The component silently killing your pneumatic conveying system's efficiency
Most cement plant and power plant engineers spend months troubleshooting their compressor, their pipeline, their separator — when the actual culprit is a worn rotary airlock valve that nobody thought to check.
Here's what actually happens when a rotary airlock valve degrades:
The gap between the rotor tips and housing bore widens from 0.1 mm to 0.4 mm — barely visible, completely destructive
Air bleeds back from the pressurized conveying line into the atmospheric silo above
Conveying velocity drops, the system chokes, the compressor works 20–30% harder
Energy costs climb. You think it's the compressor aging. It isn't.
The fix is not dramatic. It's a 0.3 mm rotor tip adjustment and a sealing system that can be reset without replacing the whole rotor assembly.
We've seen this exact failure pattern across cement plants from Rajasthan to Odisha. The valve gets replaced, efficiency jumps back to where it was two years ago, and the maintenance team wonders why nobody caught it sooner.
The answer: because nobody was measuring leakage directly. They were measuring symptoms — compressor pressure, conveying rate, energy bills — and attributing them to everything except the airlock.
Full technical breakdown of rotary airlock valve selection, failure modes, and maintenance — oswarrotocorp.in
