Dilute-PhasePneumaticConveyingofFillerinSemarang

This article presents a complete case study of a dilute-phase pneumatic conveying system for inorganic filler powder in Semarang, Indonesia. The optimized project title is "Dilute-Phase Pneumatic Conveying of Filler in Semarang." It is a representative pneumatic conveying case in Southeast Asia, demonstrating how dilute-phase conveying can efficiently handle fine mineral powders with low cost, high safety, and minimal environmental impact. The keywords for this content are: pneumatic conveying case, Southeast Asia pneumatic conveying, and dilute-phase pneumatic conveying.

The client operates a large processing plant in Semarang that uses inorganic fillers such as calcium carbonate in manufacturing rubber, plastics, and paints. The filler powder arrives at the plant in bulk and had to be transferred from an unloading area to four storage silos, which then fed the production lines. The previous mechanical system, consisting of bucket elevators and screw conveyors, suffered from frequent jamming, high maintenance, dust leakage, and product contamination. The plant management therefore sought a modern, sealed, and energy-efficient conveying solution. After evaluating several suppliers, they selected Shandong Headpowder Engineering Co., Ltd. (headpowder) to design and deliver the complete system.

Headpowder's engineering team conducted a detailed site survey in Semarang and measured the physical properties of the filler. The powder had a mean particle size of about 15 microns, a bulk density of 0.65 t/m³, and a moisture content below 0.3%. Based on these data, the system was designed for a conveying capacity of 8 tons per hour. The total conveying distance from the feed hopper to the farthest silo was 150 meters, including a vertical lift of 22 meters. The dilute-phase conveying method was selected because it provides a simple and cost-effective way to move such powders, with the material suspended in a high-velocity air stream generated by a positive displacement blower.

The key equipment included a 75 kW roots blower, a rotary airlock valve, an abrasion-resistant carbon steel pipeline with a diameter of 168 millimetres, and long-radius bends equipped with replaceable wear plates. Each of the four storage silos was fitted with a baghouse filter to separate the powder from the conveying air, a rotary discharge valve, and high/low level sensors. A programmable logic controller (PLC) managed the automatic switching between silos and monitored pressure and airflow throughout the system. The conveying velocity was set at approximately 22 metres per second, which balanced efficient transport with low particle degradation and pipe wear.

All components were prefabricated at headpowder's facility in Shandong, China, and shipped to Indonesia. The installation phase took twelve days, using a team of fitters and electricians from headpowder together with local workers. During commissioning, the tropical humidity made the filler powder slightly cohesive, which initially caused irregular flow. To solve this, the engineers integrated a small purge-air drying unit at the feed hopper and slightly increased the discharge temperature of the blower. These adjustments improved the powder's flowability. After the modifications, the system passed a continuous 72-hour performance test without any blockage, achieving a throughput of 8.2 tons per hour.

The new system delivered outstanding results for the client. Energy consumption was approximately 55 kilowatt-hours per ton of material, which was 20% lower than the previous mechanical conveyor. Material losses during conveying were less than 0.05%. Because the entire line was sealed, dust emissions were completely eliminated, improving the working environment and meeting strict local environmental regulations. Noise levels were also reduced to below 75 decibels. The PLC-based controls allowed easy operation, and the modular design made future expansion to an additional silo straightforward.

This successful project has become a benchmark for pneumatic conveying cases in Southeast Asia. It proves that dilute-phase pneumatic conveying is a reliable, economical, and environmentally friendly solution for inorganic filler powders in humid tropical climates. headpowder, headquartered in Shandong, China, has since applied the lessons learned in Semarang to other projects in Vietnam, Thailand, Malaysia, and the Philippines. The company's expertise includes dense-phase and dilute-phase pneumatic conveying, storage silos, filtration systems, and complete bulk material handling engineering.

For more information about this pneumatic conveying case or any related requirements, please contact the sales manager, Manager Zhang, at Shandong Headpowder Engineering Co., Ltd., located in Shandong, China. The WeChat number is 156627771. Headpowder is committed to providing tailor-made solutions and reliable service to clients across Southeast Asia and around the world.