Hatch PneuCalc v8.0.3: Pneumatic Conveying System Design & Analysis Software

Hatch PneuCalc v8.0.3 is a comprehensive engineering software program used to design, analyze, and troubleshoot pneumatic conveying systems that move bulk materials using air or gas through pipelines—common in industries like mining, cement, chemicals, food processing, and power plants . Developed by Hatch, a global engineering firm with over 60 years of experience, PneuCalc helps engineers determine optimal pipe diameters, calculate airflow and pressure requirements, predict material flow behavior, detect blockage or wear risks, and analyze both dense-phase and dilute-phase conveying modes .

Unlike standard industry guidelines—which do not exist for pneumatic conveying—PneuCalc eliminates guesswork by providing a clear, step-by-step workflow with real-time calculations and red flag alerts when design parameters exceed safe limits . Version 8.0.3 continues to build on over 20 years of proven performance, offering drag-and-drop interface, robust material and gas property databases, and advanced visualization of flow modes at every point in the system.

???? Primary Users

This professional pneumatic conveying software is designed for:

  • Process & Plant Engineers designing, optimizing, and troubleshooting pneumatic conveying systems for bulk materials.

  • Mining & Cement Industry Professionals handling powders, minerals, and cement across long distances.

  • Chemical & Petrochemical Engineers designing systems for plastic pellets, resins, and chemical powders.

  • Food Processing Engineers moving grains, flour, sugar, and other food-grade materials.

  • Pharmaceutical & Plastics Manufacturers designing systems for tablets, granules, and polymer pellets.

⚡ Key Features & Capabilities

???? Conveying Mode Analysis

  • Displays dilute, dense, and mixed flow modes at each point of the system, allowing users to clearly understand how material behaves in the pneumatic conveying process .

  • Distinguishes between pressure and vacuum systems, with full support for both types .

???? Material Behavior Prediction

  • Material saltation velocity calculator determines the minimum air velocity required to prevent material settling in horizontal pipes .

  • Automatic Geldart material group classification helps quickly classify powders based on their fluidization characteristics .

  • Predicts blockage risks, wear points, and potential refluxing in vertical sections .

???? System Design & Optimization

  • Pipe diameter and geometry optimization for efficient material flow .

  • Acceleration zone length calculation ensures proper material pick-up velocity .

  • Sloping line verification for gravity-assisted sections .

  • Evaluate effects of different feed points, direction changes, and vertical pipe sections on conveying efficiency .

???? Airflow & Pressure Calculations

  • Calculate required airflow and pressure for system operation .

  • Automatic parameter verification for minimum/maximum velocities and maximum pressures .

  • Calibrate calculations based on real-life application data for accurate results .

????️ Database & Reporting Tools

  • Robust material and gas properties database—customize, reuse, and share across projects .

  • Export data for reporting, specifications, equipment datasheets, and more .

  • Supports both imperial and metric units .

???? What’s New in Version 8.0.3

  • Refined material classification algorithms for more accurate Geldart grouping.

  • Enhanced database connectivity for sharing custom material properties across teams.

  • Improved red flag alert system for critical design parameter violations.

  • Expanded reporting options for equipment datasheet generation.