30120130406020

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING
6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 6, November - December (2013) © IAEME

AND TECHNOLOGY (IJMET)

ISSN 0976 – 6340 (Print)
ISSN 0976 – 6359 (Online)
Volume 4, Issue 6, November - December (2013), pp. 186-200
© IAEME: www.iaeme.com/ijmet.asp
Journal Impact Factor (2013): 5.7731 (Calculated by GISI)
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IJMET
©IAEME

PRESSURE BALANCING OF DUCT FOR DUCT EXTRACTION SYSTEM
Anil Kumar Mishra*,

Anup Kumar**

*Engineer, TRF Limited, Jamshedpur (India)
**Dept. of Mechanical Engineering, National Institute of Technology, Durgapur, India

ABSTRACT
The paper includes dust emissions at different transfer point operations in iron ore crushing
plant that is critically examined and a design of a dust extraction system is presented for proposed
layout. The traditional methodology for design is relies on empirical relations, charts, multivariable
tables and monographs. A rational technique of design is employed for understanding of actual
mechanism of problem which is predicated on fundamentals of fluid and particle mechanics. In this
paper exhaust flow rate for hoods are critically examined for optimized results from theory of air
induction that is fairly well developed. Based on exhaust volume duct and its fittings are designed
and recommended. A parametric study is performed on flow pattern in duct network and balanced
flow is achieved by comparing two different methods of obtaining balanced flow.
Keywords: Rational Design, Exhaust Volume, Mine Dust, Dust Extraction System.
1.0 INTRODUCTION
One consequence of high degree of mechanization of recent mining techniques is production
of huge quantity of mine dust throughout the process of bringing ores from seam to surface. This
dust consists of tiny solid particles carried by air current and non- specific with respect to size, shape,
and chemical composition of the particles. In ore handling plant dust is ubiquitous and may be found
at fan, stack, conveyors and crushers. In mining dust is emitted due to (Moody. Jakhete.R, 1989)i. Breaking of ore by impact, crushing, blasting and grinding.
ii. Release of previously generated dust during handling operations such as dumping, loading
transferring.
iii. Recirculation of previously generated dust by wind or by movement of workers and
machinery.
186


Depending on factors like climate, geology, technique of mining and kind of ore the potential
exists for greatly increased dust levels in the environment of mine. Mine dust is not only detrimental
to flora and fauna but it is also harmful to buildings, structures, dams and monuments (Hilson. G).
This dust is additionally responsible for amendment in land form and loss of bulk solids. Dust
control is the science of reducing harmful dust emissions by applying sound engineering principle.
Properly deigned, maintained and operated dust control systems can reduce dust emissions
effectively [9].For an effective dust control the necessary preventive measures has to be adopted in
every process of dust generation. The controlling method of dust extraction system involves dry
collection, wet dust suppression system, combination system and electrostatic precipitators (Moody.
Jakhete.R, 1989). Dry collection involves hooding or enclosing dust producing points and exhausting
emissions to a collection device. The dry collection is used at several points and crusher discharge
i.e. screening and transfer operations. In dry significant fugitive dust emissions result during
formation of new aggregate piles and erosion from previously stock piles are controlled by wet dust
suppression and devices designed to minimize the free fall distance to which the material is subjected
thus lessening its exposure to wind. In wet suppression system, basic components are dust control
agent, proportioning equipment and a distribution system and control actuators. Distribution is
accomplished by spray nozzles. In combination control systems, the wet suppression is used to
control primary crushing stage and subsequent screens, transfer points and crusher feed. Control
devices for these emissions include telescopic chutes, stone ladders and hinged stacker conveyors.
Locating stock piles behind natural or artificial wind breaks also aids in reducing wind-blown dust
(Countess, R. J, Cowherd, C).
The most common type of dust collector used in mining industry is cyclone dust collector as
it is more efficient than the other air cleaners as it is simple in operation and relatively inexpensive in
construction [9]. In this work, a rational method of design is proposed by incorporating the important
aspects of traditional design and implementing the concepts of mechanics [9]. The initial design of
dust extraction system for iron ore crushing plant is critically examined and a new design is proposed
for better performance and reliability.
2.0 DUST EXTRACTION SYSTEM
Dust extraction systems are used to collect dust emissions at various transfer point. The
extraction system for dust is essentially a ducted system that prevents excessive employee exposure to
the dust in the working zone. It comprise of four mechanisms: -

i. Capture of contaminant by hood at transfer points
ii. Transport of contaminated air through the duct network
iii. Separation of dust in dust collector i.e. cyclone
iv. Exhaust of clean air through stack.

