Collaboration blog between Venwiz and Macawber Engineering Systems India decoding dense phase pneumatic conveying systems
Precision material handling is crucial in the chemical industry to ensure the proper transfer and transportation of various materials. Dense-phase pneumatic conveying systems are very effective and use a combination of air pressure and gravity to gently and accurately move powders, granules, and other materials through a pipeline.
A conveyor system is a fast, efficient mechanical device that automatically transports loads and materials, minimising human error, reducing workplace risks, and reducing labour costs. It aids in moving bulky or heavy items using belts, wheels, rollers, air, or chains, thereby reducing workplace risks.
A pneumatic conveying system uses air or another gas to transport bulk material through a pipe in the form of granules or powders. These systems are becoming popular because of their lower operating costs compared to traditional mechanical systems. All pneumatic conveyor designs are custom made, considering product specifics, particle size, throughput, and source/destination configurations.
Pneumatic conveying systems are further classified into:
- Dense-phase pneumatic conveyor.
- Semi-dense-phase pneumatic conveyor
- Dilute-phase pneumatic conveyor
What is a dense-phase pneumatic conveying system?
Numerous industries use dense-phase pneumatic conveying as a material handling technique. It moves materials gently along the bottom of the pipeline and uses high-pressure and low-gas volumes as it moves materials via enclosed tubes from one silo to the next. The three types of dense-phase pneumatic systems:
- Continuous dense phase
- Discontinuous dense phase
- Solid flow dense phase
Principles of a dense-phase conveying systems
The basic components of dense-phase pneumatic system design include:
- Pressure Vessel: A pressure vessel stores the material to be conveyed.
- Conveying pipeline: A conveying pipeline is a closed system through which material is transported.
- Air supply system: The air supply system provides compressed air or gas to transport the material through the pipeline. It includes components such as compressors, filters, and pressure regulators.
- Control system: The control system (sensors, valves, and controllers) regulates the flow of material and air through the system.
- Receiving vessels: The receiving vessels collect the material at the end of the pipeline.
- Supporting equipment: Supporting equipment includes rotary valves, diverter valves, or feeders.
The principle of a dense-phase pneumatic system involves using compressed air pressure (typically exceeding 138 kPa) to move material at a low velocity (less than 305 m/min) to transport material through a pipeline. This helps to minimize material deterioration, air consumption, and abrasion on contact surfaces, making it appropriate for transporting fragile or abrasive items over long distances.
Remember that specialized expertise is required to design and select the best possible dense-phase pneumatic system for specific applications. Every bulk material handling system is different, and a customized solution is necessary to get the best possible outcomes.
Differences between dense-phase and dilute-phase conveying systems
| Parameter | Dense-phase conveying system | Dilute-phase conveying system |
| Air velocity | 3 to 14 m/s | 18 to 35 m/s |
| Material-to-loading ratios | Usually, more than 10 | 10 or lower |
| Pressure range | High pressure above 1 bar | Low pressure below 1 bar |
| Conveying distance | Greater or equal to 150 meters | Usually up to 150 meters |
| Conveying Capacities | Greater than 10 tons per hour | Less than 10 tons per hour |
| Conveying rates | Suitable for low to high rates | Suitable for low rates |
Applications of Dense-Phase Pneumatic Conveying Systems:
The dense-phase pneumatic conveying systems gently moves sensitive materials and mixtures. Its slow speed and minimal airflow protect your materials from damage, making it the perfect choice for delicate tasks.
- Fragile Materials and Mixtures: Dense-phase pneumatic conveying is suitable for conveying delicate materials and mixtures because the low conveying speed and reduced air volumes minimize material degradation. Examples – powders and granules used in the pharmaceutical industry.
- Abrasive and Brittle Materials: This system is particularly effective for transferring abrasive or brittle materials at low or high rates. The slow conveying speed reduces the abrasion of the conveying lines, extending their lifespan. For example plastic granules and pellets.
