30120130406020

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –

6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 6, November - December (2013) © IAEME

186

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.

INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING

AND TECHNOLOGY (IJMET)

ISSN 0976 – 6340 (Print)

ISSN 0976 – 6359 (Online)

Volume 4, Issue 6, November - December (2013), pp. 186-200

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187

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.



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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



189

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



190

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

CONVEYOR C1 C2(2 numbers) C3

Mean diameter of iron ore (mm) 250 250 80

Capacity,tph 200 100 200

Volumetric flow rate of iron ore, m3/s 0.04 0.02 0.04

Belt width, Bbmm 0.12 0.08 0.065

Belt speed, Vb m/s 1.00 0.30 1.50

Surcharge angle, degree 25 25 25

Idler trough angle, degree 35 35 35

Skirt board length, m 4 3

Leakage area at belt loading zone, Ab,

m2

0.08 0.08

Falling material stream area, As , m2 0.40 0.25 0.15

Discharge chute cross section, Acs , m2 0.36X2 0.28X2 0.20

Leakage area at conveyor head pulley,

A1 , m2

0.40 0.30 Nil

Belt inclination, degrees 15 0 0

Chute inclination, θc , degrees 60 60

Height of free fall of material on

conveyor, h ,m

3.4 4.1 1.25

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

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



191

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

Section Flow Rate

(m3/hr.)

Duct Diameter

(mm)

Velocity

(m/sec.)

Length of

Straight Duct

(m)

Flow Reynolds No.

P-3 120960 1360 23 3.53 1646315.789

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 2.2 2052631.579

Fan 359522.688 3250 12 2052631.579

Stack 359522.688 3250 12 5.0 2052631.579



192

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



193

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



194

Table 3. Flow rate for revised duct network Section Flow

Rate

(m3/hr)

Duct

Diameter

(mm)

Velocity

(m/sec)

Length

of

Straight

Duct

(mm)

Elbows

Angle

Number

(Degree)

Branch

Entry

Hoods and

Connecting

Pieces

Flow

Reynolds No.

1-3 72997.2 1055 23 4 90 3 Hood at 1 1.277x106

2-3 72997.2 1055 23 6 90 1 Hood at 2 1.277x106

60 1 30

3-5 14599.4 1499 23 2.3 2.45x106

E-E L= 575mm

F-F L= 800mm

4-5 8920.30 365 23 8 90 1 30 Hood at 4 4.418x106

60 1

5-7 275874.7 2055 23 2.1 2.487x106

G-G L=900mm

6-7 75989.08 1075 23 8.5 90 1 30 Hood at 6 1.301x106

60 1

7-8 351863.7 2325 23 2.7 Multicyclone

Inlet Piece

2.814x106

8-9 Multicyclone

9-10 351863.7 3220 12 2.2 90 2 Connecting

pieces at

multi cyclone

outlet and fan

inlet

2.033x106

10-11 351863.7 Fan

11-12 351863.7 3220 12 2.2 Fan outlet

connecting

piece

2.033x106

12-13 351863.7 3220 12 Stack 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 as-

Red = (ρa/µa)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),



195

• 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



196

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.



197

Table 4. Balance by design

Sec

tion

Flo

w R

ate

(m3/h

r.)

Duct

Dia

met

er (m

m)

Vel

oci

ty

Len

gth

of

Str

aight

Duct

Bra

nch

Entr

y

Loca

l L

oss

Co

effi

cien

t

Pressure Loss(N/mm2)

Gover

nin

g p

ress

ure

(N/m

m2)

Rem

arks

Fri

ctio

n

T

urb

ule

nce

T

ota

l

1-3 72997.2 1055 23 4 90 3 0.88 5.269 236.12 241.38 241.38

2-3 72997.2 1055 23 6 90 1 30 0.88 4.36 236 240.36 241.38

60 1

The flow is balanced at junction 3.