187


Fig. 1 Dust Extraction System
The four major components of a dust extraction system:i. Hoods
ii. Ductwork
iii. Air cleaner
iv. Fan
i) Hoods: - The hood is the point where air with captured contaminants enters the system. Its
purpose is to direct the air flow so that its direction and distribution are appropriate for the conditions
at the site of contaminant generation. Capturing hoods create a directed air current with sufficient
velocity to draw contaminants from outside the hood itself (Goodfellow.H, Smith). Enclosing hoods
surround the contaminant source as completely as possible.
ii) Ductwork: - The ductwork is a network of piping which carries the captured contaminant out of
the workspace to its final disposition. The primary goals in designing ductwork are to maintain
sufficient air velocity in the piping, and to minimize the resistance to flow created by bends,
junctions and changes in cross-sectional area. Maintenance of air velocity is important for transport
of particulate contaminants, since if the air velocity falls below a critical value, the dust will deposit
on the inner surfaces of the ducts and impede flow (Goodfellow.H, Smith). Resistance can be the
major part of the energy required to operate the system, and a poorly designed duct system may
cause so much resistance that the fan is unable to move the required volume of air.
iii) Air Cleaner: - The air cleaning device removes the captured contaminant before the exhausted air
is discharged. Collectors may range from simple centrifugal collectors much like the cyclone used to
sample Respirable dust, to elaborate filters and gas/vapor absorbers specially designed for the
188


contaminant present. All air cleaners add to the total resistance of the system; generally, the more
efficient the collector, the greater the resistance added.
iv) Fan: - The final component provides the energy to accelerate the air as it enters the hood and to
overcome friction and dynamic losses between the moving air and the surfaces of the ductwork and
cleaning device. If possible the fan is almost always placed downstream of the air cleaner, to prevent
deposition of contaminant on the fan blades, or damage due to contact with corrosive contaminants.
3.0 SYSTEM DESCRIPTION
Figure 2 illustrates the dust extraction system for a crusher house, handling iron ore at a rate
of 200 tones per hour (tph). It has following components: enclosures, hoods, duct network and
mounting systems, pressure regulating valves, multi-cyclone dust collector, fan, motor and stack.
The dust collected in the multi-cyclone hopper is fed back to the conveyor belt C3. The crusher is
single roll of capacity 200 tones per hour (tph).
The system has to operate at an altitude of 760 m having an average ambient air temperature
of 450 C. The technical specifications of conveyor belts and roll crusher are presented in Table 1.
The plant for which the system has to be designed is studied in detail to identify the points
where dust generates and the factors responsible for the same. The plant layout, process flow-sheets,
drawings and other operational details are carefully examined. The contour of fugitive dust cloud
must be identified to delimit the zone of potential dust hazard. The optimum shape and position of
the hoods depend on the dust cloud behavior. The entire working space is surveyed for installation
and sampling and monitoring instruments to find out the dust loading, particle size distribution,
shape and density and chemical characteristics of airborne dust particles.

Fig. 2 Dust Extraction System for Crusher House of Iron Ore
189


4. SYSTEM DESIGN
The conveyor and crusher specifications are given in table as follows:
Table 1. Technical Specifications of conveyor belt and crusher
Description
Design Detail
C1
C2(2 numbers)
CONVEYOR
Mean diameter of iron ore (mm)
250
250
Capacity,tph
200
100
Volumetric flow rate of iron ore, m3/s
0.04
0.02
Belt width, Bbmm
0.12
0.08
Belt speed, Vb m/s
1.00
0.30
Surcharge angle, degree
25
25
Idler trough angle, degree
35
35
Skirt board length, m
4
Leakage area at belt loading zone, Ab,
0.08
m2
Falling material stream area, As , m2
0.40
0.25
Discharge chute cross section, Acs , m2
0.36X2
0.28X2
Leakage area at conveyor head pulley,
0.40
0.30
A1 , m2
Belt inclination, degrees
15
0
Chute inclination, θc , degrees
60
Height of free fall of material on
3.4
4.1
conveyor, h ,m
Single Roll Crusher
Volumetric flow rate of iron ore, m2/s
0.04
Diameter, m
1.34
Receiving chute cross section , m2
0.56
Chute inclination, θc , degrees
60
Height of free fall, m
4.1
Impact velocity of lumps at crusher top, m/s
8.97
Capture velocity, m2/s
1.5
Chute entry loss factor, ξ , dimensionless
2.3
Coefficient of drag, cd , dimensionless
0.44

