Dense Phase Conveying Case Studies

Cement Dense Phase Conveying System

Filquip has supplied a Cement Dense Phase conveying system that has been in operation since 2012. The project involved the Design, Supply, Installation and Commissioning of a bulk bag unloading & Dense Phase transfer system for a 50m conveying distance at 35TPH.
Supply, Install and Commission Cement Unloader and Storage System:

  • Dense Phase Transfer System (BART One 900 System).
  • Cement Silo (100T Silo).
  • Silo Overfill Protection Panel.
  • Silo Dust Venting and Pressure Relief Valves.
  • Loading Bellows with integrated Dust Extractor (BellowJet Model).
  • Bulk Bag Unloader with cutting blades and integrated Dust Extraction System.
  • Air Compressor, Air Receiver and Weather Shelter.

This bulk bag unloading & transfer system has saved the client labour time and manual handling. The dense phase unit transfers the white cement faster than the forklift operator can load the bags, minimising the time required to fill the out-loading storage silo which then fills tanker trucks.

Stone Dust Dense Phase Transfer System

Filquip has supplied and commissioned a Stone Dust Dense Phase Transfer System to convey the quarry stone dust from the air classifiers to a Storage Silo at a distance of 60m and throughput of 40TPH. Filquip also supplied a Dust Conditioning System to the Storage Silo which conditions the stone dust so it can be loaded into open trucks for return to the quarry pit.
The following equipment package was supplied:

  • Dense Phase Transfer System (BART One 900 System).
  • Airline Dense Phase Boosters.
  • Compressed Air Receiver.
  • Dust Conditioning System (Dustfix 80 Model).

This dense phase transfer system replaced a Z-Conveyor previously being used which was failing on a fortnightly basis due to the extreme abrasion of the stone dust. The BART ONE 900 provides a reliable solution which minimises the maintenance requirements of the quarry.

Mixed PVC Resins Dense Phase Conveying

Filquip has supplied a Mixed PVC Resins Dense Phase conveying system that conveys the mixed PVC from the cooler to the storage hoppers before the extrusion lines. The project involved the Design, Supply and Commissioning of a the Dense Phase systems to fit into the pit underneath the existing cooler systems and convey the PVC powders a distance of 60m at a rate of 20 TPH.
The following equipment package was supplied:

  • Dense Phase Transfer System (BART One 900 System).
  • Receiver Silotop Dust Collectors.
  • Compressed Air Receiver.
  • Dense Phase Air Supply Boosters.

This dense phase conveying system provides the customer a solution to transporting the specific mixed PVC product at 20TPH from the mixer cooler 60m to each of three Injection Silos without product stratification and reduced wear on the pipelines.

Container Unloading and Transfer System

Filquip has supplied, installed and commissioned a Container Unloading and Transfer System for Unloading Containers of PVC powders and conveying it into Storage Silos. The system has been sized to fully decant a container of PVC powder in 45 minutes.
The following equipment package was supplied:

  • Container Unloading Chute and Screw Conveyor.
  • Intermediate hopper between Screw Conveyor and Dense Phase Conveyor (2.2m3).
  • Dense Phase Transfer System (12TPA500).
  • Compressed Air ReceiverBulk Bag Unloader system for additional feed from bulk bags into the storage silos.

This container unloading and transfer system from Filquip saves the customer considerable cost on specialised container suck/blow unloading trucks as simple container lifting trucks can be utilised to deliver raw materials. Along with providing a dust free bulk bag unloading system giving flexibility of raw material procurement options to the company. The system transfers full 20T Container loads of PVC or Calcium Carbonate up to 60m to four different selectable silo locations in 45 minutes.

Manganese Dioxide Dense Phase Conveying

Filquip has supplied and commissioned a Dense Phase Conveying System for the transport of Manganese Dioxide from Bulk Bags into a weigh hopper on the Brick Manufacturing line. The system is capable of conveying 1.5T per hour of Manganese Dioxide a distance of 20m.
The following equipment package was designed, supplied and commissioned:

  • BARTONE 80 Dense Phase Conveying System (80L Vessel).
  • Conveying Line Air Boosters.

