Discontinuous Dense Phase System for Foundry Sand Conveying
Discontinuous Dense Phase System for Foundry Sand Conveying
Project Overview
Efficient reclaimed sand handling is essential for maintaining productivity and process continuity in foundry operations. For this application, Macawber supplied two independent dense phase conveying systems within the same facility, each designed to transport reclaimed sand from a single feed point to two reception silos.
The project consisted of a 10 TPH system and a 4 TPH system located adjacent to one another. To enable flexible material distribution between the receiving silos, both systems were equipped with dump valves for path diversion. Utilising a dense-phase pneumatic conveying system India solution, the installation was engineered to handle abrasive, high-density sand while maintaining reliable and efficient conveying performance.
Application Requirements
The foundry required a conveying solution capable of handling reclaimed sand at elevated temperatures while minimising wear on pipelines and equipment. In addition to material handling challenges, the system needed to support automatic operation, reduce manual intervention, and provide controlled distribution to multiple storage silos.
The demanding material characteristics made it essential to implement a robust pneumatic conveyor for the foundry application capable of delivering reliable performance under continuous operating conditions.
Process Configuration
The two systems were designed to serve different process streams within the facility while maintaining a similar conveying philosophy.
System 1
In the first application, reclaimed sand is discharged from the Vibro-Wedge into a surge hopper. The material was then fed into a Denseveyor and conveyed to either of the two reception silos through a dump-valve arrangement.
System 2
For the second application, reclaimed sand was transported by a bucket elevator into a surge hopper. From there, the Denseveyor transferred the material to one of the two designated silos based on process requirements.
This arrangement provided operational flexibility while ensuring smooth and controlled material movement throughout the plant.
Engineered Solution
As a leading pneumatic conveying system manufacturer, Macawber designed both installations using Denseveyor technology to ensure efficient handling of hot and abrasive reclaimed sand. The systems were configured to provide controlled material transfer while minimising wear on conveying lines and critical components.
The inclusion of dump valves enabled seamless diversion of material between the two reception silos without interrupting conveying operations. This provided greater flexibility for plant operators while improving overall material management.
To further enhance operational efficiency, both systems were integrated with complete automation and SCADA controls, allowing centralised monitoring, process control, and system optimisation.
Operational Benefits
1. Fully Automated Operation
The systems operate through complete automation and SCADA-based control, reducing operator dependency and improving process consistency.
2. Minimal Maintenance Downtime
Robust equipment design and controlled conveying conditions help reduce maintenance requirements and support uninterrupted plant operations.
3. Cleaner Material Handling
Integrated pollution control and dedusting capabilities minimise material spillage and dust generation, creating a cleaner working environment.
4. Reduced Wear and Tear
The conveying approach significantly reduces wear on pipelines, bends, and system components despite the abrasive nature of reclaimed sand.
5. Lower Operating Costs
Automation, reduced maintenance requirements, and efficient material handling contribute to lower overall operating and lifecycle costs.
6. Performance Beyond Design Capacity
During operation, both systems demonstrated the ability to exceed the specified conveying rate when loaded, highlighting the effectiveness of the engineered solution.
Project Outcome
Macawber successfully delivered two customised dense phase conveying systems that enabled reliable handling and distribution of reclaimed foundry sand within the facility. The installation combined automated operation, flexible material routing, low maintenance requirements, and efficient conveying performance to support the customer’s production objectives.
The project demonstrates how a well-engineered dense phase conveying solution can provide long-term reliability, operational efficiency, and cost-effective performance for challenging foundry applications.
Project Summary Table
The conveyed material consisted of reclaimed foundry sand with properties that required a durable and wear-resistant conveying solution.
| Material | Reclaimed Sand |
|---|---|
| Temperature | 150°C |
| Bulk Density | 1500 kg/m³ |
| Particle Size | Below 1 mm |
| Characteristics | Free Flowing, Abrasive, Heavy |
The presence of all three factors, namely temperature, bulk density, and abrasiveness, in such quantities could become a cause for concern during the operation of the conveyor system. Thus, an optimal system design was of paramount importance.
| Parameter | System 1 | System 2 |
|---|---|---|
| Feed Points | 1 | 1 |
| Reception Points | 2 | 2 |
| Capacity | 10 TPH | 4 TPH |
| Conveying Distance | 30 m | 30 m |
| Number of Bends | 3 | 3 |
The compact layout enabled efficient distribution of reclaimed sand to multiple destinations while maintaining stable conveying performance across both systems.
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