Dense phase conveying systems are ideal for materials that convey over long distances and different feeding points. It works at a low velocity, which helps to increase the service life of the system.
Also, a dense phase pneumatic conveying system ensures there is less wear and tear, which reduces breakdown.
At times, you will need to follow up for troubleshooting the dense phase system. The dense phase system has four main components - Air Compressor, Convey Lines, ASME Code Pressure Vessel, and Filter Receiver.
Let us discuss the potential issues each component would face and how you can detect the problem for solutions.
Air compressors
● The air compressor is the powerhouse of the system, which falls into two main categories - dedicated to the sole system and a part of the plant air system. Despite it being the best, it can cause problems with the compressor.
Common issues with air and water separators:
● Air compressors generate a lot of water - when there is a failure in the air dryer, the water slips down the line, which causes a mess.
● At times, the filters plugin and air volume start to fall off. When you detect this issue, you can change the filter.
● Accumulator should pump between the batch cycles, and you can check the pressure gauge to see if it's using enough air.
Filter receivers and bin vents
There is no particular design difference in the filter receiver for the dilute phase system and the dense phase system. But, it comes from being able to identify the problem.
When there is an average flow, the DPT is conveying, which means the product is conveying through the system.
When there is a zero flow, the DPT is filling, which means nothing is going in the system, and the vessel is recharging.
When there is a peak flow, the DPT is in the blowdown. The vessel can go empty and have an air surge.
Convey lines and elbows
The dense phase systems utilize a thicker wall pipe, and the couplings are grooved in different compression styles. The elbow support in pneumatic support is vital, but in the dense system, it is compulsory.
Moreover, the slugs of the product that comes down have a deal of, mass. If an elbow is not supported - you will blow the elbow off the line.
Also, like elbows, the slugs can have similar effects depending on the design of the wall.
Dense phase transmitter
There are two main types of transmitters available - top discharge style and bottom discharge style. However, it is decided by the material that is conveyed in the dense system.
The top discharge is ideal for fluidizable materials like talc. The bottom discharge style is perfect for parable materials like plastic pellets.
Most importantly, the materials used in the system depend on the product or industry. The system allows for transmitting complex routes compared to other parts.
Air management system
Airflow is managed differently, and it depends on the system you choose. Air management falls into two types - CFM constant and PSIG constant.
When the system is correctly applied and the operation is done efficiently - you will begin filling up the vessel.
As the system airflow kicks on and high-level temperature kicks, it helps to convey material down the line - rising the system pressure. when this works correctly, the material will go out of the vessel.
But the pressure will stay constant throughout the entire lifecycle.
When the convey line plugs, you will see the airflow of the system. The vessel fills up with the material, and the airflow drops off.
Checking the material
You can also look for conveying issues in your material. The material must be consistent and won't work if it has a different particle size. Also, if the fines get mixed with your uniform material size, it will cause plugging. If you have specified application issues - you can contact the manufacturing company for solutions.
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