- Slightly Hygroscopic Materials: Dense-phase pneumatic conveying is suitable for handling slightly hygroscopic materials without requiring additional air-drying equipment. For example salt, sugar, and dehydrated vegetables.
Some chemical industries that widely use dense-phase pneumatic system include:
- Dyes and chemical units
- Pigment plants
- Speciality chemical plants
- Construction chemical plants
- Fertilizer, pesticides, and manufacturing plants
- Inorganic chemical manufacturing plants
Advantages of dense-phase pneumatic conveying systems
Dense-phase pneumatic conveying system transcends mere material transport; it’s a technological champion for industries handling sensitive and demanding bulk materials.
| Property | Dense Phase | Benefits |
| Conveying Velocity | 1/6th – 1/8th lower than the dilute phase conveying system. | Minimizes material degradation, equipment wear, and segregation |
| Maintenance | Very low wear and tear of the system. | Reduced costs, increased uptime |
| Material Degradation | Up to 80% reduction | Preserves material value and quality |
| Blend Integrity | Up to 95% preserved | Maintains consistent product properties |
| Power Consumption | Low power consumption | Reduces energy costs and environmental impact |
| Handle delicate material | Low air volumes (<20% voidage) | Ensures fragile material arrives intact. |
| Long-distance logistics | Can handle complex and long distances | Efficient delivery over vast distances. |
| Energy efficiency | Low air-to-material ratios | Reduces operating costs, wear & tear, and maintenance |
| Protect product quality | Enclosed system shield material | Preserves integrity and quality by preventing moisture and contamination |
Venwiz and Macawbre Engineering Pvt. Ltd: A Partnership for Efficient Material Transport
As a leading platform for the discovery and procurement of industrial service vendors, Venwiz carries out rigorous vetting procedures to ensure clients are connected with reliable service providers. Macawber Engineering Systems India is one of the leading material handling companies in India.
Macawber Engineering Systems, India
Macawber Engineering Systems India, a leading manufacturer of advanced conveying systems in India, has revolutionized material handling processes. With a 28-year legacy, the company has consistently driven excellence and innovation in the industry, offering customized solutions for complex materials. Macawber’s commitment to research and development ensures their conveying systems remain at the forefront of technological advancements.
Dense-phase conveying systems offered by Macawber Engineering Systems India
Denseveyor
The Denseveyor® is a low-velocity pneumatic conveying transporter capable of transporting numerous materials using compressed air and nitrogen. Its simple design, with a Dome Valve®, ensures dust-free, cost-effective, and environmentally sustainable operation.
The Macpump
The Macpump is a twin vessel pneumatic conveyer designed for high tonnage bulk material transport over long distances, minimizing rest time and maximizing pipeline conveying capacity by alternately filling and conveying each vessel.
The other products that are part of their product range
- Dome valves
- Dump valve diverters
- Switch valve diverters
- DV type Y diverter valves
Noteworthy projects
| S.no | Industry/Sector | Project description | Project highlights |
| 1 | Paint Industry | Putty manufacturing | Scope consisted of complete plant, design, engineering, supply, manufacturing of bag handling, pneumatic conveying, day silos, batching screws, weigh hoppers, RAV’s, dedusting systems. Total plant capacity of app. 500 TPD with high batch accuracy. |
| 2 | Food industry | Corn flakes manufacturing & packing unit | Scope consisted of design, engineering, supply, manufacturing of bin handling, pneumatic conveying, batching vibratory feeders, and weigh hopper. For muesli mix. |
| 3 | Chemical industry | Pigments & chemicals handling | Scope consisting of pneumatic conveying, piping, bends, filters, automation, etc. |
Guest Author
Mr. Kedar Kamath, a seasoned professional with a BTech in Electrical Engineering from VJTI Matunga, has been instrumental in Macawber India’s success for over 13 years. His expertise spans from equipment design and administration to application engineering and front-end sales. He has also played key roles in sales project management and internal policy design. Kedar’s strategic decision-making and technical expertise have made him a valuable asset to the company. His ambitious vision is to take Macawber India to new heights and establish the company as an industry leader.
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