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Conveying Technologies

Pelletron’s Solution for Gentle Material Handling – pellcon3®: The New Conveying Process

Overview of Conveying Technologies

Pelletron offers various types of pneumatic conveying systems for powders and other granular applications. Selection of the suitable pneumatic conveying transfer system for dry bulk solid materials (pellets, granules, chips, regrind and powders) is important for the function and the economical, reliable operation of an entire plant. Complex and unreliable systems lead to high maintenance costs and plant shut downs.

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Material properties vary in size, shape, surface, weight and other factors, all of which have a significant influence on the sizing and selection of a conveying system. The length of the system and the number of elbows are also very important design factors in the sizing process. In many cases, a conveying test in a pneumatic conveying test lab is necessary to determine the parameters for the correct system calculation. For this reason, Pelletron maintains its own test lab to perform a wide range of pneumatic conveying tests for its customers. The test lab is also the platform for the development of new conveying technologies.

Traditionally, dilute phase was the technology of choice for conveying. Today, other options are available from slow motion, dense phase and STRANDPHASE® conveying to special by-pass systems for sticky powders. The major characteristics of dilute, dense and STRANDPHASE® conveying are described as follows:

Dilute phase conveying

Product completely dispersed in gas flow

High gas velocities: v=25-40 m/s (5000-8000 ft/min)
Low product-to-air ratio:  range 1-5 to 1 
Low to medium pressure drop: p=0.1-1.0 bar (1.5-15 psig) 

Strandphase® Conveying

Product partially dispersed in gas flow, partially moving at higher concentration at bottom of horizontal runs.

Optimized gas velocity: v=15-25 m/s (3000-5000 ft/min) 
Medium product-to-air ratio: range 5-20 to 1 
Medium to high pressure drop: p=0.5–2.0 bar (7–30 psig) 

Slow motion or dense phase conveying

Product moves in plugs or dunes throughout the pipe.

Low gas velocities: v=2-10 m/s (400-2000 ft/min) 
High product-to-air ratio:  range 15-50 to 1 
High pressure drop:  p=0.5-3.5 bar (7-50 psig) 

The pellcon3® process

DeDuster® installation solutions
DeDuster® installation solutions

Any pneumatic conveying system creates friction and fines. In addition to optimized STRANDPHASE® conveying, Pelletron uses Pellbow® pipe bends to further reduce the creation of fines and the DeDuster® to remove remaining fines. Pelletron calls the combination of all three pellcon3®.

Download: The New Thinking in Pneumatic Conveying »

This pellcon3® process does not require special pipe supports or high pressure compressors. It is very economical, and most importantly, it does not create the fine micro dust that is characteristic of dense phase systems or the long streamers that are characteristic of dilute phase systems.

New, high-capacity plants can be designed to utilize this modern technology. Existing dense phase and dilute phase systems can be upgraded to take advantage of the benefits of the pellcon3® technology. This new pellcon3® process fulfills the customer requirements for highest quality end products with dust levels well below 50 ppm and no streamers.

Conveying Phase Diagram
Conveying Phase Diagram