Case Study: Dilute Phase Pneumatic Conveying for EPS Pellet Distribution
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The Challenge: High-Volume Transport of Low-Density Polystyrene
An expanded polystyrene (EPS) production plant required an efficient way to move lightweight pellets from bulk storage silos to daily hoppers. Because EPS beads have a very low specific weight and are highly prone to static electricity, the system needed a high-velocity air stream to prevent “clogging” and a robust earthing strategy to eliminate ignition risks and material “clinging” within the pipes.
An expanded polystyrene (EPS) production plant required an efficient way to move lightweight pellets from bulk storage silos to daily hoppers. Because EPS beads have a very low specific weight and are highly prone to static electricity, the system needed a high-velocity air stream to prevent “clogging” and a robust earthing strategy to eliminate ignition risks and material “clinging” within the pipes.
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The Solution: Automated Blower & Venturi Injector System
We engineered a high-performance Dilute Phase Pneumatic Conveying System designed for continuous material distribution:
We engineered a high-performance Dilute Phase Pneumatic Conveying System designed for continuous material distribution:
- High-Velocity Air Movement: A 5.5kW Blower provides the motive force, conveying the EPS pellets through a D160mm pipeline at optimized velocities to keep the beads in full suspension.
- Precision Injector Feeding: Material is fed from the primary silo into the air stream via a specialized injector hopper, ensuring a consistent air-to-product ratio and preventing surges.
- Multi-Point Automated Routing: We integrated automatic diverter valves into the network. This allows a single blower package to manage a complex routing schedule: emptying two main silos and precisely feeding two separate daily production hoppers.
- Static Safety Compliance: To manage the inherent static charge of polystyrene, the entire D160mm pipeline is fully earthed (grounded) to HSE and industry safety standards, ensuring safe operation and smooth material flow.
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The Result: Efficient, Safety-First Material Logistics
The automated diverter system transformed the plant’s internal logistics, allowing for a “set-and-forget” distribution cycle. By eliminating manual hopper filling and ensuring 100% static dissipation, the facility achieved a cleaner, safer, and more predictable production flow for their EPS insulation and packaging lines.
The automated diverter system transformed the plant’s internal logistics, allowing for a “set-and-forget” distribution cycle. By eliminating manual hopper filling and ensuring 100% static dissipation, the facility achieved a cleaner, safer, and more predictable production flow for their EPS insulation and packaging lines.
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Pneumatic Conveying System – Technical Specifications Table
| Specification | Technical Details |
|---|---|
| System Type | Dilute Phase (Lean Phase) Pneumatic Conveying |
| Blower Power | 5.5 kW |
| Pipeline Diameter | D160 mm |
| Feeding Method | Venturi Injector Hopper |
| Routing Control | Automated 2-Way Diverter Valves |
| Safety Standard | Full Pipeline Earthing (Anti-Static) |
| Material Handled | Expanded Polystyrene (EPS) Pellets |
| Application | Silo Discharge & Daily Hopper Feeding |