Development of a model to predict the life of pneumatic conveyor bends subject to erosive wear

The erosion processes resulting from flow of fluids (gas-solid or liquid-solid) are encountered in nature and many industrial processes. The common feature of these erosion processes is the interaction of the fluid (particle) with its boundary thus resulting in the loss of material from the surface. This type of erosion in detrimental to the equipment used in pneumatic conveying systems. The puncture of pneumatic conveyor bends in industry causes several problems. Some of which are: (1) Escape of the conveyed product causing health and dust hazard; (2) Repairing and cleaning up after punctures necessitates shutting down conveyors, which will affect the operation of the plant, thus reducing profitability. The most common occurrence of process failure in pneumatic conveying systems is when pipe sections at the bends wear away and puncture. The reason for this is particles of varying speed, shape, size and material properties strike the bend wall with greater intensity than in straight sections of the pipe. Currently available models for predicting the lifetime of bends are inaccurate (over predict by 80%. The provision of an accurate predictive method would lead to improvements in the structure of the planned maintenance programmes of processes, thus reducing unplanned shutdowns and ultimately the downtime costs associated with these unplanned shutdowns. This is the main motivation behind the current research. The paper reports on two aspects of the first phases of the study-undertaken for the current project. These are (1) Development and implementation; and (2) Testing of the modelling environment. The model framework encompasses Computational Fluid Dynamics (CFD) related engineering tools, based on Eulerian (gas) and Lagrangian (particle) approaches to represent the two distinct conveyed phases, to predict the lifetime of conveyor bends. The method attempts to account for the effect of erosion on the pipe wall via particle impacts, taking into account the angle of attack, impact velocity, shape/size and material properties of the wall and conveyed material, within a CFD framework. Only a handful of researchers use CFD as the basis of predicting the particle motion, see for example [1-4] . It is hoped that this would lead to more realistic predictions of the wear profile. Results, for two, three-dimensional test cases using the commercially available CFD PHOENICS are presented. These are reported in relation to the impact intensity and sensitivity to the inlet particle distributions.

Effect of particle characteristics on the two-body abrasive wear behaviour of a pearlitic steel

The specific wear rate and friction coefficient of a pearlitic microstructure subjected to different abrasive environments (i.e. SiC and alumina) were examined. A CSM high temperature pin-on-disc tribometer was used to simulate the two-body abrasive condition (i.e. the metallic surface abrading against the abrasive particles). The characteristics of the abrasive particles (i.e. particle size and density) revealed a significant impact on the amount of material loss. The specific wear rate of the pearlitic microstructure decreased with a reduction in the abrasive particle size, irrespective of the particle type. In addition, distinct particle deterioration mechanisms were observed during the abrasion process, which was largely determined by the abrasive particle size. Attrition, shelling and fracture were some of the dominant particle deterioration mechanisms occurring in both of the abrasive environments. SEM and EDX analysis on the wear debris displayed a unique metallic chip formation with respect to the particle type. Furthermore, the abrading efficiency (i.e. threshold level) of the abrasive particles was identified by means of interrupted abrasive wear tests. The dense packing nature of the alumina abrasive particles resulted in a significantly higher material removal rate than the SiC abrasive environment.

Comparisons of the two-body abrasive wear behaviour of four different ferrous microstructures with similar hardness levels

The abrasive wear resistance of four distinct metallurgical steel microstructures - bainite, pearlite, martensite and tempered martensite, with similar hardness levels was investigated. A pin-on-disc tribometer was used to simulate the two-body abrasive condition (i.e. the metallic surface abrading against the silicon carbide abrasive particles) and evaluate the specific wear rate of the microstructures. Each microstructure had a unique response towards the abrasion behaviour and this was largely evident in the friction curve. However, the multi-phase microstructures (i.e. bainite and pearlite) demonstrated better abrasion resistance than the single-phase microstructures (i.e. martensite and tempered martensite). Abrasion induced microstructural changes at the deformed surfaces were studied using sub-surface and topographical techniques. The properties of these layers (i.e. surface profile measurements) determined the amount of material loss for each microstructure. These were directly linked to the single-wear track analysis that highlighted a marked difference in their mode of material removal. Ploughing and wedge formation modes were dominant in the case of bainite and pearlite microstructures, whereas the cutting mode could be attributed to the higher material loss in the single-phase microstructures. The combination of brittle and ductile phases in the multi-phase microstructure matrix could be one of the driving factors for their superior abrasion resistance.

Diesel bus emissions of submicrometer particles measured in a tunnel study

The emission factors of a bus fleet consisting of approximately three hundreds diesel powered buses were measured in a tunnel study under well controlled conditions during a two-day monitoring campaign in Brisbane. The number concentration of particles in the size range 0.017-0.7 m was monitored simultaneously by two Scanning Mobility Particle Sizers located at the tunnel’s entrance and exit. The mean value of the number emission factors was found to be (2.44±1.41)×1014 particles km-1. The results are in good agreement with the emission factors determined from steady-state dynamometer testing of 12 buses from the same Brisbane City bus fleet, thus indicating that when carefully designed, both approaches, the dynamometer and on-road studies, can provide comparable results, applicable for the assessment of the effect of traffic emissions on airborne particle pollution.

Indoor exposure to submicrometer particles and PM2.5 in residential houses in Brisbane, Australia

As part of a large study investigating indoor air in residential houses in Brisbane, Australia, the purpose of this work was to quantify indoor exposure to submicrometer particles and PM2.5 for the inhabitants of 14 houses. Particle concentrations were measured simultaneously for more than 48 hours in the kitchens of all the houses by using a condensation particle counter (CPC) and a photometer (DustTrak). The occupants of the houses were asked to fill in a diary, noting the time and duration of any activity occurring throughout the house during measurement, as well as their presence or absence from home. From the time series concentration data and the information about indoor activities, exposure to the inhabitants of the houses was calculated for the entire time they spent at home as well as during indoor activities resulting in particle generation. The results show that the highest median concentration level occurred during cooking periods for both particle number concentration (47.5´103 particles cm-3) and PM2.5 concentration (13.4 mg m-3). The highest residential exposure period was the sleeping period for both particle number exposure (31%) and PM2.5 exposure (45.6%). The percentage of the average residential particle exposure level in total 24h particle exposure level was approximating 70% for both particle number and PM2.5 exposure.

Relationship between indoor/outdoor concentrations of particles : a critical review

The relationship between indoor and outdoor concentration levels of particles in the absence and in the presence of indoor sources has been attracting an increasing level of attention. Understanding of the relationship and the mechanisms driving it, as well as the ability to quantify it, are of importance for assessment of source contribution, assessment of human exposure and for control and management of particles. It became particularly important to address this topic when evidence came from epidemiological studies on the close association between outdoor concentration levels of particles and health effects, yet with many studies showing that indoor concentrations could be significantly higher than those outdoors. This paper presents a summary of an extensive literature review on this topic conducted with an aim to identify general trends in relation to the I/O relationship emerging from studies conducted worldwide. The review considered separately a larger body of papers published on PM10, PM2.5, as well as the smaller database on particle number and number or volume size distribution. A specific focus of this paper is on naturally ventilated houses. The conclusion from the review is that despite the multiplicity of factors that play role in affecting the relationship, there are clear trends emerging in relation to the I/O relationship for particle mass concentration, enabling more general predictions to be made about the relationship. However, more research is still needed on particle number concentration and size distribution.