Dense Phase Pneumatic Conveying Systems

What is Dense Phase Pneumatic Conveying?

Dense phase pneumatic conveying is a type pneumatic conveying and a method of moving bulk materials through pipes using low air velocity (as low as 100 fpm) and high pressure (15–100 psi). Materials travel in compact “slugs” rather than being suspended in air. This system is ideal for abrasive, fragile, or heavy materials like sand, cement, and pellets because it reduces damage and equipment wear. It uses a high material-to-air ratio and typically includes compressors, pressure vessels, piping, and filters. Dense phase systems must be carefully engineered to ensure consistent flow and reliable performance.

Where Dense Phase Pneumatic Conveying Fits Within Pneumatic Conveying Systems

Pneumatic conveying systems are not used in all applications and are best used for moving materials like powders, pellets, and other products. Within pneumatic conveying, dense phase fits a certain kind of need and exists within a broader set of pneumatic conveying approaches. Many aspects of where dense phase fits into pneumatic conveying systems include:

When Dense Phase Pneumatic Conveying is Used

The high-pressure, low-velocity conveying makeup ensures that dense phase conveying systems are the ideal choice for many applications involving fragile and abrasive materials. Dense phase conveying also provides long-distance transport for many needs. Common applications of dense phase pneumatic conveying include:

• Transferring catalysts, pigments, and fine powders into reactors in chemical & pharmaceutical
• Moving fly ash, bottom ash, and sorbents in power plants for power generation
• Transporting many materials in environmental control systems
• Moving raw building materials from mixers to filling lines or handling materials that tend to segregate or clump
• Transporting delicate products, powder & ingredients, and pre-blended items in food and beverage

Key Dense Phase Conveying System Design Considerations

Designing dense phase conveying systems involves many considerations to ensure a system capable of maximum performance. IR Process has developed the most efficient style of dense phase conveying by utilizing air injectors to inject energy along the entire convey line.  Our staff has over 120 years of experience designing and supplying start of the art dense phase pneumatic conveying systems. We take a comprehensive process engineering approach to our systems and our design-build structures. Some key considerations include:

• Material characterization and testing: Review of materials being processed, including particle size distribution, bulk density, and cohesiveness and flowability of the material
• Pipeline layout & routing considerations: Ensuring short and direct, minimal elbows/bends, avoiding inclines, and whether to use vertical or horizontal
• Air supply, pressure control, and system control philosophy

Dense Phase Pneumatic Conveying as Part of a Complete Process System

While dense phase pneumatic conveying is great for transporting materials, the specialty fits into an overall process equipment structure to suit an entire process makeup. The dense phase conveying structure ultimately uses high-pressure and low-velocity to move materials from and to bulk storage & ingredient, batching & feeding, and blending, mixing & agitation systems through the conveying line. After removing these materials, the process system also uses a bagging and packaging system to collect the transported materials. This system is designed as part of a whole, and many other process systems should be designed alongside additional systems for the most efficient performance outcomes.

How IR Process Approaches Dense Phase Pneumatic Conveying

IR Process has specialized in the design, development, and integration of complete industrial process systems for customers across North America. We take an engineering-first, system-driven approach to consider all factors at play to design a system that will meet the unique requirements of each situation. Our process involves collaborating with our customers during a pre-engineering phase to gain all their needs and expectations, then developing a system that goes beyond these needs. We develop multiple process engineering systems to fit any need, and can be your one-stop shop for a reliable and efficient system.

Discuss Your Dense Phase Conveying Application

For a top high-pressure, low-velocity system designed for abrasive materials, reach out today! Contact us to discuss your dense phase conveying needs or request a quote for more detailed pricing.