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- ISO 9001:2015
Positive Pressure Pneumatic Conveying for Fly Ash Handling
A client in the power & chemical sector faced challenges in handling large volumes of fly ash generated during their process. Their old mechanical handling method created:
Frequent spillage & dust leakage, making the work environment unsafe
High manual intervention, slowing operations and risking operator health
Unreliable material flow, causing bottlenecks in storage and disposal
Non-compliance with pollution control requirements
The client needed a dust-free, efficient, and continuous conveying solution to move ash over long distances.
Material property
Fine, abrasive fly ash with bulk density ~0.8 t/m³
Capacity requirement
15 TPH continuous conveying
Conveying distance
120 meters including bends and vertical lifts
Objective
Continuous operation with reduced manual handling and improved plant cleanliness
Dust-Free Transfer
Complete elimination of visible dust leakage
Higher Throughput
Transfer capacity improved from 3–4 TPH → 15 TPH
Reduced Downtime
60% lower maintenance needs vs mechanical handling
Operator Safety
Minimal manual handling ensured safer working conditions
Compliance:
Achieved pollution control standards (<2 mg/m³ emissions)
By implementing a Positive Pressure Pneumatic Conveying System, Orchid enabled the client to achieve 4X higher throughput (15 TPH) while ensuring a dust-free, reliable, and compliant ash handling process.
Performance Snapshot
| Parameter | Before Orchid (Mechanical) | After Orchid (Positive Conveying) | Improvement |
|---|---|---|---|
| Transfer Capacity (TPH) | 3–4 | 15 | 4X higher |
| Downtime (hrs/month) | 20+ | <8 | -60% |
| Dust Emissions (mg/m³) | 6.5 | <2 | Compliance achieved |
| Manual Labor Requirement | High | Minimal | Safer ops |