Dense phase pneumatic injection saves energy, improves operations

Metals ProcessingSignificant savings in power consumption, tap-to-tap times and minimization of refractory wear can be realized with the range of dense phase pneumatic convey and pneumatic injection solutions provided by Mac Process.

Iron Steel Brochure
Schenck Process Iron Steel Process Flow Diagram
RotoFeed Batch Data Sheet
Spheri Valve Data Sheet

Improved control of slag iron levels can be achieved through highly accurate, controlled and reliable feed of carbon and lime directly into electric arc furnaces (EAF).


Listed below are some types of systems and processes Mac Process has designed for customers in the metals industry.

  • Granular coal injection
  • Injection of carbon and lime into Electric Arc Furnaces
  • Long distance conveying of lime
  • Carbon conveying and injection within mini blast furnaces, producing pig iron
  • Injection of raw materials used in alternative iron making processes
  • Dense Phase Transfer from a single collection point to either single or multiple reception points
  • Dense Phase Transfer almost all types of dry bulk solid materials to include filter dusts, blast furnace dust, ores, fluxes and fuels
  • Dense Phase Systems available for materials at temps up to 850 degrees F, rates of over 400 tons/hour, and distances up to 1.5 miles, all in a single pipeline
  • Convey and inject metal concentrates, ores, mattes, white metal, silica, coal, dusts, reverts, other additives, alumina, fluorides, cryolite and recycled scraps.
  • Provide solutions for copper, nickel, zinc, tin, lead, aluminum and platinum producers
  • Provide solutions, regardless of process employed, including anode furnaces, aluminum pot lines, carbon houses
  • Submerged stable pulseless lance injection for bath processes
  • Stable and pulseless burner feed for flash type processes
  • Stable and pulseless tuyere injection
  • Transport an array of aluminum refining materials

Technology Review

Dense Phase Pneumatic Conveying

Next generation conveying for the ferrous manufacturing industry

Dense Phase technology is suitable for transporting difficult, abrasive and/or friable materials, and conveying material along a pipe in plug form at very low velocities.

This results in minimal wear on pipes and bends, promoting minimum maintenance and long life. Efficient use of compressed air also gives low power consumption and running costs.

Our complete range of Dense Phase systems have been designed to provide a simple and effective method of transferring material from a single collection point to either single or multiple reception points, and can be used throughout the iron & steelmaking industries to transfer almost all types of dry bulk solid materials including filter dusts, blast furnace dust, ores, fluxes and fuels.

Systems are available for materials at temperatures up to 850°F, rates of over 300 tons/hour, and for distances up to 1.5 miles, all in a single pipeline.

  • Lower energy
  • Lower maintenance costs
  • Lower operational
  • Reduced risk of material costs spillage
  • Increased productivity
  • Increased reliability
  • Reduced system footprint
  • Flexibility to extend application


Mac Process’s high pressure volumetric Rotofeed has been used in abrasive materials systems to inject carbon and lime into Electric Arc Furnaces.The feeder can be adjusted to deliver material over a 5:1 feed rate range. The rate can be changed at any time, on the fly, with accuracy and repeatability. Materials typically injected to EAF’s include:

  • Carbon, for chemical energy and/or slag foaming, either pet. coke or coal/anthracite.
  • Lime/Dolomite for adjustment of slag chemistry
  • Ferro silicon
  • Silicon Carbide
  • Recycled slag and/or spent refractory
  • Plastic/rubber waste

Products can be continuously dosed into process environments at smooth, easily controlled rates up to and over 150 tph, over long distances, with accuracies of ±0.5%, and against back pressures of 450 psig or more if needed.

  • Increased process control
  • Increased injection accuracy
  • Increased productivity
  • Increased reliability
  • Increased utilization of raw material

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