Dense phase transports, whether by pressure or vacuum, are characterised by medium or high pressure and lower speed. (Typically pressure pumps and compressors). The transport pressure with pressure pumps is up to 900 mbar, and with compressors, up to 7 bar.
Dilute phase transports, whether by pressure or vacuum, are characterised by low or medium pressure and higher speed. (Typically high-pressure fans and pressure pumps). The transport pressure with fans is up to 100 mbar, and with pressure pumps, up to 900 mbar.
Dilute, semi-dense, and dense continuous phase
Characteristics:
Pressure: Pressure conveying (Max. 0.9 Kg/cm²)
Phase: Dilute, semi-dense, and dense
Average speed: Between 5 and 20 m/s
Throughput: Very irregular batches
Observations:
Normally for low-density products
Can be with or without fluidisation
With Tangential V or double V
The conveying is continuous
It is an advanced system that uses different pneumatic conveying phases to move bulk materials efficiently, depending on the material characteristics and process conditions. This combination allows the adaptation of the material and air flow to the specific needs of each type of load and transport distance, resulting in a highly flexible and efficient solution for a wide range of industries.
In this system, three distinct phases of pneumatic conveying are used to move the material:
Dilute phase: In this phase, the material is transported suspended in the air with a high air-to-material ratio. The air is injected at high speed, generating a turbulent flow in which the particles remain fully suspended in the air. This phase is used when the material is light or when rapid movement over short distances is required.
Semi-dense phase: Here, the air-to-material ratio is more balanced. The particles are partially suspended but do not float completely in the air. This type of conveying is used when greater control over the material is needed or when it is necessary to reduce the air speed to prevent damage or abrasion of the material.
Dense continuous phase: In this phase, the material is transported in a dense bed, with a low air-to-material ratio. The particles remain suspended but in a more controlled manner, and the air flow is smoother. It is mainly used for heavier or more delicate materials that require efficient transportation without excessive use of compressed air.
The combined system automatically or manually adjusts the conveying phase based on the material type and operating conditions, ensuring a constant and efficient flow throughout the process.
This type of pneumatic conveying system is especially useful in situations where the material to be conveyed has variable characteristics or where the transport processes need to be optimised based on changing environmental conditions. Some of the most common applications include:
Food industry: For conveying various bulk ingredients, such as flours, sugars, salt, spices, or powdered products, which require careful yet flexible handling depending on the fragility or abrasiveness of the product.
Pharmaceutical industry: For moving active powder materials, excipients, or sensitive products, where the flexibility of the system is key to adapting to variations in material density and transport distances.
Chemical industry: In the handling of powdered or granular chemicals, where transport conditions may change depending on the nature of the material, such as pigments, fertilizers, or petrochemical products.
Recycling and waste treatment: For conveying recyclable materials or solid waste with variable characteristics, such as powders or large particles, allowing the system to adapt to the needs of the moment.
Construction materials industry: For moving products such as cement, plaster, lime, or aggregates that may vary in size and shape, requiring a conveying system capable of adapting to different phases to optimise the process.
Flexibility and adaptability: By combining three conveying phases, the system can automatically adapt to the material characteristics and process conditions, making it ideal for environments where materials with different physical properties are handled.
Optimisation of energy consumption: By using compressed air efficiently based on the selected conveying phase, energy consumption can be reduced, especially in phases like the dense phase, where less air is required.
Increased conveying capacity: The ability to switch between dilute, semi-dense, and dense phases allows for the transportation of a wider variety of materials, both light and heavy, without losing efficiency.
Reduction of wear and damage: Controlling the air flow and the adaptability of the phases minimises wear on pipes and other system components, while protecting sensitive materials from damage or abrasion.
Greater control over the process: The combination of phases provides greater control over the speed and distance of transport, resulting in more precise handling of bulk materials.
Optimisation of transport distance: Depending on the process requirements, the system allows materials to be conveyed over long distances without loss of performance, making it ideal for complex industrial installations.
More complex maintenance: As the system manages three different conveying phases, maintenance needs to be more detailed, especially in the controls and regulation systems that enable phase switching.
Implementation cost: Installing a combined system with multiple phases may have a higher initial cost due to the need for specialised equipment and advanced control infrastructure. However, this cost can be offset by greater long-term efficiency.
Precise control required: To ensure the system's effectiveness, it is essential to have precise control over operating conditions, such as air pressure and flow velocity, which may require advanced monitoring systems and trained personnel for management.
The combination of pneumatic conveying by pressure in dilute, semi-dense, and dense continuous phases is a highly versatile and efficient solution for bulk material handling. Its ability to adapt to different types of materials and transport conditions makes it an excellent choice for industries handling a wide variety of products. Additionally, by optimising air consumption and reducing system wear, this approach offers a perfect balance between operational efficiency, flexibility, and cost.
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