C3
80
200
0.04
0.065
1.50
25
35
3
0.08
0.15
0.20
Nil
0
60
1.25

5. HOOD DESIGN
The concept of air movement induction from the surroundings takes place when a falling
material steam enters an enclosed space. This concept is used to find the exhaust volume in material
handling and processing plants for transfer point operation taking place in an enclosed space. The
theory of air induction is well developed for estimating exhaust flow rate through hoods for a number
of enclosed material flow rates through hoods for a number of enclosed material handling transfer
point operations. The rate of induced air flow depends upon the material flow rate, height of free fall
and size of falling particles. It is also influenced by the chute cross section and the open area through
which the induced air enters the enclosure. The effect of air induction will be reduced if the open
190


area is large. A high pressure zone will be created at the enclosure bottom when the falling material
hits the base of the enclosure. As a result dust particles would escape through the leakage area
around the impact zone. Hence, for effective control of dust emission, the net air volume flowing due
to induction should also include an additional component of air volume that provides the necessary
velocity for the capture of dust particles over the leakage area in material impact zone of the
enclosure. It is generally agreed that the there is no best method for finding exhaust flow rate for
hoods. In conveyor to conveyor discharge operations the component associated with capture velocity
is much larger than the induced air component because of presence of large openings. The net air
volume for exhaust ventilation consist of two components• Air flow to capture fugitive dust
• Induced air flow from surroundings
The exhaust air entering the hoods are estimated from given standards and practicing norms
that takes into account both the induced air and captured air components. The proposed model for
ventilation floe rate for material transfer from conveyor to conveyor/crusher/screen in an enclosure is
given by the following relations:
Qc = f(Al, Vc) and Qi = f(Vi , Qbs , Acs, dp,θc )
Table 2. Exhaust flow rate through hood
Duct Diameter Velocity
Length of
(mm)
(m/sec.)
Straight Duct
(m)
1360
23
3.53

Section

Flow Rate
(m3/hr.)

P-3

120960

1-3

72997.2

1055

23

4.7

1277105.26

2-3

72997.2

1055

23

4.7

1277105.26

3-7

266954.4

2025

23

2.3

2451315.79

4-6

8685

360

23

8.7

435789.4737

5-6

75989.08

1075

23

3.2

1301315.79

6-7

84674.088

1140

23

3.2

1380000

7-10

351628.488

1160

23

2.5

1404210.526

8-10

3947.1

245

23

1.5

296578.9474

9-10

3947.1

245

23

2.2

296578.9474

10-11

359522.688

1160

23

1404210.526

11-12

359522.688

3250

12

2052631.579

12-13

359522.688

3250

12

Fan

359522.688

3250

12

Stack

359522.688

3250

12

191

2.2

Flow Reynolds No.

1646315.789

2052631.579
2052631.579

5.0

2052631.579


5.1 Critical analysis of hood design
A critical analysis of induced air and velocity assists in proper location of hoods. If Qi is
greater than Qc, the hood must be located some distance away from the point of material impact to
prevent the capture of coarse dust particles. For larger value of Qc, the hood must be located close to
the source. Hood locations for enclosed transfer point operations of materials are shown in Figure 3.
The air velocity at the face of hood for all enclosed transfer point operation must be in the range of 2
to 5 m/s. The hood dimensions will have to be selected on the basis of hood face velocity of the
ventilated air and the available space of the casing on that it has to be installed. The following points
may be noted for location and design of hood for conveyor to conveyor discharge. If Qi is greater
than Qc, the hood must be located some distance away from the point of material impact to prevent
the capture of coarse dust particles. For a larger value of Qc the hood must be located close to the
source.

