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Pneumatic Conveying

Optimal solutions for


Specialised Mechanical Equipment
TENOVA is a worldwide supplier of advanced technologies, products and engineering services for
the iron & steel and mining industries.
PNEUMATIC CONVEYING SYSTEMS
Tenova TAKRAF ensures the most cost-effective solution,
providing state-of-the-art products, system design,
manufacture, turnkey installations and after-sales service.
I Lean-phase pneumatic conveyors (pressure and
vacuum).
I Medium-phase pneumatic conveyors.
I Dense-phase pneumatic conveyors.
I Pneumatic drying and transport systems.
Tenova TAKRAF markets the Mactenn range of dense-
phase pneumatic conveying systems.

APPLICATIONS
I Minerals and metals (eg base metals, gold, platinum).
I Precious gems, ie diamonds, etc.
I Chemicals and plastics / resins.
I Food / pharmaceuticals.
I Pulp / paper.
I Utility power plants.
I And many other processes and applications.

BENEFITS
Low material velocity along the pipeline considerably
reduces wear and maintenance. Other benefits are
I low air consumption and energy cost.
I little or no degradation of fragile materials.
I small reception hopper filters.
I no segregation of conveyed mixtures.
I environmentally acceptable as total product contain-
ment in the pipeline eliminates spillage, dust and
hygiene problems of exposed product handling.
I compact equipment which can be located beneath
discharge mechanisms.
I state-of-the-art automatic control and fault diagnostics
and operator friendly intervention for manual control.
PNEUMATIC DRYING AND TRANSPORT
SYSTEMS
The Pneumo-Drier dries a wet particulate solid, while
conveying it along a pneumatic conveying system driven
by heated air. Used in the diamond industry to handle
kimberlite, alluvial diamond ore and marine silica, Pneumo-
Driers also convey and dry other materials such as coal,
foundry sands, salt, crushed rubber and platinum.
The Pneumo-Drier is a Bateman owned patent.

THE PNEUMO-DRIER
I Controls drying of and handles moisture levels of up
to 25 %, depending on the nature of the material.
I Maintains system efficiency through continual on-line
temperature monitoring to ensure effective and effi-
cient drying and accurate product dosage.
I Saves cost, being simple and robust with few compo-
nents, replacing dual drying and transport systems.
I Enhances security by securely enclosing material from
entry to delivery, with few handling stages.
I Compact and flexible, requiring far less headroom than
existing systems, whether new or replacement.
I Allows for easy retrofitting into existing establishments,
due to flexibility of pipe routing.
I Environmentally friendly, completely enclosing product
to prevent contamination of product and surrounds.
I Provides optimum availability due to low maintenance.

SPECIFICATIONS
I Conveys up to 30 t/h.
I Dries at up to 350 C, depending on material thermal
properties.
Tenova TAKRAF is a key supplier of equipment and systems for open pit mining and bulk handling, having provided
hundreds of complete systems, as well as individual machines to clients all over the world. Comminution systems for
milling and crushing requirements in mining and mineral processing are based on a track record dating back to the
1920s. Air pollution control, specialised handling equipment, and technology for the cement and fly ash industries and
pneumatic conveying, ensure selection of optimal processing options. A comprehensive after sales service is provided.
Bateman Engineered Technologies (previously part of the Bateman Engineering Group) is now trading as Tenova TAKRAF.
Tenova TAKRAF has a wide range of pneumatic conveying systems, as well as vacuum systems, suitable for conveying
diverse particulate materials. The patented Pneumo-Drier is a technological breakthrough, combining pneumatic
conveying with product drying.
Tenova Mining & Minerals is a total integrated solutions provider to the global mining, bulk materials handling and
minerals beneficiation and processing sectors, offering innovative technological solutions and full process and
commodity knowledge across the mining industry value chain.
LEAN-PHASE PNEUMATIC CONVEYING
Lean-Phase Pneumatic Conveyor systems discharge
granular material from one or many points and are
economical and efficient for conveying relatively low
tonnages over short routes. They are suitable for
conveying food, plastics, chemicals, powders, wood chip,
sawdust, tobacco, cement, scrap metal, ores and more.
Pressure systems are used for multi-discharge point
transfer systems.
I Optimum hygienic conditions vital for food products.
I Optimum availability as it requiries minimal mainte-
nance.
I Throughputs from a few kg/h to over 50 t/h.
I Handling of particle sizes from <1 mm to 40 mm.
I Conveying routes that may be horizontal, vertical and
tortuous, up to over 200 m.
I Propelling forces provided by a Roots-type blower.
I Pressure systems typically using a maximum pressure
of 60 kPa.
I Vacuum systems typically using a maximum negative
pressure of -90 kPa.

