Software Estimates Bulk Solid Behaviour

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, on 20. Jan. 2012 - 12:07

Free Software calculates/estimates bulk solid behaviour

When I worked at the BASF in Ludwigshafen/Germany, it took me years to find proper theoretical solutions discribing the various phenomena when dealing with bulk materials. A high amount of published experimental results were combined using standardised, interlocking physical basics. In the end algorithms were developed discribing mass flows from silos, heat transfer and chemical reactions in fluidized beds as well as size and power requirements of pneumatic conveying systems etc.

The Files of the free software, written in VISUAL BASIC and offering a direct way of practicing the main results, are available under the following link:

https://skydrive.live.com/redir.aspx...s60rZ0M*8fA%24

The language is German. Nonetheless using the program should be easy. It runs even under Windows 7.

The theoretical backgrund is published in Germany as an ebook:

http://www.epubli.de/shop/autor/Manfred-Heyde/3168

Best regards

ManfredH

Postscript 1

I am interested to learn how the german "Umlaute" effect the program's displays on "english" Windows platforms.

Postscript 2

I do not know if in this case a disclaimer is really necessary, but here is a common one in English and German.

Conditions for program use, disclaimer:

The use of the program is at your own risk, meaning that users carry the entire risk on the results and the function of the product. The author does not guarantee the accuracy of the calculated values. In addition, there is no liability on you or any other person or entity for any direct, indirect or consequential damage, including, but not limited to, loss of revenue or profit, lost or corrupted files, claims of third parties, or for other commercial or economic loss, even if the author had been informed of the possibility of such damage or if it was foreseeable. This also applies to damage caused by this program to properties or persons, poor planning, incorrect interpretations or malfunctions. Furthermore the author is not liable for damage to the computer that runs the program and to other hardware on your computer or network related.

This program is freeware, i.e., you may freely use, copy, and pass it, if you agree with the conditions above. However, users should be careful by downloading the software only from the link given here in bulk-online and in my publication.

Bedingungen zur Programmnutzung, Haftungsausschluss:

Die Nutzung des Programms erfolgt auf eigene Gefahr. Die Benutzer tragen das vollständige Risiko bezüglich der Ergebnisse und der Funktion des Produktes. Der Autor übernimmt keinerlei Garantie für die Richtigkeit der berechneten Werte. Außerdem wird keine Haftung gegenüber Ihnen oder irgendwelcher andererer Personen oder Organisationen für irgendwelche direkten, mittelbaren oder unmittelbaren Schäden, einschließlich, aber nicht begrenzt auf, Verlust von Einnahmen oder Gewinn, verlorene oder beschädigte Daten oder anderen kommerziellen oder ökonomischen Verlust, auch wenn der Autor von der Möglichkeit eines solchen Schadens informiert worden war oder sie absehbar war, oder für Ansprüche Dritter. Das gilt auch für durch dieses Programm verursachte Schäden an Sachen oder Personen, Fehlplanungen, falsche Auslegungen oder Betriebsstörungen. Desweiteren haftet der Autor nicht für Schäden am Computer, auf dem das Programm läuft, an anderer Hardware am Computer oder am damit verbundenen Netzwerk.

Dieses Programm ist Freeware, d.h., Sie dürfen es beliebig benutzen, kopieren und weitergeben, sofern Sie den obenbestehenden Bedingungen zustimmen. Benutzer sollten jedoch zu ihrer Sicherheit darauf achten, dass sie für das Herunterladen nur den von mir auf den Seiten von bulk-online und in der Buchveröffentlichung angegebenen link benutzen.

Postscript 3

The software download now contains a translation of the various terms.

Postscript 4

Regarding to my state diagram for the pneumatic conveying, I refer here to the express of thanks to the users Mantoo and Teus in the thread "Dense Phase Pneumatic Conveying of MgCl2":

Because of your explanation I am now in the position to interpret my own state diagram and its limits better. So, the measured values apply in the dense phase region only to fine materials with particle diameters up to about 300 microns, possibly up to 700 microns. The maximum mass flow rate in these installations is 19,5 t/h. In contrast lie the operating data from systems with higher mass flow rates (35 t/h and 50 t/h) in the dilute phase area near the instable transition area. Bulk solids with particle diameters in the millimeter range lie always in the dilute phase area.

