principles of Pneumatic Conveying 18

Incorporates the World renowned Clyde Bergemann

Principles of Pneumatic Conveying 20

Balance Vent valve

Principles of Pneumatic Conveying 21

▪ Discharge Dome Valve fitted with valve positioner

Principles of Pneumatic Conveying 24

▪ For conveying dry, fluidisable materials

▪ High transfer rates over medium to long

▪ High material : air ratio low air and power

High Volume Batch Transfer System

Incorporates the World renowned Clyde Bergemann

Principles of Pneumatic Conveying 27

▪ Cheap and Cheerful.

No fancy controls required.

APH Grit Handling System

▪ Low Pressure System Usually run from a 1

An airlock is needed to transfer

Disc Swings Open

Type “HC” Material Handling Valve

This valve works on the same,

TYPE “E” Valve

▪ Economical for one destination with many pick-up points.

▪ limited to 200m distance max.

▪ Power industry is price driven.

Thank You for Listening

Dense-Phase Pneumatic Conveying 37

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