Pneumatic conveyors rarely break down by chance. Most often, there is a set of identifiable factors that, together, wear out the system faster than they should.
If your processes operate in demanding conditions within the metallurgical, energy production, or mineral industries, you'll recognise the challenge: materials are abrasive, temperatures are high, and production pressures are intense. Explore pneumatic conveying solutions, which are designed precisely for these conditions.
Common causes of conveyor damage in harsh conditions
Premature breakdown is not caused by a single reason. It's usually a sum of multiple factors, all accelerating each other.
Incorrect transport method for material
One of the most common mistakes is using dilute phase transport in a situation where the material requires a dense phase solution. When hard or granular bulk material moves at high speed through a pipeline, it quickly wears down the pipe walls, valves, and other components.
Dense phase transport, or slugging, uses a lower gas velocity and a higher material concentration. This significantly reduces both pipeline wear and material degradation during transport.
Excessive operating pressures and incorrect sizing
An overloaded pneumatic conveying system prematurely stresses seals, joints, and pressure components. Incorrect sizing leads to the system constantly operating at its capacity limits.
A correctly sized system takes into account the material properties, pipe run length, height differences, and required capacity. Neglecting these factors is directly reflected in maintenance costs and unexpected downtime.
Abrasive material without wear protection
The harshest industrial materials, such as ash, fine mineral powders, or slag, rapidly wear out pipework and components without appropriate material selections.
Wear-resistant steel and the right component materials are crucial when handling abrasive bulk materials. Standard constructions simply won't withstand the most demanding processes for long enough.
Inadequate fluidisation system
Uneven material flow in the pipeline causes blockages and pressure spikes, which put stress on the entire system. A functioning fluidisation system ensures smooth transfer and prevents mechanical stress.
Copper solutions for long-lasting and reliable operation
With almost 50 years of experience, we have supplied hundreds of pressure conveyors for the most demanding industrial processes. This experience is directly reflected in our approach to every project.
We favour pulse plug conveying whenever possible. It uses less compressed air, which lowers operating costs. The low material velocity reduces wear and improves availability.
Our solutions offer concrete advantages in demanding conditions:
- A lower gas velocity reduces pipeline wear from abrasive materials.
- Durable material options, such as wear-resistant steel and acid-proof stainless steel
- In-house design and manufacturing of the most critical components, such as cap valves
- A fully automated system integrated with the plant's DCS control system
- Implementation in accordance with ATEX requirements, if necessary
- The same hardware functions as both dense phase and dilute phase transport with minor software changes.
We continuously test new materials at our own testing facility. This means we understand the behaviour of materials in pneumatic transport before the system is installed in production.
Explore our pressure transmitters and see how the ELMO series pneumatic conveyors fit your process's capacity needs.
Every project is different. That's why we don't offer standard solutions, but always size the system based on material properties, capacity requirements, and the overall demands of the process. This is the only way to ensure that the pneumatic conveying system operates reliably year after year.
Get in touch – let's map out the right solution for your process
If a pneumatic conveyor is causing recurrent problems, or if you're planning a new conveyor system for demanding conditions, it's worth starting from the right place: a thorough analysis of the material and the process.
The right solution isn't always the most expensive or complex. It's the solution that's tailored precisely to your process requirements.
Contact us and I'll tell you about our process. Together, we'll map out which transport solution best suits your operating conditions and materials.
You have a challenge that needs solving?
Let us help! Contact us for more information about our products and services.