Details like these as well as many more additional information like a list of published data sets of pneumatic conveying installations are content of my publication.

Postscript 5

After my remarks on my state diagram for pneumatic conveying and its interpretation I verified the published field data of the following conveying installation for plastic granules: conveying rate 1 t/h, particle diameter 2 mm, equivalent pipe length 50 m, bore 65 mm. My software calculates for the state of minimum pressure drop in the dilute phase a gasflow of 245 kg/h (average gas velocity 17.6 m/s) at a pressure loss of 0,14 bar. This corresponds almost perfectly to the published data set.

Postscript 6

Some "hidden" ways offer possibilities to get additional physical information. In the section "Einzelpartikel" (single particle) under the point "Relativgeschwindigkeit" for example, the sinking velocity of a particle is calculated by clicking the help button. Apart from the gas data this requires only the diameter and the density of the particle.

Postscript 7

Calculation of the parameters for dense phase conveying slightly changed. 03.23.2012

Postscript 8

A list of published data from industrial conveying installations will support the design of pneumatic conveying:

https://forum.bulk-online.com/showth...-Installations

Postscript 9 (April 3rd 2012)

On the basis of some more data of industrial bulk solid conveying installations, I have modified the calculation of the suggested values for the dense phase in the pneumatic conveying section of my software, so that now the coordinates of the borderline are available. An explanation of the state diagram and its use will follow soon in my thread "Software Estimates Bulk Solid Behaviour": https://forum.bulk-online.com/showth...olid-Behaviour ■

Conveying

Transport

Pneumatic Conveying

Dense Phase Conveying

Conveying Modes

Dilute Phase Conveying

Replies

Posted on 20. Jan. 2012 - 02:40

ManfredH

I am very intersted in reviewing your software but it will not run in Windows 7 - I get an error message saying that it is not compatible when I run the Install.exe file. I have another PC running Windows XP so I will try it on that one. ■

Gary Blenkhorn
President - Bulk Handlng Technology Inc.
Email: garyblenkhorn@gmail.com
Linkedin Profile: http://www.linkedin.com/in/gary-blenkhorn-6286954b
Offering Conveyor Design Services, Conveyor Transfer Design Services and SolidWorks Design Services for equipment layouts.

Posted on 20. Jan. 2012 - 02:51

Originally Posted by Gary Blenkhorn

Hi, Gary!

Try the exe-file directly without installation.

Regards ■

Posted on 20. Jan. 2012 - 02:54

Originally Posted by ManfredH

Hi, Gary!

Try the exe-file directly without installation.

Regards

I tried Fluid.exe and got the same error. I run a 64 bit version of Windows 7 and it must not be compatible with the 64 bit version. ■

Posted on 20. Jan. 2012 - 03:01

Originally Posted by Gary Blenkhorn

I tried Fluid.exe and got the same error. I run a 64 bit version of Windows 7 and it must not be compatible with the 64 bit version.

I just tried it on a 64-bit system........ and you are right. ■

Posted on 8. Mar. 2012 - 08:31

The software download now contains a translation of the various terms.

ManfredH ■

Posted on 11. Mar. 2012 - 03:19

Originally Posted by ManfredH

The software download now contains a translation of the various terms.

ManfredH

Dear sir

I tend to download the software , but iam witnessing an error while downloading

Please forward me the dowanlodable links

rahul ■

Posted on 12. Mar. 2012 - 10:05

Originally Posted by guddu

Dear sir

I tend to download the software , but iam witnessing an error while downloading

Please forward me the dowanlodable links

rahul

Hi, Rahul! I myself tried the download again...... and everything ran well by clicking "Ordner herunterladen". The download is a zip-file that must be unzipped. Best regards, ManfredH ■

Posted on 5. Apr. 2012 - 03:19

Originally Posted by ManfredH

I just tried it on a 64-bit system........ and you are right.

Did you ever get this to work on a 64 bit system? ■

Posted on 5. Apr. 2012 - 10:31

Originally Posted by Gary Blenkhorn

Did you ever get this to work on a 64 bit system?