MEDIUM-PHASE PNEUMATIC CONVEYING
Medium-Phase Pneumatic Conveying systems provide
the optimum solution for medium-rate transfer of
aeratable, abrasive or friable materials.
I Capacities of up to 80 t/h through various modes of
loading and unloading.
I Air delivered via a Roots-type blower at pressures of
up to 120 kPa.
MACTENN DENSE-PHASE PNEUMATIC
CONVEYING
Mactenn Dense-Phase Pneumatic Conveying systems
utilise low-velocity and high-pressure conditions for high-
tonnage conveying of aeratable or non-aeratable abrasive
or friable powdered, granular and lumpy materials.
I Minimum power requirement, pipeline wear and prod-
uct degradation due to ultra-low conveying velocities.
I Capacities of up to to more than 400 t/h through bot-
tom discharge conveyor vessels.
I Distances of up to 2 km.
I Motive force in the form of high-pressure, low-volume
air supply.
I Pressures typically in the range of 100 kPa to
600 kPa.

ASH CONVEYING SYSTEMS
Ash Conveying systems transfer ash through standard
pipelines at low velocity, using small sized equipment that
is virtually maintenance free.
I Multiple pick-up (feed) points on a single pipeline.
I Low profile equipment excellent for retrofitting.
I Low power cost per ton transferred.
I Maintenance free equipment no continuously mov-
ing parts.
I Very low material transfer velocity schedule 40
pipelines possible.
I FBC bed drains.
I Ash re-injection systems for returning carbon-rich ash
back into the combustion process.
I Long distance ash conveying up to 2,000 m at
temperatures up to 600 C.
Dune Flow Dense Phase: For issues such as power
economy, pipe erosion and material degradation.
Lean and Medium Phase: Ideal for most products.
Vacuum conveying of wet or dry product.
Dense Phase: Excellent regime for fragile or abrasive
materials.
Moving Bed Dense Phase: Used for handling powders
that can be fluidised.
MACTENN PRODUCT RANGE
MINIMAXFLO

The MiniMaxflo

is a sensible altenative to high material


conveying systems, such as lean-phase and medium-
phase pneumatic conveying systems. High efficiency
material transfer without material degradation is achieved
in a very compact, low cost system. This is a perfect
choice for low transfer rate requirements for fragile and
abrasive materials.
MAXFLO

The ultimate system for handling difficult-to-convey


materials and hot, abrasive and wet materials, or for
providing gentle handling of products to prevent
degradation of friable materials or separation of blended
materials.
SUPERMAXFLO

The SuperMaxflo

achieves a solid dense phase


conveying regime for very low material velocities, with little
or no degradation of the most fragile materials, such as
food products.
MACPUMP

& VARIFLO

The Macpump

conveys high capacities over great dis-


tances. It is capable of conveying materials such as
cement, lime and fly ash at rates of 250 t/h up to dis-
tances of 2,000 m.
The Variflo

is a continuous transfer system for longer


distances and rates in excess of the Maxflo

range.
MAXSANDFLO

Designed specifically for dry sand conveying, MaxSandflo

is based on proven dense phase pneumatic principles. Air


introduction, simplified system controls, and top discharge
have been designed specifically for this use. MaxSandflo

can be manufactured without custom modifications and


sold off-the-shelf for fast, easy installation.
MULTIASHFLO

Designed specifically for conveying hot, abrasive ash,


MultiAshflo

conveys bottom ash, clinkers or fly ash from


fluid boiler beds, baghouses or electrostatic precipitators
at temperatures up to 350 C. It may be arranged in
multiples of one to 10 units in a single line. It uses about
50 % less power than existing fly ash conveying systems.
MACTENN INFLATEK

VALVE
Mactenn Inflatek

Valves are fitted to all the Mactenn


dense phase pneumatic conveying systems.
Used in a variety of applications in almost every process,
the Mactenn Inflatek

