Energy Efficiency Improvement Methods for Pneumatic Conveying

1. Equipment Selection and Matching Optimization

Select air source equipment precisely based on material properties (particle size, humidity, flowability). For highly abrasive materials, dense-phase conveying technology reduces airflow velocity (5–15 m/s) to increase the material-to-air ratio, minimizing pipeline wear and energy consumption. For instance, a chemical enterprise adopted high-temperature ceramic composite pipes, extending system lifespan by 40% and reducing annual maintenance costs by 33%.

2. Intelligent Control System Upgrades

Deploy integrated PLC and SCADA systems to monitor pressure, flow rate, and temperature in real time, enabling dynamic air supply adjustment via PID control. A lithium battery materials manufacturer implemented this technology, achieving a 28.7% reduction in energy consumption and significantly enhanced equipment stability. Intelligent turbulence valves automatically supplement air based on pressure feedback, eliminating pipeline blockage risks.

3. Pipeline Layout and Resistance Control

Optimize pipeline routing using CFD simulations to reduce bends and adopt large-radius curves, lowering local resistance. A cement plant renovation project shortened conveying distance by 15% through 3D layout modeling, resulting in an 18% energy reduction. Regular pipeline cleaning is also essential to prevent increased frictional resistance from material buildup.

4. Residual Pressure Energy Recovery and Variable Frequency Drives

Install residual pressure recovery devices at conveying terminals to convert excess gas pressure into electrical energy. A thermal power plant’s fly ash conveying system achieved annual electricity savings of 100,000 kWh through this method. Additionally, variable frequency fans adjust rotational speed based on real-time demand, avoiding inefficient "overcapacity" operation. A food processing enterprise reported a 22% improvement in energy efficiency after retrofitting.

Pneumatic conveying equipments