ATEX Production Plant: Chemical Industry

Every project represents a new challenge for us, and this one was no exception. One of our clients, operating in the chemical industry, entrusted us to design and implement a comprehensive powder system, taking care of storaging, transportation, and dosage of raw materials. The goal was to integrate the new system into the existing production cycle, optimizing the process meanwhile meeting the most stringent safety standards, since part of the system needed to be ATEX compliant.

The result? A system that combines efficiency, safety, and advanced technology, tailored to meet the client’s specific needs.

A Custom System for ATEX Environments

The primary challenge of the project was the requirement to operate in an ATEX-classified environment, where the risk of explosions is significant due to the presence of combustible powders. To address this challenge we had to:

• choose only ATEX-certified materials, electrical components, and accessories, designed to operate safely even under critical conditions;
• Every detail of the system, from the storage silo to the receiving stations, was designed to ensure maximum reliability and compliance with regulations.

Safety was an absolute priority, but not the only one. The system also needed to guarantee efficiency, ease of use, and minimal impact on existing infrastructure.

Dense Phase Pneumatic Conveying System: The System’s Core

The powder transport process was entrusted to a dense phase pneumatic conveying system, a technologically advanced solution that offers unique advantages:

• Energy Efficiency: This system uses minimal amounts of compressed air, reducing consumption and operating costs;
• Gentle Transport: Powders are conveyed at controlled speeds, preserving their integrity and minimizing the risk of material degradation;
• Low Wear: The pipelines and components are made from materials selected to minimize wear, ensuring a long lifespan without frequent maintenance;
• Long-Distance Coverage: In this project, powders are transported over 70 meters, reaching receiving stations without efficiency loss.

This type of transport also stands out for its low impact on the company infrastructures, thanks to its compact design and ease of integration.

The Process: From Raw Material to Finished Product

The system starting point is a new storage silo, installed alongside an existing one, that we overhauled and integrated into the project. Powders are then transferred via pneumatic conveying to receiving stations located in various areas of the facility, two of which are in the ATEX zone.

The receiving stations play a crucial role:

• They separate the air used in transport from the powders, ensuring the product is ready for use;
• They locally store raw materials near the mixing machines;
• They manage dosing with a high-precision weighting system, allowing operators to select the exact quantity required for each recipe.

To transfer the material to the mixing machines, screw conveyors with inverters are used, regulating the flow to optimize mixing and improve the final product quality.

Simple Technology, Maximum Efficiency

Each station is equipped with a touch-screen operator panel with a customized interface designed to be intuitive and user-friendly. Thanks to this configuration it is possible to:

• monitor parameters in real time and adjust system settings;
• Keep track of the supplied quantities and check for discrepancies, creating a complete and network-accessible log.

This simplicity of use translates into quick operator training, minimizing startup times and boosting productivity.

A Versatile System for Every Sector

 Although designed for the chemical industry, this system is also ideal for other industrial applications, including:

• Food Industry: Transport of flours, sugars, and other sensitive powders.
• Construction Sector: Handling of cement powders and granular materials.
• Plastics Industry: Transport of powders and resins.

Thanks to its versatility, low consumption, and reduced maintenance costs, this system represents an ideal solution for companies seeking efficiency and reliability.

Conclusion

This project stands out for well-designed custom solutions combining safety, innovation, and sustainability. The ability to operate in ATEX zones, combined with the efficiency of dense phase pneumatic conveying, makes this setup a winning choice for the most demanding companies.

If you’d like to discover how we can adapt this technology to your needs, contact us: we design custom systems to ensure maximum performance and safety.