Fig. 3 HOOD LOCATION

In Figure 3.2, no hood has been provided at X but the hood at Y is nearer to the point of
material impact than in Figure. The hood at Y has been designed to capture the net ventilated air due
to induction and capture velocity. A hood has been provided at X in Figure and to provide a path for
the flow of ventilated air associated with capture velocity through the skirt seal gap. Hood at Y
collects the induced air and air flow associated with the moving material load. No hood will be
required at X if the ventilated air component associated with capture velocity for the skirt seal gap is
very low. It must always be tried to have a minimum number of hoods. A good skirt seal should be
192


provided to eliminate the hood at X. Usually; no hood is required at Z. However, a hood will have to
be provided at Z, if there is a perfect sealing at the impact zone of material in the downstream. The
hood in this case must be designed to handle the ventilated air associated with induction.
Thus, it is essential to redesign and relocate the hoods.

Fig 4. Revised Design of Dust Extraction System

Fig 5. Schematic Line Diagram for Dust Extraction System

193


Table 3. Flow rate for revised duct network
Section

Flow
Rate
(m3/hr)

Duct
Diameter
(mm)

Velocity
(m/sec)

Length
of
Straight
Duct
(mm)

1-3
2-3

72997.2
72997.2

1055
1055

23
23

4
6

Elbows
Angle
Number
(Degree)

14599.4

1499

23

1

Hoods and
Connecting
Pieces

Flow
Reynolds No.

Hood at 1
Hood at 2

3
1

60
3-5
E-E

90
90

Branch
Entry

1.277x106
1.277x106

30
2.45x106

2.3
L= 575mm

F-F

L= 800mm

4-5

8920.30

365

23

8

5-7
G-G

275874.7

2055

23

2.1

6-7

75989.08

1075

23

8.5

7-8

351863.7

2325

23

90
60

1
1

30

2.7

Hood at 4

4.418x106
2.487x106

L=900mm
30

1.301x106
2.814x106

Connecting
pieces at
multi cyclone
outlet and fan
inlet

2.033x106

Fan outlet
connecting
piece
Stack

8-9

1
1

Hood at 6
Multicyclone
Inlet Piece

90
60

2.033x106

Multicyclone

9-10

351863.7

3220

12

2.2

10-11
11-12

351863.7
351863.7

3220

12

2.2

12-13

351863.7

3220

90

12

2

Fan

2.033x106

6. DUCT DESIGN
Many graphs and empirical relations for friction losses in straight ducts are available in
standard design manuals. However, most of them are used for new or clean ducts. The manufacturers
have their own proprietary standards and graphs for estimation of pressure drop but these are not
easily available for friction factor over the range of feasible operating conditions.
The turbulent or laminar nature of flow in duct is given by Reynolds number which is
expressed asRed = (ρa/µ a)Vdd = νaVdd
The air velocity in the duct must be equal to the transport velocity to move the dust particles
without settling. The norms for transport velocity in duct for coal dust are given as (Russian Norms
1996),

194


•
•
•
•
•

For horizontal ducts and ducts aligned at less than 60o Vd>18 and 20<Vd (m/s) 25.
For vertical ducts and duct with inclination greater than 60o transport velocity condition is
given by 10< Vd<18.
For duct after the dust collector Vd >10 preferably between 14 to15 m/s.
Duct diameter less than 100 mm should be avoided to prevent dust build up and duct
plugging.
The transport velocity should be preferably uniform in the entire duct network.

The fluid flow is associated with two types of pressure namely Static Pressure (Ps) and
Dynamic or Velocity Pressure (Pg). Total pressure is the algebraic sum of Static Pressure (Ps) and
Dynamic or Velocity Pressure (Pg). Fluid flow through duct encounters resistance to flow from
friction and turbulence Friction loss takes place due to the shear forces between (i) fluid particles
resulting from the viscosity of the fluid and (ii) fluid particles and the boundary walls of the pipe.
Dynamic loss occurs due to fluid turbulence from changes in flow direction or variations. It is always
exerted in the direction of fluid flow and is expressed by the following equation,

Total pressure PT is algebraic sum of static pressure and velocity pressure.

