In industrial processes, there can be no compromise on conveyor structural integrity. When the conveyed material is hot, abrasive or fine dust, any compromise in equipment quality is reflected directly in production reliability.
A pneumatic conveyor is one of the most demanding components in the entire material handling chain. It is worth spending time on its selection. Discover our pneumatic conveying solutions and see how they fit right into your process.
When the process does not allow for compromises
In metallurgical processes, mining environments and power generation, material handling takes place under conditions that wear down equipment rapidly. Temperatures can rise to hundreds of degrees, materials are abrasive, and the process has to run round the clock.
Pneumatic conveying offers a practical solution to this. Transfer through a closed pipeline eliminates dust problems, reduces material waste and enables transport over long distances without intermediate mechanical components.
In bulk material handling, two operating principles stand out above the rest:
- dilute phase Therefore, the lean-phase pneumatic conveying is suitable for light and easily flowing materials where a simple and cost-effective solution is needed.
- Dense phase dense phase conveying operates at a lower gas velocity and with larger material volumes, which reduces wear, pipe stress and material degradation.
We favour pulse dense phase conveying whenever possible. It consumes less compressed air, lowers operating costs and keeps material movement controlled. This is particularly important for abrasive and sensitive materials.
Structure and materials that last for years
A durable industrial conveyor is not created by cutting corners on materials or construction. Equipment used in demanding conditions must withstand both mechanical wear and thermal stress without the need for constant maintenance.
Pressure conveyors are built as required from carbon steel, wear-resistant steel or acid-resistant stainless steel. The choice of material is always based on the process conditions, not on cost optimisation at the expense of quality.
The most critical component of the equipment is the dome valve. We design and manufacture it ourselves, which means complete control over quality and functionality. When the valve is designed precisely for that specific application, it lasts longer and requires less maintenance.
A typical system consists of the following components:
- Header tank (optional)
- Dome valve
- pressure vessel, or the actual body of the pneumatic conveyor
- Fluidisation system
- Control unit and automation
- Pipework, receiving silo filter
The system is fully automated and can be integrated into the plant's DCS control system. Operation is simple, and the same equipment can function in both dense phase and dilute phase modes with minor software modifications, if required.
Would you like to see what kind of results we have achieved in similar projects? View our case studies and see examples from different industries.
A tailored solution for every process
There is no single correct pneumatic conveyor that would suit all processes. The material properties, transport distance, capacity requirement and conditions vary so much that each system must be designed individually.
Pneumatic conveying systems are supplied for a wide capacity range. Standard pressure vessel sizes cover volumes from 20 litres up to 10,000 litres, and systems are designed for a capacity of 0 to 70 t/h. The pipeline length can be 10 to 300 metres, and the temperature resistance reaches 250 degrees Celsius.
This flexibility means that the same technology serves the side streams of a small smelter just as well as the concentrate transport of a large mine. The crucial factor is that the system is correctly dimensioned to meet the exact requirements of your process.
Mechanical conveyance and pneumatic conveyance are not mutually exclusive. Often the most functional overall solution combines both technologies so that each handles the phase to which it is best suited. Nearly 50 years of experience in various projects gives us a good foundation to assess which solution works in any given situation.
Would you like to know if pneumatic conveying is right for your process? Read more about pneumatic conveying and evaluate different options.
Get in touch – let's figure out your needs
Every project is different. That is why we do not offer ready-made packaged solutions, but always start by mapping out your process requirements and material properties.
Kopar has supplied hundreds of pneumatic conveyor systems to demanding industrial environments around the world. Our reference list covers deliveries dating from the 1970s to the energy, metallurgical, mining and chemical industries.
Making contact commits you to nothing. It is the quickest way to find out if pneumatic conveying is the right solution for you and how the system should be sized.
- Tell us your process conditions and material
- You will receive an assessment of the most suitable method of transport
- If necessary, we can test your material in our own testing facility
Contact us and let's figure out together what kind of solution best serves your specific production.
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