Pneumatic Conveying, Storage, Batching, Weighing For Graphite & Other Dust
Pneumatic Conveying, Storage, Batching, Weighing For Graphite & Other Dust
Overview of the Client
This case study features Macawber India, the top pneumatic conveying system manufacturer, rolling out a cutting-edge Dense Phase Pneumatic Conveying System for pneumatic conveying in the refractory industry in Odisha. Targeting highly abrasive fine dusts, challenging Graphite powders, and tough coarse refractory materials over a vast 60x10m silo array, it masters dust-tight storage, precision batching, and accurate weighing amid extreme abrasion, varied densities, and complex flow behaviours typical of demanding refractory operations.
Why Clients Choose Macawber India
Macawber India developed a simple hybrid system with the use of dome valves to achieve smooth conveying in the refractory industry. Pneumatic transport of fines in Dense Phase to many silos, and mechanical transport for coarser materials using heavy-duty skips. This involves simple rotary diverters, improved dust control, and large bag feeds to provide accurate, segregated quantities everywhere in the large plant.
The Challenge We Addressed
- Various materials had to be distributed over a large area: very abrasive fine dust (0.5-1.5 T/M3, -225 Mesh), Graphite (1.1-1.3 T/M3, -18 to -300 Mesh), and coarse powder (1.5-2.2 T/M3).
- Fine dust as well as graphite to be conveyed to an adjacent battery of silos at ~30 m elevation with routing constraints.
- Abrasion-proof, fully automated operations in refractory's harsh, ambient conditions with minimal moisture content challenges.
Solutions We Provided
- Dense phase PCS at 5 TPH for dust and graphite conveying over 30 meters vertical distance, with Rotary type Multiport Diverter Valve for accurate routing from jumbo bags to a series of silos.
- 7 TPH skip hoist and reversible shuttle conveyor for coarse materials (50 meters horizontal and 30 meters vertical) effectively supplies 18 pairs of silos with optimal batch routing.
- Comprehensive de-dusting systems and SCADA integration for automated batching and weighing with real-time monitoring.
- This is a hybrid system configuration customised for refractory applications with optimal efficiency, durability, and seamless plant integration.
System Advantages
- Precision-fit for unique plant layouts and clean operations.
- Total dust suppression, low-loss handling.
- Breakthrough rotary diverters and space-saving high-lift skips.
- SCADA-driven for non-stop reliability.
- Spill-free, low-abrasion, easy automation tie-in.
Result Time
Macawber India’s dense phase pneumatic conveying systems were unique in the Refractory Industry for: 5-7 tons per hour smooth flow, accurate silo dosing, and dust-free performance for Graphite mixes. It enhances efficiency, minimises waste, and reflects expertise in processing a substantial quantity of material.
Project Summary Table
| Property | Fine Dust | Graphite | Coarse Powder |
|---|---|---|---|
| Bulk Density | 0.5–1.5 T/M3 | 1.1–1.3 T/M3 | 1.5–2.2 T/M3 |
| Particle Size | -225 Mesh | -18 to -300 Mesh | – |
| Temperature | Ambient | Ambient | Ambient |
| Nature | Free flowing, Abrasive | Sluggish flow & puffy | Coarse |
| Moisture | 0.5% | Nil | Nil |
• Pneumatic (Dust/Graphite): Dense Phase, Denseveyor, 5 TPH, 5 m horizontal + 30 m vertical, Jumbo Bag to Silos, Rotary type Multiport Diverter Valve USP.
• Mechanical (Coarse): Skip & Shuttle, 7 TPH, 50 m horizontal + 30 m vertical, Jumbo Bag to 18×2 Grid Silos, 90° Lift USP.
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