Hi! I have written this software during the time of Visual Basic 1, 2, and 3 at the beginning of the 1990s. Those were 32 bit versions, I think. Microsoft then changed the basis of the programming software, and I was not able to adapt my program to Visual Basic 4. So, it remained 32 bit. It does not run under Windows 7 (64 bit), and I never tried to make it run. A solution could be to run Windows XP Mode under Windows 7 Professional, Enterprise, or Ultimate.

best regards

ManfredH ■

Posted on 6. Apr. 2012 - 09:41

Dear Manfred,

If the program is not too big, you could start a new program under VisulBasic 2010 Express.

(VisulBasic 2010 Express is a free download)

Copy/Paste and then repair the syntax errors.

Might cost a few days, but the knowledge is saved for the future.

Success

Teus ■

Teus

Posted on 12. Apr. 2012 - 10:42

Originally Posted by Teus Tuinenburg

Hi Teus,

thanks for the hint. But I guess taking over the database part will not be so easy, and I am too long out of practice.

Best regards, ManfredH ■

Posted on 11. Jan. 2013 - 04:17

During the last days I tried to produce an english version of my software program. The files can be downloaded from the following link:

https://skydrive.live.com/#cid=0239E...2F136DDE%21936

Surely the program is now easier to handle, and I hope, you enjoy using it.

Best regards

Manfred Heyde ■

Posted on 16. Apr. 2015 - 02:21

The Files of the free software, written in VISUAL BASIC and offering a direct way of practicing the main results, are available at the following latest links:

The German version can be downloaded (as zip file) at the following link:

https://skydrive.live.com/redir.aspx...s60rZ0M*8fA%24

An English version of the software can be downloaded (as zip file) at the following link:

https://skydrive.live.com/#cid=0239E...2F136DDE%21936

Another link leads to Google Drive. From there you can download as zip file all programs as well as documents in English and German together.

https://drive.google.com/drive/folde...lRmVXlhR1dabFk

Best regards

ManfredH ■

Posted on 9. Dec. 2016 - 04:54

Originally Posted by ManfredH

Auf BulkOnline die Threads von 10 Jahren auf tragfähige Betriebsdaten aus pneumatischen Förderanlagen durchforsten und auf der Basis des von mir eingeführten dimensionslosen Kennfeldes diskutieren zu können, war eine einzigartige Möglichkeit der Verifizierung. Zugleich zeigt die Zahl der Zugriffe auf dieses Thread das große Interesse an nachvollziehbaren Darstellungen des Fließverhaltens bewegter Schüttgüter.

Die in einer kleinen Abhandlung dargelegten Betriebsdaten geben nach Ansicht eines Projektingenieur eines ausländischen Anlagenbauers einen guten Einblick in die strömungsmechanischen Eigenheiten der pneumatischen Förderung. Bezüglich einiger zugelieferter Förderanlagen, die zum Verstopfen neigen, konnte er feststellen, dass deren Betriebspunkte im instabilen Bereich liegen; zugleich ließen sich die bezüglich der Betriebsweise anbietenden Korrekturen abschätzen.

Die Art der gewonnenen Erkenntnisse spielt meiner Ansicht nach eine Rolle bei der aktuell von Teus Tuinenburg angestoßenen Diskussion um die in den letzten Jahren abnehmende Nachfrage nach Auslegung bzw. Beurteilung der Betriebsbedingungen industrieller pneumatischer Förderanlagen. Vielleicht liegt das daran, dass die Fachleute Auslegungsvorschläge bei aller apparate- und betriebstechnichen Kompetenz oft nach dem Motto "Friss Vogel oder stirb" unterbreiten. Verifiziert werden die theoretisch ermittelten Anlagendaten meist nie, was sicher auch an der (zunehmenden?) Zurückhaltung der Betreiber liegt.

