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The FPE Global team has extensive experience in designing, building and installing pneumatic conveying systems. We are experts in all types of pneumatic systems and can help you create the right system whatever your operational challenges.
What are pneumatic conveying systems?
Pneumatic conveying systems use a pipe network and air pressure to transport bulk materials from one location to another. Pneumatic conveying systems come in a variety of shapes and sizes depending on the type of material being transported, the transfer distance, and the layout of the production process. There are Dilute or Lean Phase (vacuum and positive pressure systems), and Dense Phase and Neu Phase for longer distances or friable, difficult to handle products.
How do pneumatic conveying systems work?
Above we discussed different phases, the name phase comes from ‘phase density’ this means the mass of product compared to mass of air in the system. The types of system are all classified based on their phase density and operate slightly differently as a result.
Dilute or Lean Phase Conveying Systems
The system can move materials in several ways.
Firstly the material can be suspended in a stream of air that transports them along the pipes (known as a positive pressure system). The air is at a very low pressure, up to around 1 bar gauge with typical conveying velocities in the range of 20-35m/s. This system is ideal for short route, continuous conveying with low throughputs up to 10 tons per hour.
Key features of positive pressure systems:
Suitable for higher pressures
Offer an economical solution
Suitable for multiple destinations
This system also allows for material to be transported by the removal of the air from the system (known as a vacuum system). In this system a suction effect is created by removing the air which pulls the material through the vacuum.
Key features of vacuum systems:
Offer dust free product entertainment
Suitable for multiple entry points
suitable for closed loop nitrogen conveying
keep dust egress to a minimum
It is common to find both material moving methods used in the same system. For example, vacuum system to pick up a raw powder and positive pressure to push it through the pipe network. Both systems are suitable for batch and continuous transfer applications and for batch weighing applications. They can also both be used for conveying explosive products.
Dense Phase and Neu Phase Conveying Systems
In Dense Phase the pipeline operates at pressures ranging from 1-6 Bar gauge with typical conveying velocities in the range of 15-20m/s. This process is ideal for a cohesive or damp product and for high bulk densities. It uses air to push denser pellets down the line in a similar way to a piston. The system can be arranged for either discontinuous or continuous operation. For continuous operation twin blow tanks are used with the HDP rotary valve method to ensure economical filling at pressure.
In Neu Phase the pipeline also operates at pressures ranging from 1-6 Bar gauge with typical conveying velocities in the range of 4-6m/s. This uses a wave like motion to keep the material moving with minimal friction, The low velocity reduces wear making it ideal for fragile or abrasive products.
Key features of these systems:
Suitable for the majority of powdered products
Lower conveying velocities than lean phase
Higher operating pressures
Longer conveying distance achievable
Higher products to air ratios resulting in higher throughputs
Minimal moving parts gives saving on equipment wear
Suitable for hygienic applications and conveying explosive products
The FPE Global Solution
When deciding on a system companies must consider not just the method of transport but also material feeding, separating devices, and running costs. Our years of experience meant that the FPE Global team can talk you through all the stages of the process and design a system that suits the needs of your individual business.. We can select the most appropriate customised design for the application based on our reference plants, material test data and understanding of the inherent strengths and weaknesses of the systems.
No matter what the challenges of your operations, FPE Global can create a system using a variety of technologies to make sure you get the right solution for your needs.
FPE Global engineers have successfully commissioned thousands of individual systems. Our systems offer reliable, low maintenance solutions which are clean, safe and cost effective. Contact FPE Global today to find out how we can help you with all your pneumatic conveyor needs.
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FPE Global offer a wide range of technologies to suit most bulk material handling application whether it be high or low capacity, long or short transfer distances, simple or complicated system designs.
We have an unrivalled mix of capabilities plus a wide range of reference equipment and projects operating across Europe, Asia, Africa and the Americas.
We design and build equipment and systems that optimises the return on capital employed by reduced maintenance, lower power consumptions and most importantly, increased availability and reliability.
We are experts in mechanical belt conveyors, screw conveyors, chain conveyors and bucket elevators to move materials – and also have a complete range of pneumatic conveying solutions.
Bulk Material Handling Systems
FPE can offer truly complete bulk materials handling systems for your business. We can supply the right system for each phase around your production steps, ensuring that the activity of moving raw ingredients, intermediate materials and finished bulk products is a seamless part of your operation.
We provide systems to transfer processed products to final storage or packing and supply bulk packing equipment to put these materials into FIBCs.
As our existing customers know, working with FPE means having a partner who delivers the very best for your business.
Whatever your process, FPE can provide the systems to make it work better.
Mechanical Handling Equipment
Typically mechanical handling systems are used for higher capacity transfer rates in more challenging environments and therefore the conveyors and elevators used need to be robustly designed and built. Our range of mechanical transfer equipment is specifically designed for arduous duties with minimum downtime thus ensuring production are not put at risk. We can manufacture in carbon or stainless steel as required and all equipment is supplied suitable for the appropriate ATEX zone.
We design and manufacture high quality screw, chain and belt conveyors together with bucket elevators with capacities up to 800 tonnes per hour. All equipment is specifically designed for the duty.
Big Bag Discharges and Filling Machines (FIBC)
FPE is the manufacturer of the FLOMAT BAGFILLA range of FIBC discharging and filling equipment. This brand has been an established force in the handling of Big Bags for over thirty years and is able to offer unequalled expertise in the design of equipment to empty and fill 1 tonne FIBCs.
We supply standard discharger configurations that meet most requirements and these can typically be delivered from stock but we are also experts in designing customised arrangements to meet specific process applications. Our bag filling equipment and systems are supplied in a variety of standardised configurations to suit filling rates up to 60 bags per hour. Our years of experience mean we can guarantee the right system specification no matter what bag type is to be used or material is to be handled.