Discontinuous Dense Phase Conveying System for Filter Aid/Pre-coat Material & Lime/Sulphur Powder
Discontinuous Dense Phase Conveying System for Filter Aid/Pre-coat Material & Lime/Sulphur Powder
Project Overview
Handling low-bulk-density filter aid and pre-coat material alongside reactive lime and sulphur powder calls for a conveying technology that protects product quality while removing manual handling risk from the plant floor. For this application, the customer needed two independent systems: one to convey filter aid/pre-coat material to six reception storage tanks and a second to transfer lime and sulphur powder to a single reception silo.
To meet these requirements, Macawber India, a pneumatic conveying system manufacturer in India, engineered two customised dense phase conveying systems built for reliable, low-velocity material transfer using nitrogen as the conveying medium, an approach essential wherever product sensitivity and inert handling are non-negotiable.
Project Challenges
The application involved two materials with very different handling profiles operating side by side within the same facility:
- An extremely fine, low-density filter aid material (16-micron particle size, 220–320 kg/m³ bulk density) that needed careful, degradation-free transfer to six separate storage points.
- Reactive lime and sulphur powders (740 kg/m³ and 920 kg/m³ bulk density, respectively) that required conveying under an inert atmosphere to prevent moisture pickup and reaction risk.
Beyond the differing material behaviour, both systems needed to run fully automated with minimal manual intervention, eliminate spillage through integrated dust control, and keep long-term wear on pipelines and equipment to a minimum despite continuous duty cycles.
Get a custom dense phase conveying system for your chemical or powder processing application.
Engineered Dense Phase Conveying Solution
Macawber designed two dense-phase pneumatic conveying systems operating on discontinuous dense-phase principles, moving material at low velocity to minimise degradation and pipeline wear.
System 1 conveyed filter aid/pre-coat material from a single feed point to six reception storage tanks using nitrogen as the conveying medium, protecting the fine, 16-micron powder from moisture pickup and oxidation during transfer.
System 2 handled lime and sulphur powder from a single feed point to one reception silo, using a nitrogen/air conveying medium suited to the higher bulk density of these materials while maintaining the same low-velocity, low-degradation transfer principle.
Both systems were engineered using Macawber’s Denseveyor pneumatic conveying technology and integrated with PLC- and SCADA-based automation for controlled, reliable operation. An integrated dedusting system captured displaced dust at the receiving points, minimising material spillage and maintaining a cleaner plant environment.
This solution is well suited for applications requiring a pneumatic conveyor for chemicals, where inert-gas conveying and minimal product degradation are critical to protecting reactive or moisture-sensitive materials.
Operational Benefits
1. Reduced Manual Labour
Both systems operated with complete automation, significantly reducing dependency on manual handling across the plant.
2. Lower Material Handling Costs
Automated conveying eliminated the recurring cost of hiring bulkers for pumping material between process points.
3. Minimal Maintenance Downtime
The engineered dense-phase design kept maintenance requirements low, limiting downtime during scheduled servicing.
4. Fully Automated, SCADA-Controlled Operation
Complete PLC and SCADA integration gave the plant consistent process control across both systems.
5. Clean, Dust-Free Plant Operations
An integrated dedusting arrangement with built-in pollution control eliminated material spillage and supported safer working conditions.
6. Low Wear, Reliable Long-Term Performance
Low-velocity dense-phase transfer minimised wear on pipelines, equipment, and the conveyed material itself, with both systems exceeding their specified conveying rates under load.
Project Outcome
By engineering two customised dense-phase conveying systems, Macawber successfully delivered reliable, independent solutions for handling filter aid/pre-coat material and lime/sulphur powder within the same facility. Both installations have continued to operate efficiently, with actual performance exceeding the specified conveying capacity under load.
The combination of nitrogen-based dense-phase conveying, full automation, and integrated dust control resulted in two dependable, low-maintenance installations. This project further demonstrates Macawber’s expertise in engineering dense-phase pneumatic conveying solutions for demanding chemical and industrial powder applications.
Whether your plant handles fine, moisture-sensitive powders or reactive bulk materials, Macawber India engineers dense-phase conveying systems built around your specific material characteristics, automation needs, and plant layout. Talk to our team to design a conveying solution that keeps your operations clean, efficient, and running with minimal downtime.
Project Summary Table
| Parameter | System 1: Filter Aid / Pre-coat Material | System 2: Lime / Sulphur Powder |
|---|---|---|
| Bulk Density | 220–320 kg/m³ | 740 kg/m³ (lime) / 920 kg/m³ (sulphur) |
| Particle Size | 16 microns | Fine powder |
| Conveying Media | Nitrogen | Nitrogen/Air |
| Parameter | System 1 | System 2 |
|---|---|---|
| Feed Points | 1 | 1 |
| Reception Points | 6 | 1 |
| Conveying Capacity | 10 TPH | 2.5 TPH |
| Horizontal Distance | 45 m | 30 m |
| Vertical Distance | 5 m | 15 m |
Explore Macawber's pneumatic conveying solutions for chemical and bulk powder handling.
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