Optimized Pressure Vessel Design for Reliable Multivessel Conveying Arrangement

At Rieco, we are continuously striving to enhance the performance of our Pneumatic Conveying Systems . Recently, we embarked on an in-depth research to optimize blow tank designs for the reliable Dense phase conveying of ash, particularly for economizer hoppers, 2nd & 3rd field of ESP (Electrostatic Precipitator).

Our goal was to ensure efficient and consistent ash feed into the pressure conveying pipeline, which requires blow tanks specifically designed for varying ash characteristics across different collection points.

The Challenge

Traditional blow tanks were designed for handling ash from ESP (Electrostatic Precipitator) first fields, which have high ash collection rates. However, when it comes to the finer ash collected in ESP second and third fields, as well as from air preheaters and economizers, standard blow tanks proved unnecessarily large and inefficient. The challenge was to optimize the blow tank size and weight to handle lower ash discharge rates effectively, while ensuring reliable dense-phase conveying with minimal air consumption.

Methodology and Development

Our multi-phase approach involved several critical steps:

Ash Characterization:We collected samples from economizers, ESP fields, and bag filters, assessing key properties like bulk density, particle size distribution, and the angle of repose. These measurements provided valuable data for tailoring the blow tank design. The following table shows the physical properties of ash samples.

S. No.	Fly ash	Particle size range (µm)
1	Fabric Filter	2 to 50
2	Field 1	4 to 90
3	Field 3	3 to 50
4	Economizer	100 to 400

CFD Simulations:Using computational fluid dynamics (CFD), we simulated multiple blow tank designs to evaluate flow characteristics. Different designs were tested to determine the optimal results and minimize wear on the tank’s internal surfaces.

Flow Visualization:Transparent conduits allowed us to visualize the flow behaviour of ash under various conditions, confirming the simulation data and helping us fine-tune the tank’s design.

Validation & Testing:Three blow tank prototypes were fabricated based on the simulation results and tested under real conditions. This hands-on testing ensured that the optimized blow tanks could handle the variations in ash properties effectively.

Outcomes and Benefits:

By optimizing the blow tank design and weight, we have developed a solution that:

Reduces Air Consumption:By facilitating efficient dense-phase conveying, the new design reduces the amount of air required for conveying, cutting energy costs.
Enhances Reliability: The optimized design ensures consistent discharge of both coarse and fine ash, preventing blockages and ensuring smooth operation.
Increases Equipment Longevity: By minimizing the wear on the internal surfaces of the blow tanks, we’ve significantly increased the lifespan of the equipment, reducing maintenance needs.

This optimization project has allowed Rieco to refine our blow tank designs to meet the demanding requirements of dense-phase pneumatic conveying systems for ash. Our new solutions not only improve efficiency and reliability but also reduce operational costs, reinforcing our commitment to delivering innovative and tailored solutions to our clients. Stay tuned for more advancements in pneumatic conveying technology from Rieco Industries! Curious to know more? Contact us at rieco@rieco.com