3-5 14599.4 1499 23 2.3 19.92 19.92 770.7

1-3-5 261.3 770.7 Use

Damper

in 1-3

4-5 8920.30 365 23 8 90 1 30 0.462 2.87 767.83 770.7 770.7

60 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 42.9

8

6 90 1 30 0.73 26 683 709 770 2-3

5-7 277903.47 2055 23 2.1 19.5 19.5 790.2

4-5-7 790.2 790.2

6-7 78018.55 1075 23 8.5 90 1 30 0.89 4.26 243.69 247.9 790.5

60 1

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 16.73 60 76.63 790.2 Use

Damper

in 6-7

4-5-7-8 866.6

8-9 357453.43 Multicyclone 1000 1866.6 Vendor’s

data

9-10 357453.43 3220 12.5 2.2 90 2 0.166 1.68 16.30 17.98 1884.58

Fan 357453.43 Fan 196 2080.58 Fan loss

is 10% of

total loss

11-12-

13

357453.43 3220 12 2.2 1.25 1.68 91.21 92.89 2173.47



198

Table 5. Balance by dampers S

ecti

on

Flo

w R

ate

(m3/h

r)

Duct

Dia

met

er

(

mm

)

Vel

oci

ty

Len

gth

of

Str

aight

Duct

Bra

nch

Entr

y

Local

Loss

Coef

fici

ent

Pressure Loss(N/mm2)

Gover

nin

g

pre

ssure

(N/m

2)

Rem

arks

Fri

ctio

n

Turb

ule

nce

Tota

l

1-3 72997.2 1055 23 4 90 3 0.88 5.269 236.12 241.38 241.38

2-3 72997.2 1055 23 6 90 1 30 0.88 4.36 236 240.37 241.38 Use

Damper

in 2-3

60 1

3-5 14599.4 1499 23 2.3 19.92 19.92 770.7

1-3-5 261.3 770.7 Use

Damper

in 1-3

4-5 8920.30 365 23 8 90 1 30 0.4622 2.87 767.83 770.7 770.7

60 1

5-7 275874.7 2055 23 2.1 19.5 19.5 790.2

4-5-7 790.2 790.2

6-7 75989.08 1075 23 8.5 90 1 30 0.89 4.26 243.69 247.95 790.2

60 1

7-8 351863.7 0.214 16.73 57.45 74.18 847.65 Use

Damper

in 6-7

4-5-7-

8

847.65 847.65

8-9 351863.7 1000 1847.65 Vendor’s

data

9-10 351863.7 0.1668 1.68 16.30 17.98 1865.63

Fan 351863.7 Fan 196 2062.51 Fan loss

is 10% of

total loss

11-12-

13

351863.7 3220 12 2.2 1.25 1.68 91.21 92.89 2155.40

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.



199

Notations

Acs - cross sectional area of the chute, m2

Al - cross sectional area through that the dust escapes into the surroundings after

the material impact on the receiving system, m2

d - duct diameter, m

dp - particle mean diameter, m

ld - total length of the duct, m

Pg - dynamic pressure, N/m2

Pg1-3 - dynamic pressure in section 1-3 of the duct and so on, N/m2

PS1-3 - static pressure in section 1-3 of the duct and so on, N/m2

PS - static pressure, N/m2

Qbs - volumetric flow rate of the bulk solids being handled, m3/s

Qi - volumetric flow rate of air due to induction, m3 /s

Q1-3 - volumetric flow rate of air in the section 1-3 and so on

Qa - volumetric flow rate of air, m3 /s

Red - Reynold's number for fluid flow in duct, dimensionless

R1-3 - resistance to flow in the section 1-3 and so on

RS - total resistance to the flow, N s2 m-8

Rf - frictional resistant, N s2 m-8

Rt - turbulence resistant, N s2 m-8

Vc - capture velocity required to prevent the dust from escaping though the

leakage area Al of the material impact zone, m/s

VD - velocity of air in duct, m/s

Vi - mean velocity of the individual lump of falling stream of bulk solids at the

impact point, m/s

∆Pf - pressure drop due to friction per unit length, N/m2/m

∆PF - total pressure drop due to friction, N/m2

∆PT - total pressure loss,N/m2

∆P1-3 - pressure drop in section 1-3 of the duct and so on, N/m2

ηF - overall efficiency of fan

θc - slope of chute, degree

µa - dynamic viscosity of air, kg/ms

νa - kinematic viscosity of air, m2/s

ρa - air density, kg/m3

ρp - particle density, kg/m3

Σ - local loss coefficient

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