What is pneumatic conveying?
Pneumatic conveying is a method of transporting granular materials along a closed pipeline using the energy of air flow, representing a specific application of fluidization technology. Pneumatic conveying devices are simple in structure, easy to operate, and can be used for horizontal, vertical, or inclined conveying. During conveying, materials can also be subjected to physical operations such as heating, cooling, drying, or air classification, as well as some chemical operations. In dry mortar production lines, pneumatic conveying is primarily used for the following purposes:
Raw material conveying: Pneumatic conveying can transport raw materials such as cement, sand, and fly ash from storage bins to batching machines. It offers advantages such as long-distance conveying, high capacity, and minimal environmental impact, effectively improving raw material utilization and production efficiency.
Additive conveying: Pneumatic conveying can transport additives, pigments, and other materials from storage bins to batching machines. It ensures uniform mixing of additives, thereby enhancing product quality.
Material blending: Mixing two or more materials uniformly.
Material classification: Classifying materials based on particle size.
Finished product conveying: Pneumatic conveying can transport finished mortar from mixers to packaging machines, reducing manual handling and improving packaging efficiency.
Waste material conveying: Transporting waste materials from processing equipment to disposal equipment.
Components of a pneumatic conveying system:
A pneumatic conveying system mainly consists of the following components:
Compressed air system: Generates conveying airflow.
Conveying pipeline system: Transports materials.
Pipeline valve system: Controls airflow and material flow direction.
Silo system: Stores materials.
Application of pneumatic conveying in dry mortar production lines:
In dry mortar production lines, pneumatic conveying can rapidly and evenly transport mortar within pipelines, significantly shortening construction cycles and increasing production efficiency. Additionally, positive-pressure pneumatic conveying systems in dry mortar production lines enable precise metering, avoiding waste and losses caused by human error.
Furthermore, the metering system, in conjunction with screw conveyors, introduces raw materials from storage bins into metering hoppers and meters materials based on sensor feedback data. Metered materials are then fed into bucket elevators by screw conveyors, lifted to the upper part of the mixing machine for mixing. The waiting mixing bin is a pneumatic gate type, which can quickly feed materials into the gravity mixer, enabling continuous production of dry mortar.
Advantages of pneumatic conveying in dry mortar production lines:
The application of pneumatic conveying in dry mortar production lines offers the following advantages:
High conveying efficiency: Pneumatic conveying enables long-distance, large-batch transportation, enhancing production efficiency.
Easy operation: Pneumatic conveying systems are simple in structure, easy to operate, and easy to maintain.
Cost savings: Pneumatic conveying reduces labor costs and production costs.
Environmentally friendly: Pneumatic conveying reduces dust pollution.
Disadvantages of pneumatic conveying systems:
While pneumatic conveying is widely used in dry mortar production lines to improve production efficiency and reduce production costs, it also has some disadvantages:
High equipment investment costs: Pneumatic conveying systems require equipment such as compressed air systems, conveying pipeline systems, pipeline valve systems, and silo systems, resulting in high equipment investment costs.
Dust pollution: Some materials may generate a small amount of dust pollution during pneumatic conveying, requiring stricter dust control measures. Dust collection equipment can be added to pollution points to effectively collect and dispose of dust.
Material separation: Some materials are prone to separation during pneumatic conveying, resulting in uneven mortar.
Solutions to overcome the disadvantages of pneumatic conveying:
To mitigate the disadvantages of pneumatic conveying, the following solutions can be implemented:
Reduce pneumatic conveying investment costs.
Adopt advanced pneumatic conveying design technology to improve equipment efficiency and performance, thereby reducing equipment investment costs. For example, using new compressed air systems can improve air utilization and reduce compressed air consumption.
Use suitable equipment based on specific conveying requirements to reduce equipment investment costs. For example, low-pressure pneumatic conveying systems will reduce equipment investment costs.
Adopt energy-saving technologies to reduce operating costs and overall equipment investment costs. For example, using frequency control technology can adjust the flow rate and pressure of compressed air according to actual needs, thereby reducing compressed air consumption.
Reduce dust pollution.
Adopt dense-phase conveying to reduce friction between materials and pipeline walls, thereby reducing dust generation.
Use dust suppression devices to effectively collect and dispose of dust, reducing dust pollution. For example, cyclone separators and bag filters can collect and process dust.
Strengthen management: Enhancing employee safety awareness and dust prevention measures can reduce dust pollution.
Reduce material separation.
Choose suitable conveying methods based on material characteristics to reduce material separation. For example, for materials prone to separation, continuous conveying can be used to reduce the residence time of materials in pipelines.
Optimize conveying processes to reduce vibration and collision of materials during conveying, thereby reducing material separation. For example, buffer devices can reduce pressure fluctuations in conveying pipelines.
In conclusion, the application of pneumatic conveying in dry mortar production lines is an effective means to improve production efficiency and reduce production costs. However, like any equipment or method, pneumatic conveying also has its drawbacks. By understanding its advantages, disadvantages, and solutions to overcome shortcomings, you can make informed decisions regarding its implementation in dry mortar production lines.
