Energy Efficiency Enhancement in Cotton Pneumatic Transport Systems Using Parallel Pipelines

Abstract

The efficiency of pneumatic conveying systems plays a decisive role in the energy performance of cotton-processing plants, where airflow is the dominant electrical power consumption. Despite widespread industrial use, conventional single-duct systems still suffer from high pressure losses and energy inefficiency due to excessive air velocity and wall friction. Previous studies primarily focused on granular or powdered materials, while the specific aerodynamic behaviour of low-density fibrous cotton remains insufficiently investigated. This knowledge gap limits the optimisation of energy-saving designs for cotton pneumatic transport.
This research develops a mathematical and experimental model for a resource-efficient pneumatic conveying system employing parallel pipelines to enhance energy efficiency and transport stability. The model integrates Bernoulli’s principle, the Darcy–Weisbach equation, and empirical correlations for friction and particle-air interaction. Comparative simulations and experiments were performed for single- and dual-pipeline configurations operating at air velocities of 15-20 m/s.
The results show that the parallel configuration reduces pressure drop by 23-26% and total power consumption by 20-25% compared to the conventional 355 mm single-duct system, while maintaining stable fibre transport and minimising clogging. The findings validate the theoretical framework and provide practical guidelines for retrofitting existing cotton pneumatic systems to achieve substantial energy savings.
This study fills a key research gap by demonstrating the aerodynamic advantages of parallel airflow distribution for fibrous materials. It contributes to sustainable industrial modernisation by offering a scalable, energy-efficient pneumatic transport design suitable for cotton-processing facilities worldwide.