7. FRICTION LOSS IN DUCT
Pressure drop due to friction in a duct is given by well-known Darcy Weisbach equation
which is given by,

Friction loss in a duct of length ld is given by,

7.1 Dynamic pressure loss
The co-efficient of dynamic resistance is used to find the dynamic pressure loss due to
turbulence or local resistance in duct accessories and fittings.

7.2 Total pressure loss

195


8. BALANCING
There are two common approaches for computing the pressure drop in a duct network. In the
first approach pressure drop of fittings expressed in terms of dynamic pressure is computed with the
help of standard tables and graph and added to the pressure drop of straight duct and in the latter
approach equivalent length of fittings is computed and added to the length of straight duct to find the
total pressure.
•
•

Blast gate adjustment (by use of dampers, valves, diaphragms, venturis, etc)
Balanced system design (by proper design of duct diameter)

8.1 Balancing by system Design
A balanced system in any two branches at a junction may be obtained when (i) static and
dynamic pressure as well as total pressure are balanced or (ii) both the branches have the same
pressure losses (frictional and turbulence). It can easily show that the two approaches of balancing
are not different i.e. when Ps, Pg and
are balanced P is also balanced. According to the first
approach, the flow at junction 3 will be in balance when any one of the following condition is
satisfied:

Therefore,
The junction at point 7 will be in balance when the following condition is met:

The duct diameter of the section having a lower pressure drop is reduced if the pressure. The
duct diameter of the section having a lower pressure drop is reduced if the pressure. By trial and
error and repetitive calculation a diameter can be chosen for that the difference in pressure is less
than 5%. Balanced flow may be obtained by increasing the exhaust air flow rate in the section of
lower pressure drop if the pressure differences of the two branches are less than 20%.
8.2 Balancing with Dampers
In this approach no attempt is made to balance the pressure resistance. At each section branch
flow is added to the main flow path and duct is sized to maintain the required transport velocity. The
balance is achieved by using pressure regulating devices, blast gates and dampers.

196


Table 4. Balance by design

3

2-3

72997.2

1055

23

6

90

1

60

1

30

236.12

241.38

241.38

0.88

4.36

236

240.36

241.38

19.92

770.7
770.7

770.7

770.7

Friction
5.269

261.3

Entry

0.88

Remarks

90

Governing pressure
(N/mm2)

4

Total

Branch

23

Turbulence

Length of Straight Duct

1055

Local Loss Coefficient

Velocity

72997.2

Flow Rate (m3/hr.)

1-3

Section

Duct Diameter (mm)

Pressure Loss(N/mm2)

The flow is balanced at junction 3.
3-5

14599.4

1499

23

2.3

19.92

1-3-5

4-5

8920.30

365

23

8

90

1

60

30

0.462

2.87

767.83

Use
Damper
in 1-3

1

Reduce the diameter of section 1-3 & 2-3 and recheck for balance. Section 1-3, 2-3 is balanced at flow rate 72997.2 m3/hr & duct
dia is 775 mm.
The flow is balanced at junction 5.
2-3

75025.97

775
2055

42.9
8
23

5-7
4-5-7
6-7

277903.47
78018.55

6
2.1

1075

23

8.5

90

1

30

0.73

26

683

709

770

243.69

19.5
790.2
247.9

790.2
790.2
790.5

19.5
90
60

1
1

30

0.89

4.26

2-3

Reduce the diameter of section 6-7 and recheck for balance. Section 5-7 is balanced at flow rate 78018.55 m3/hr & duct dia is
1075 mm
The flow is balanced at section 6-7
7-8

