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The zinc industry is a key area of the global metals market with enormous applications in galvanising, die-cast alloys, chemicals, and batteries. As the world’s fourth most widely used metal, zinc provides corrosion protection, strength, and durability in infrastructure, automotive, and energy markets. Pneumatic conveying in the zinc industry is of utmost significance for dust-free, safe, and efficient transportation of zinc concentrates, oxides, and by-products. Dense phase pneumatic conveying systems convey materials at low velocities to prevent wear, spillage, and contamination. This ensures operating reliability, conformity with environmental norms, and compatibility with smelting and refining without any issues.
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Nature of Materials in the Zinc Industry
- Dry fine powder, granular powder
- Good flowability
- Abrasive in nature
- Moderately powdery
The combination of these characteristics makes pneumatic conveying systems the ideal solution for transporting diversified materials while ensuring pneumatic conveying zinc safety standards, productivity, and energy-saving pneumatic conveying for zinc industry operations.
Solutions Offered by Macawber
1. Dense Phase Pneumatic Conveying System
The dense phase conveying is most appropriate for abrasive bulk materials, including zinc concentrate, blended calcine, fluxes, and coke. It utilises low-velocity, high-pressure air to transfer material in slug flow, reducing pipeline wear and preserving material integrity. Our dense phase pneumatic conveying systems are for effective long-distance transfer with minimum maintenance and downtime, with capacities from 1 TPH to 100 TPH.
2. Lean Phase Pneumatic Conveying System
For less abrasive and lighter products, such as baghouse dust, secondary residue, flux, and additives, Macawber’s lean phase pneumatic conveying systems are engineered. The materials are carried in the air stream by high-velocity air and transported continuously at low pressure. The system offers flexible routing, smooth integration, and efficient handling of free-flowing powders in the zinc industry.
3. Aeration & Vibration
In processing zinc, aeration and vibration are utilised on silos to provide free-flowing of bulk solids, such as zinc oxide, calcine, and concentrates. Aeration provides controlled air to minimise particle cohesion, while vibration prevents bridging or ratholing, providing continuous discharge and consistent feeding.
4. Boosting Systems
Boosting systems are crucial during the transport of bulk powders in the zinc industry over long distances. Macawber offers dedicated solutions, such as density stabilisers and pipe-in-pipe designs, for the safe introduction of flow, leading to improved conveying efficiency and conserving energy.
5. De-dusting System
Fine powder handling in the zinc industry requires strict dust control. In-built filtration systems capture airborne particles during conveying, improving plant cleanliness and staff safety. These types of systems allow for easy compliance with environmental regulations as well as equipment protection against wear resulting from dust.
6. Automation
Macawber’s automation solutions enhance accuracy, efficiency, and safety in pneumatic conveying of bulk powder in the zinc industry. With the use of better sensors, controls, and real-time monitoring, our automation reduces manual intervention, achieves precise delivery, and minimises downtime.
Macawber Products Supplied
- Denseveyor
- Bag filters
- Wear-resistant bends
- Screw Conveyor
- Telescopic unloading chute
- Line boosting (Density stabiliser, pipe-in-pipe)
Macawber, a well-known pneumatic conveying systems manufacturer in India, offers durable industry-specific zinc solutions.
Unique Selling Points (USPs) of Our Design
- ASME Compliance
ASME-designed pressure vessels for safety, reliability, and efficiency.
- Dome Valves
- Ceramic, tungsten carbide, or frit-coated hard-coated dome valves for optimum wear resistance.
- Rotary airlock valves
Special designs for abrasive zinc solids with specially optimised rotor, end plate, and venting designs.
- Heavy-Duty Design
Well-established 30-year track record, with systems designed for durability in harsh environments.
- Optimal Sizing Design
Vessel and pipeline sizes designed for capacity, performance, and energy optimisation.
- Healthy Filtration Area
Adequate venting to prevent back pressure and system malfunction, ensuring normal operation.
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Conclusion
Macawber’s pneumatic conveying solutions for the zinc industry offer the ultimate level of efficiency, safety, and reliability. With long industry experience, decades of expertise, and through innovative engineering, we offer the best quality pneumatic system for the conveying of zinc powder with energy efficiency and safety.
FAQ's
Pneumatic conveying in the zinc industry refers to the transportation of zinc concentrates, oxides, and fine powders in sealed pipes under pressure with pressurised air. It ensures dust-free, efficient, and safe handling of bulk, limiting material loss while maintaining product integrity with safety.
Pneumatic transport of zinc powder is a better choice compared to mechanical systems as it reduces spillage, abrasion on equipment, and dusting. It provides cleaner workplaces, enhanced safety, and less maintenance, hence more secure and sustainable for processing abrasive zinc materials.
Pneumatic conveying ensures safety in plants by eliminating high dust emissions, lowering risks of manual handling, and avoiding contamination. Pneumatic conveying also ensures environmental and workplace safety standards compliance, protecting employees as well as maintaining hygiene and efficiency in zinc processing plants.
Zinc pneumatic conveying systems can handle powdered and fine zinc materials, such as zinc powder, zinc oxide, and zinc sulfate, as well as other processed forms like calcined zinc. These systems ensure the safe, dust-free, and efficient transportation of various zinc products used in industry.
Kedar Kamath
Kedar Kamath is a highly accomplished bulk material handling professional with 14+ years of experience at Macawber Engineering Systems India Pvt Ltd. Starting as a junior sales engineer, he progressed to his current role heading Business Development and Sales. His expertise encompasses proposals, estimations, sales, marketing, design engineering, project execution, and factory operations. Mentored by industry leaders, Kedar's technical acumen (B.Tech in Electrical Engineering, VJTI, Mumbai) and innovative approach deliver tailored solutions. He's passionate about sustainable practices and driving excellence within the industry.