Was den Stand der Beschreibung des Fließverhaltens bewegter Schüttgüter ganz allgemein angeht, gibt die kürzliche Anfrage einer Studentin der Textiltechnik an der Hochschule Reutlingen Auskunft. Sie schreibt derzeit ihre Bachelorarbeit zum Thema "Fluidisiergewebe" und war über das Internet auf eine frühere Veröffentlichung meiner Broschüre "Fluidisieren von Schüttgütern" gestoßen. In dem Mail an mich drückte sie ihr Bedauern darüber aus, dass ich die Arbeit zurückgezogen hätte, weil es kaum Literatur zu diesem Thema gäbe. Mit der in BulkOnline angegebenen Downloadadresse konnte ich ihr jedoch weiterhelfen.

Ich habe um 1980 herum in der BASF angefangen, mich mit der Schüttguttechnik zu beschäftigen. Daraus ist dann Anfang der 90er die noch heute unter Windows 7 nutzbare Software entstanden. Ich bin erstaunt, wieviel Zeit seitdem vergangen ist, und wie aktuell das Thema trotzdem noch zu sein scheint.

Manfred Heyde ■

Posted on 9. Dec. 2016 - 11:57

Vielleicht liegt das daran, dass die Fachleute Auslegungsvorschläge bei aller apparate- und betriebstechnischen Kompetenz oft nach dem Motto "Friss Vogel oder stirb" unterbreiten. Verifiziert werden die theoretisch ermittelten Anlagendaten meist nie, was sicher auch an der (zunehmenden?) Zurückhaltung der Betreiber liegt.

-Experts design on the principle “Eat bird or die” or “do or die”

-The, theoretically achieved data are almost never verified.

Two important observations.

It seems that theoretically achieved data are not sufficient to use as a design basis and therefore not usable for verification.

Many pneumatic conveying installations are clones of previous installations and require no design.

For offshore installations (cement, barite, bentonite), the hose connection between a PSV and a drilling rig is maximized at 6”, because of handling reasons (hose reel size).

For a 6” hose size, a 30 m3/min compressor is required for all conveying lengths.

In practice, the achieved capacity is something to live with.

Long term practical experience and standard installations may be the cause of disinterest of manufacturers and engineers in pneumatic conveying.

Nevertheless, many claim to know everything, how pneumatic conveying works.

(example: the variety of dense- dilute definitions)

Bezüglich einiger zugelieferter Förderanlagen, die zum Verstopfen neigen, konnte er feststellen, dass deren Betriebspunkte im instabilen Bereich liegen; zugleich ließen sich die bezüglich der Betriebsweise anbietenden Korrekturen abschätzen.

Regarding delivered pneumatic conveying installations, which tend to the choke, it was possible to determine that their operating points were in the unstable area; at the same time it was possible to estimate the fixes with regard to the mode of operation.

This quote underlines the importance of proper and practical theory and calculation programs for pneumatic conveying. ■

Teus

Posted on 10. Dec. 2016 - 07:19

In many newly built industrial plants, the scale up is a problem, even if the operation of the exemplary system runs smoothly. For complex production units (for example, fluidized-bed reactors), a physical model is indispensable, for simpler systems such as pneumatic conveying, one can try to apply the principle of physical similarity as I have tried. First of all, however, a suitable dimensionless similarity parameter K had to be found. In the present case K derives from my own theoretical view on the pressure loss and the heat transfer in turbulent tube currents, which you will find in my brochure. Using K, a characteristic map could be created from the operating data published in the technical literature, and on this basis the operating data available in BulkOnline were discussed.

Manfred Heyde ■

Posted on 10. Dec. 2016 - 11:04

Originally Posted by ManfredH

In many newly built industrial plants, the scale up is a problem, even if the operation of the exemplary system runs smoothly. For complex production units (for example, fluidized-bed reactors), a physical model is indispensable, for simpler systems such as pneumatic conveying, one can try to apply the principle of physical similarity as I have tried. First of all, however, a suitable dimensionless similarity parameter K had to be found. In the present case K derives from my own theoretical view on the pressure loss and the heat transfer in turbulent tube flow, which you will find in my brochure. Using K, a characteristic map could be created from the operating data published in the technical literature, and on this basis the operating data available in BulkOnline were discussed.

Manfred Heyde ■

Posted on 10. Dec. 2016 - 11:36

In many newly built industrial plants, the scale up is a problem, even if the operation of the exemplary system runs smoothly

I fully agree with this statement.