Valve enables continuous reliable


operation, where conventional valves fail to perform.
Other benefits include
I continuous wear compensation when handling abra-
sive materials or operating under high pressure
differential.
I inflatable seal provides compensation throughout
temperature range of 0 C to 350 C.
I closes and seals through packed material.
I seal protection by cleaning ring removing particles
adhering to the dome surface.
I drive options include automatic double acting actua-
tors.
I reliability heavy duty valve rated for hundreds of
thousands of cycles between inspections in approved
applications.
The Mactenn Inflatek

inflatable seat valve is an innova-


tive departure from the traditional valve seat approach to
achieving sealing efficiency and acceptable valve seat life.
It is unique in its ability to close and seal through a moving
column of material.
PRESSURE TIGHT SEALING
The inflatable flexible seats entrap particles that are nor-
mally the cause of seat erosion. Particles are induced to
move across valve seats under the influence of pressure
differentials on either side of the closing member.
Entrapping particles within a flexible face during the
period of valve closure, prevents particle movement and
considerably reduces valve seat wear. Inflatable seats
allow automatic wear compensation. The seal is easily
removed for inspection.
Standard Options
Size Options: 50 mm to 400 mm
Design Temperature: 100 C to 350 C
Design Pressure: 7 Barg.
Flanges: PN 16, PN 10 or ANSI 150
Construction: Cast Iron A278, Stainless Steel 304/316.
Non-Standard Options
Size Options: To 1,100 mm
Design Temperature: <600 C
Design Pressure: To 43 Barg.
IBAU SCREW PUMP
IBAU Screw Pumps offer a number of advantages.
I The short cylindrical space between the end of the
screw and the non-return flap is filled with pulverised
material during conveying, which means there is no
blowback of air. Therefore
I material feeding is variable between 0 100 %.
I pulsation free charging of material into conveying
line due to sealing plug.
I low wear.
I no penetration of the screw shaft into the
pressurised discharge box.
I The screw is secured in a sturdy barrel with a cone-
shaped inlet connection. This means
I quieter running even under no-load conditions.
I easy removal and refitting of the screw, without
disturbing the bearing seats.

IBAU FPIPE
The IBAU Fpipe conveying system for material removal is
a combination of a normal pneumatic conveying system
and airslide transport.
I Since the final conveying air velocity inside the Fpipe
is 12 14 m/s (normal pneumatic conveying system
is 20 22 m/s), the system needs approximately 30
40 % less conveying air, and energy consumption
is reduced accordingly.
I As the material velocity is approximately 66 % of the
air velocity, it is also lower than usual with resulting
lower abrasive effects.

LEAN-PHASE VACUUM CONVEYING
Suction technology is designed to suit harsh mining and
industrial conditions. Simplicity of design, control and
maintainability is emphasised.
Tenova TAKRAF has the rights to all intellectual property
of Vac Air Technologies and is the sole provider for the
design, manufacture, servicing, installation and supply of
all spare parts for all new and existing pneumatic
equipment, both in positive and vacuum applications.
Suction machines are high performance machines
offering maximum productivity, minimal maintenance and
simple operating techniques. They are
I used successfully to recover fines, diamonds and
other valuable materials in the mining industry.
I ideal for industrial cleaning.
I ideal for dust-free conveying of bulk materials up to
600 C.

SPECIFICATIONS
I Range from small but powerful 3 kW to 325 kW units.
I Conveying distances in excess of 300 m horizontally
and up to 70 m vertically. Negative pressure down
to -90 kPa, depending on product and conditions.
I Can be mobile to enable transportability from plant to
plant, or stationery.
Suction equipment sucks up and transports wet and dry
materials via a pipe column from pick up points to a
collector. The unit may be installed at a reasonable
distance from the collector, depending on the length of
the suction pipeline.
The collector is a standard drop out unit, a cyclone or a
complete filter unit with jet repulse cleaning. This
provides ease of cleaning, as only the vacuum flexible
hose and tools need to be moved.
www.tenovagroup.com
www.bet.bateman.com
TECHINT GROUP
Edition 1 August 2012
MINING & MINERALS
Tenova TAKRAF
Tenova Mining & Minerals (Pty) Ltd
1 Kramer Road
Bedfordview
Johannesburg
PO Box 75996
Gardenview, 2047
South Africa
phone +27 11 201 2300
fax +27 11 455 4547
enquiries.TMM@za.tenovagroup.com
TAKRAF GmbH
Torgauer Strae 336
04347 Leipzig
Germany
phone +49 341 2423 500
fax +49 341 2423 510
sales@takraf.com
Bahnhofstrae 26
01979 Lauchhammer
Germany
phone +49 3574 854 0
fax +49 3574 854 100
service@takraf.com
Tenova S.p.A
Via Albareto, 31
16153 Genoa
Italy
phone +39 010 6054067
fax +39 010 6054710
bulkhandling@it.tenovagroup.com
Tenova MINING & MINERALS
Tenova Mining & Minerals (Pty) Ltd
58 Emerald Parkway Road
Greenstone Hill, Ext 21 1609
PO Box 7737
Johannesburg 2000
South Africa
phone +27 11 899 9111
fax +27 11 899 2302
enquiries.TMM@za.tenovagroup.com

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