Pneumatic Conveying Injector with Pressure-Triggered Gas Injection
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Solution Overview
Problem
Existing dense phase pneumatic conveying systems face issues with unpredictable material flow and increased energy consumption due to erratic conveying rates and pipeline blockages, particularly in materials with low permeability and high friction, which are exacerbated by inefficient gas injection methods.
Innovation Solution
A system with injector arrangements along the pipeline that detect pressure differentials and increase the flow rate of conveying gas when a predetermined threshold is exceeded, maintaining material permeability and preventing blockages by continuously injecting gas at increased rates before material plugs form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compressed air is injected through multiple delivery points along the pipeline to maintain material flow, then material conveying reliability is improved, but gas consumption increases
Solution Approach 1:
The system applies different injection strategies at different locations along the pipeline. Injectors are equipped with pressure sensors that detect local pressure conditions, and gas injection is activated only at specific injectors where material stagnation is detected, rather than uniform injection at all points. This localized approach maintains flow stability while reducing overall gas consumption.
Solution Approach 2:
Pressure sensors are installed at each injector location to provide real-time feedback on material flow conditions. When a sensor detects pressure indicating material stagnation or blockage, it triggers gas injection at that specific location. This feedback mechanism ensures gas is injected only when and where needed, optimizing both reliability and energy efficiency.
2Reliability
If higher volumes and pressures of compressed air are injected along the pipeline to prevent blockages, then conveying reliability is improved, but energy consumption increases
Solution Approach 1:
Pressure sensors continuously monitor pipeline conditions and detect early signs of material stagnation before blockages form. Gas injection is triggered proactively at the detected location to prevent blockage development, rather than waiting for blockages to occur and then responding. This preliminary action prevents energy-wasting blockage events while maintaining reliable conveying.
Solution Approach 2:
The system dynamically adjusts gas injection parameters (volume and pressure) based on real-time pressure sensor readings. When stagnation is detected, gas injection is activated at optimized levels sufficient to clear the specific local condition, rather than applying constant high-volume high-pressure injection throughout the pipeline, thereby reducing overall energy consumption.
3Productivity
If material is conveyed at higher velocities to maintain flow, then conveying speed is improved, but pipeline wear increases
Solution Approach 1:
The system dynamically adjusts gas injection timing and volume based on real-time pressure sensor feedback rather than operating at constant high velocity. Gas is injected selectively at locations and times when material stagnation is detected, creating variable velocity profiles that maintain productivity while reducing excessive velocity-induced wear in specific pipeline sections.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach stabilizes particulate material flow, reduces overall gas consumption, and minimizes pipeline wear by maintaining permeability and preventing blockages, allowing for efficient and predictable conveying with reduced energy requirements.
Implementation Method 1
pressure transducers, and to inject compressed air via non-return valves only at specific injectors, in response to pressure conditions in the pipeline
Implementation Method 2
The pressure vessel is pressurised with compressed air, delivered for example from a compressor 11a via a control valve 13. The pressurised air in the pressure vessel 7 expands into the conveying pipeline 17 and the air flow propels particulate material 15 along the pipeline
Implementation Method 3
the pressure at the outlet (for example in the second hopper 19) is reduced, by a vacuum pump 11b
Implementation Method 4
the additional air flow increases the particulate material velocity along the pipeline
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
Disclosed is a system for conveying particulate material, in which particulate material is conveyed along a conveying pipeline (117) by a flow of a conveying gas. A plurality of injector arrangements (121) are positioned along the conveying pipeline, for injecting a continuous flow of conveying gas into the pipeline. The system includes pressure differential apparatus for detecting whether a pressure differential in the pipeline between an injector arrangement and an adjacent injector arrangement is above or below a threshold value. In use each injector arrangement is operable to increase the flow rate at which conveying gas is injected into the pipeline when a pressure differential rises above the threshold value is detected between adjacent injection locations along the pipeline. The present invention provides a continuous flow of conveying gas at each of the plurality of injector arrangements, reducing the risk of blockage. Pressure differentials along the conveying pipeline are reduced. Together this facilitates stable and predictable conveying of the particulate material and reduced conveying gas usage.