Energy-Efficient Air Control for Dense Phase Convey Systems
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Summary
Problems
Existing low pressure continuous dense phase pneumatic convey systems face inefficiencies due to critical air flow control systems, which result in excessive energy consumption and unnecessary air production, as they rely on constant supply pressure and venting of excess air, leading to increased power requirements and energy loss.
Innovation solutions
A non-critical air flow control system that adjusts the air supply pressure and control valve position dynamically based on real-time pressure readings, using pressure transducers and a controller to maintain a lower supply pressure relative to convey pressure, reducing energy consumption and minimizing air venting.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If a critical air flow control system is used with constant supply pressure and mechanical relief valve, then the air flow rate is predictable and stable, but energy consumption increases significantly due to excessive air production and venting
Why choose this principle:
The patent transitions from a static critical air flow control system with constant supply pressure to a dynamic non-critical control system where supply pressure varies with downstream pressure. The control valve dynamically adjusts to maintain a constant pressure differential (e.g., 3-5 psi) rather than maintaining constant absolute pressure, allowing the system to adapt to changing conveying conditions and minimize energy consumption while maintaining reliable air flow control.
Principle concept:
If a critical air flow control system is used with constant supply pressure and mechanical relief valve, then the air flow rate is predictable and stable, but energy consumption increases significantly due to excessive air production and venting
Why choose this principle:
The invention changes the fundamental operating parameters from critical air flow regime (where downstream pressure has no effect on flow rate) to non-critical air flow regime. By maintaining a constant pressure differential across the control valve rather than constant absolute supply pressure, the system operates in a regime where air flow rate is directly controllable by valve position, eliminating the need for excessive pressure generation and venting.
Application Domain
Data Source
AI summary:
A non-critical air flow control system that adjusts the air supply pressure and control valve position dynamically based on real-time pressure readings, using pressure transducers and a controller to maintain a lower supply pressure relative to convey pressure, reducing energy consumption and minimizing air venting.
Abstract
An air control system for a low pressure continuous dense phase convey system employs a non-critical air flow control system that allows for a supply pressure to be only incrementally larger than a convey pressure. The convey system has an inlet for introduction of pressurized air into the system and an airlock associated with a feedpoint for introduction of particulate into the system. A first pressure sensor is positioned immediately downstream of an air source to measure the supply pressure, and a second pressure transducer is positioned proximate an airlock to measure the convey pressure. The non-critical air flow control system is dependent on the supply and convey pressures and a position of a control valve, such as a sonic nozzle. The difference between the convey pressure and the supply pressure is less than 10% of the supply pressure.