357453.43

2325

0.214

4-5-7-8
8-9

357453.43

9-10
Fan

357453.43
357453.43

3220
Fan

12.5

11-1213

357453.43

3220

12

16.73

60

2.2

90

2

0.166

2.2

1.25

197

1.68

1.68

16.30

91.21

790.2

Use
Damper
in 6-7

866.6
1000

Multicyclone

76.63

1866.6

Vendor’s
data

17.98
196

1884.58
2080.58

92.89

2173.47

Fan loss
is 10% of
total loss


4-5

8920.30

365

23

8

5-7
4-5-7
6-7

275874.7

2055

23

2.1

75989.08

1075

23

8.5

7-8

351863.7

60

236.12
236

241.38
240.37

241.38
241.38

19.92
261.3

770.7
770.7

767.83

770.7

1

770.7
790.2
790.2
790.2

19.92

90
60

1
1

30

0.4622

2.87

351863.7

3220

16.73

57.45

74.18

847.65

1847.65

17.98
196

1865.63
2062.51

92.89

Use
Damper
in 1-3

2155.40

0.1668

12

Use
Damper
in 2-3

847.65

Fan

11-1213

243.69

30

351863.7
351863.7
351863.7

4.26

1000

1
1

0.89

847.65

9-10
Fan

19.5
90
60

19.5
790.2
247.95

0.214

4-5-78
8-9

Remarks

2.3

30

5.269
4.36

Governing
pressure(N/m2)

23

0.88
0.88

Total

1499

3
1

Turbulence

14599.4

90
90

Friction

3-5
1-3-5

Entry

4
6

Local Loss Coefficient

Length of Straight Duct

23
23

Pressure Loss(N/mm2)

Branch

Velocity

1055
1055

(mm)

72997.2
72997.2

Flow Rate (m3/hr)

1-3
2-3

Section

Duct Diameter

Table 5. Balance by dampers

2.2

1.25

1.68

1.68

16.30

91.21

Use
Damper
in 6-7

Vendor’s
data
Fan loss
is 10% of
total loss

9.0 CONCLUDING REMARKS
The mining industry is not generally regarded as a high technology sector. Nonetheless many
developments in advanced technology are revolutionizing mining by improving process efficiency
and capacity to achieve and sustain best practice environmental management. The traditional method
of design was not taken into consideration as the actual process and physical reality and most
empirical models lack sound theoretical basis. In many instances the traditional method of design
results in faulty system which includes additional cost and maintenance problems. This work results
saving towards maintenance and installation of dust extraction system. A number of standards are
available for pressure loss in duct fittings. Pressure loss can be obtained from complex multivariable
tables and charts. There are wide discrepancies in the results obtained from different sources. In this
work pressure loss coefficients for different fittings are presented in the form of mathematical
relations to facilitate easy computation for balanced flow design. Different approaches for balanced
flow is examined and it is found that there is no difference in the methods of balancing a duct
network.
198


Notations
Acs
Al

-

d
dp
ld
Pg
Pg1-3
PS1-3
PS
Qbs
Qi
Q1-3
Qa
Red
R1-3
RS
Rf
Rt
Vc

-

VD
Vi

-

Pf
PF
PT
P1-3
ηF
θc
µa
νa
ρa
ρp
Σ

-

cross sectional area of the chute, m2
cross sectional area through that the dust escapes into the surroundings after
the material impact on the receiving system, m2
duct diameter, m
particle mean diameter, m
total length of the duct, m
dynamic pressure, N/m2
dynamic pressure in section 1-3 of the duct and so on, N/m2
static pressure in section 1-3 of the duct and so on, N/m2
static pressure, N/m2
volumetric flow rate of the bulk solids being handled, m3/s
volumetric flow rate of air due to induction, m3 /s
volumetric flow rate of air in the section 1-3 and so on
volumetric flow rate of air, m3 /s
Reynold's number for fluid flow in duct, dimensionless
resistance to flow in the section 1-3 and so on
total resistance to the flow, N s2 m-8
frictional resistant, N s2 m-8
turbulence resistant, N s2 m-8
capture velocity required to prevent the dust from escaping though the
leakage area Al of the material impact zone, m/s
velocity of air in duct, m/s
mean velocity of the individual lump of falling stream of bulk solids at the
impact point, m/s
pressure drop due to friction per unit length, N/m2/m
total pressure drop due to friction, N/m2
total pressure loss,N/m2
pressure drop in section 1-3 of the duct and so on, N/m2
overall efficiency of fan
slope of chute, degree
dynamic viscosity of air, kg/ms
kinematic viscosity of air, m2/s
air density, kg/m3
particle density, kg/m3
local loss coefficient

REFERENCES
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