Scaling up from a lab test to a real installation must account for:

-length horizontal

-length vertical

-diameter

-Number of bends and bend orientation

-Reynolds number

-Solid Loading Ratio

-Material Loss Factor (Is a function of SLR and Re)

-Temperatures (Gas and material)

-Heat exchanges.

-Additional pressure drops s.a. clean air piping, filters, silencers, heat exchangers, etc.

Accounting for all these parameters is almost undoable.

For complex production units (for example, fluidized-bed reactors), a physical model is indispensable

Agreed

for simpler systems such as pneumatic conveying, one can try to apply the principle of physical similarity as I have tried. First of all, however, a suitable dimensionless similarity parameter K had to be found. In the present case K derives from my own theoretical view on the pressure loss and the heat transfer in turbulent tube currents, which you will find in my brochure. Using K, a characteristic map could be created from the operating data published in the technical literature, and on this basis the operating data available in BulkOnline were discussed.

The principle of physical similarity is, as I see it, also a scaling technique whereby the similarity factor acts as a scaling factor.

If the similarity factor or scaling factor is based on properly functioning models (existing installations), this method should result in working designs. ■

Teus

Posted on 11. Dec. 2016 - 07:34

The Files of the free software, written in VISUAL BASIC and offering a direct way of practicing the main results, are available at the following latest links:

This link leads to Google Drive. From there you can download as zip file all programs as well as documents in English and German together.

https://drive.google.com/drive/folde...lRmVXlhR1dabFk

Best regards

Manfred Heyde ■

Posted on 11. Dec. 2016 - 05:10

Mathematical description of State diagram.

Is this derivation correct?

Internal gas energy = function (mgas * dp)

Material loss energy = function (1/2 * K *mmat * v^2 * L/D)

SLR = (mmat)/(mgas)

mmat = SLR * mgas

Resulting in:

Internal gas energy = function (mgas * dp)

Material loss energy = function (1/2 * K *= SLR * mgas * v^2 * L/D)

thus:

(mgas * dp) # (1/2 * K * SLR * mgas * v^2 * L/D)

Re = (rhogas * v * D)/(etagas)

v = (Re * etagas) / (rhogas * D)

Combined:

(mgas * dp) # (1/2 * K * SLR * mgas * ((Re * etagas) / (rhogas * D))^2 * L/D)

Worked out:

SQRT(SLR) = [SQRT(2)/(Re*SQRT(K))] * SQRT[(dp*D^3*rhogas^2)/(etagas^2 * L)]

or

SQRT[(dp*D^3*rhogas^2)/(etagas^2 * L)] = SQRT(SLR * K/2) * Re

This formula is representing a line in the State Diagram for a specific material (K) and a specific SLR.

Conclusion:

- The state diagram accounts for material and SLR.

- By calculating “SQRT[(dp*D^3*rhogas^2)/(etagas^2 * L)]” and “Re” the installation parameter “SQRT(SLR * K/2) “ is determined, although SLR and K are not directly known.

Note:

In this derivation, only the pressure drop, caused by material losses, is used and the other pressure drops (Elevation, gas, suspension, acceleration, intake, filter, etc.) are ignored, although the total pressure drop is entered in the formula.

Applying the principle of physical similarity, the factor K is acting as the similarity factor. ■

Teus

Posted on 12. Dec. 2016 - 04:31

Hi, Teus!

For this I can only confirm the following: When transferring the operating data, I could discover no subliminal functional dependencies of SLR or the type of bulk material. The bulk material throughput in Kg / h remained as the only parameter, quite independent of other influencing variables.

Manfred Heyde ■

Posted on 12. Dec. 2016 - 04:50

Note:

As far as my approach is concerned, it can be found at the following link, that leads to Google Drive. From there you can download as zip file all programs as well as documents in English and German together.

https://drive.google.com/drive/folde...lRmVXlhR1dabFk

Manfred Heyde ■

Posted on 8. Sep. 2019 - 07:19

here another (new) download address

https://c.gmx.net/@33467048205169497...Tc6NisW5wHJUlw

Manfred Heyde ■

bulk-online, the Powder/Bulk Portal

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