Pneumatic powder conveying: Movingfluid pumps

In this article:

• From manual to automated conveying: a question of efficiency
• How Movingfluid’s proposed pneumatic powder conveying pump works
• The in-house test to dispel any doubts
• All advantages of the dense phase pneumatic pump: a concept that revolutionises powder conveying

Pneumatic powder conveying: the Movingfluid revolution for Synthesis Spa

When we say our job is not to sell a product no matter what, but to provide the best solution for every customer, we truly mean it. This is demonstrated by the case of Synthesis Spa which specialises in the distribution of petroleum and petrochemical derivatives, and now saves up to 15% raw material thanks to our pneumatic powder conveying pump.   

Yet, at first, this was not what the company had in mind: this is how we responded to their need and helped improve production, environmental safety and results in just two weeks, exceeding expectations.   

From manual to automated conveying: a question of efficiency

When Synthesis came to us, they knew what they wanted: to switch from manual conveying of powders for the production of a special grease, to automatic conveying. Until then, the oxide powder needed for the compound was added by the operator inside the chemical reactor where it was mixed with the oil. An unnecessarily wasteful operation, in many respects: due to its high volatility, powder tends to spread into the environment with consequent waste; personnel must spend their time filling and replacing batches; the line suffers constant production stoppages with potential repercussions on the quality of the finished product.

Precisely to address this obvious shortcoming, Synthesis had already turned to the ARO® pumps, of which Movingfluid is an authorised distributor. High-performance solutions but which, due to their particular technical specifications, did not lend themselves to the needs of the case. And this is where the added value of our expert consultants comes into play. They guided the Parma-based company in the purchase of another system as simple as it is perfect for the purpose: the dense-phase powder conveying pneumatic pump.  

How Movingfluid’s proposed pneumatic powder conveying pump works

Ideal for handling powders and granules, the pneumatic pump allows solid materials to be transported from the collection batch to the reactor without contamination and environmental dispersion. To do so, it makes use of compressed air: it creates a continuous and adjustable double suction and release movement through a system of four asynchronously opened and closed propeller pipes. In fact, a simple pressure reducer is sufficient to customise the amount of powder per minute required for mixing, in a range from 0 to 8 kg per minute.
This way, pressure generated inside the sealed mixing tank can also be monitored, minimising smoke in the delivery.   

Powders can be of different grain sizes and compositions, always distributed in dense, undiluted stage.

Furthermore, the patent-protected pump can also handle materials over long distances (up to 40 m with a height difference of 10 m thanks to the constant differential pressure) and integrate perfectly into any existing system thanks to its compact dimensions.

Lastly, it is extremely user-friendly and can also be interfaced with a PLC for logical process management.

All aspects that Synthesis Spa was able to see first hand and appreciate from the very first use, when the device was still being tested. 

The in-house test to dispel any doubts

How do you measure a company’s professionalism? In our opinion, with actions more than words.
For this reason, in addition to the documentation and technical details, we offered Synthesis Spa the option of carrying out a paid test of the pump at favourable conditions: if the test was successful, we would deduct the cost from the total cost of the machine. We then installed the pump in the production line, calibrated the amount of powder per minute required for preparation and let the operators use it independently for a fortnight.  

At the end of the agreed period, not only was the order confirmed, but a further working table was opened for a second job in another production branch.

To date, an overall saving of 15% on product waste and 10% on operator time has been quantified: numbers that, when translated into raw material and human resource costs, are even more significant. And these are certainly not the only advantages of our solution! 

All advantages of the dense phase pneumatic pump: a concept that revolutionises powder conveying

As previously mentioned, operation of the pump is quite straightforward and so is its design: ingenious in its apparent simplicity, it provides several benefits.  

It is worth mentioning first of all the evident ones, some of which have already been covered:  

• the absence of material dispersion, at all stages. Whereas previously it was required to cut the batch, for example, it is now sufficient to drill a 4 cm diameter hole to allow the pick-up pipe to draw the powder without it being released into the air;   

• a practice that also has positive effects on the quality of the surrounding environment and on potential contamination and leakage, thus on the ecological and economic level; 

• reducing operator workloads, allowing them to take care of more skilled tasks instead of wasting time on repetitive and delicate activities. 

 In addition to these, there are several others closely related to the pump configuration and its use.   

Continuous and faultless production

On a technical level, the dense phase pump helps improve the precision and quality of the final product. In contrast to manual dosing, it is possible to adjust the amount of powder to be fed per minute with a high degree of accurately, also differentiating it according to the type of mixture to be prepared.

Furthermore: there is no longer any need to stop production, as the pump is designed to work even when dry without damage. What does this mean? That the system operates continuously With this solution, there is no need to stop the production cycle to open the mixer, fill it and start it up again each time, as is normally the case when an operator is present: simply replace the supply batch without switching off the device.

Breakage and segregation of powder or granular material are typical problems in conveying, but not for this dense phase pump. Operating at controlled speeds, it prevents degradation and separation of sensitive granules and powders, which remain intact. This results in a uniform, smooth and correctly formulated end product. Qualitatively impeccable.  

Minimised consumption and maintenance

The medium/low speed at which the dense phase pump operates is also crucial for another reason: this way, friction and erosion of the pipes caused by the passage of material is minimised. This extends the lifespan of individual components, which are also easy to maintain. The rubber hoses are easily cleaned by means of a blast of compressed air, and can be quickly replaced when worn out.

Less wear therefore and less energy consumption: this system uses less compressed air than diluted phase systems – and in greater quantities per unit of time – which results in less energy used and increased production.  

Versatility and safety and quality certifications

If you know us, you already know that solving one problem for us is not enough: whenever possible, we try to anticipate and solve more. The dense phase pump fully meets this criterion: it is ATEX certified for use in explosive environments and can be supplied with FDA-compliant materials for the food industry.

A feature that allows various companies to use it for conveying powders, granulates and polymers. Any examples?

In addition to chemical and food sectors, it can be applied in pharmaceutical and ceramic, as well as in the automotive sectors (e.g. for powder vehicle coating, thanks to easy cleaning and contamination-free colour change).

All areas that would benefit greatly from the implementation of automated systems such as those designed and implemented by Movingfluid.

Synthesis Spa was well aware of its production deficit and acted promptly to resolve it, however not all companies possess the same degree of awareness and foresight. Very often, in fact, the most incisive operational and economic optimisations arise from the resolution of problems that companies are not even aware of: actual misfortunes that compromise their efficiency and quality. Fortunately, we at Movingfluid are always ready to step in, even – and especially – where others cannot.  

Do you also still resort to manual powder conveying and dosing?
It is time to evolve and get the most out of technology!

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