The experience of Filquip with handling abrasive and difficult products such as Manganese Dioxide using Dense Phase Conveying technology provided a compact Unloading and Conveying system that could be installed into the tight space available in the operating brick manufacturing plant.

Lime Dense Phase Conveying

Filquip has supplied and commissioned a Dense Phase Conveying System for the movement of Hydrated Lime from Bulk Bags into a weigh hopper on the Brick Manufacturing line. The system is capable of conveying 1T per hour of Hydrated Lime a distance of 20m.
The following equipment package was designed, supplied and commissioned:

  • BARTONE 50 Dense Phase Conveying System (50L Vessel).
  • Conveying Line Air Boosters.

The experience of Filquip with handling difficult products such as Hydrated lime using Dense Phase Conveying technology provided a compact Unloading and Conveying system that could be installed into the tight space available in the operating brick manufacturing plant.

Sand Dense Phase Conveying

Filquip has supplied and commissioned a Dense Phase Conveying System for the transport of Sand from Bulk Bags into a weigh hopper on the Brick Manufacturing line. The system is capable of conveying 0.5T per hour of Sand a distance of 20m.
The following equipment package was designed, supplied and commissioned:

  • BART Dense Phase Conveying System (24L Vessel).
  • Conveying Line Air Boosters.

The experience of Filquip with handling abrasive such as Sand using Dense Phase Conveying technology provided a compact Unloading and Conveying system that could be installed into the tight space available in the operating brick manufacturing plant.

Sugar Dense Phase Conveying System

Filquip has specified, supplied and commissioned a Sugar Dense Phase Conveying System to transport 6TPH of sugar a distance of 270m between the existing sugar refinery and the new sugar processing facility on the other side of the plant.
The following equipment package was supplied by Filquip:

  • Full Pipeline Dense Phase System for White Sugar 12TPA600 FP Model.
  • 1699L Vessel Capacity, Hazardous Zone 21 Rated, IECEX Certified Instruments.
  • Inclusive of Electrical Control and Air Control Panels and Pipeline Air Boosters.

Without this Dense Phase conveying system, the sugar refinery would not be able to build the new processing facility on the other side of the plant 270m away with 8 pipe bends and receive the sugar in a cost-effective manner.

Clinker Dense Phase Conveying

Filquip has specified, supplied and commissioned a Clinker Dense Phase Conveying system to transport 3TPH of Abrasive Clinker Dust a distance of 140m from the grinding plant bag house dust collector to the process silos. This system allows the customer to recycle the clinker dust into the process:
The following equipment package was supplied by Filquip:

  • Full Pipeline Dense Phase System for Clinker Dust 8TPA100FP Model.
  • 283L Vessel Capacity, Throughput capacity of 3,000kg/hr at 140m distance.
  • Inclusive of Electrical Control and Air Control Panels and Pipeline Air Boosters.
  • Drop Through Rotary Valve (Model RV05.20, CS, 1.1kW Motor).

With the extreme abrasion of the clinker dust the Full Pipeline Clinker Dense Phase System provides a reliable solution with minimised maintenance requirements for the plant while retaining the dust and returning it to the process to reduce company costs.

Salt Dense Phase Conveying

Filquip has specified, supplied, installed and commissioned a skid mounted Salt Dense Phase Conveying system to transport 1TPH of Sodium Sulphate Salt from IBC containers to a receiver hopper.
The following equipment package was supplied by Filquip:

  • 24L SS304 Dense Phase Conveyor
  • PLC Dense Phase Control Panel Locally Mounted
  • Forklift moveable SS304 Skid fabricated with local air receiver
  • Compressed air filtration package for clean dry air on the skid
  • Fabrication and installation of Site Receiver Hopper on load cells
  • Site installation of conveying pipeline with camlock connection

The installation of this system has allowed the plant operators to load an IBC of product onto the Salt Dense Phase Conveying Skid and transfer it up into the plant weigh hopper on demand from the control room for each mix that required it, saving manual handling and labour from the previous hand pouring method.