Dense phase transports, whether by pressure or vacuum, are characterised by medium or high pressure and lower velocity. (Typically pressure pumps and compressors). The transport pressure with pressure pumps is up to 900 mbar, and with compressors, it is up to 7 bar.
Dense phase booster injectors
Characteristics:
Pressure: Pressure (Max. 6 kg/cm²)
Phase: Dense
Average velocity: Between 1 and 5 m/s
Transfer: Continuous batches
Observations:
Normally for non-fluidisable fine products
Without fluidisation
With injectors
Continuous transport with two pulsers in parallel
It is an advanced variant of pneumatic conveying systems, specifically designed to move bulk materials efficiently over long distances. This system incorporates booster injectors, which are devices that increase the air pressure at strategic points in the process to enhance the system's performance and ensure a constant material flow, even in situations that require high transport capacities.
In this type of pneumatic conveying, the material is introduced into a conduit along with compressed air, similar to the fluidised dense phase conveying process. However, instead of relying solely on the air pressure provided by the main compressor, the system includes booster injectors, which are devices located at key points of the system. These injectors act as pressure amplifiers, increasing the air energy as it moves through the conduit, facilitating the movement of heavier materials or those with difficult-to-handle characteristics.
The booster injectors allow compressed air to flow with higher pressure at certain points of the system, ensuring that the material flows at a constant and efficient speed, without blocking or creating excessive friction. This combination of compressed air and flow reinforcement through the injectors ensures that the system operates at high capacity without the need for large volumes of compressed air.
Pneumatic conveying by pressure in dense phase with booster injectors is used in a wide variety of sectors, especially where there is a need to transport large volumes of bulk material or materials with particular characteristics that hinder flow in conventional systems. Some of the most common applications are:
Mining industry: For the transport of minerals and metals in powder form, which require robust and efficient handling.
Chemical and petrochemical industry: In the transport of bulk chemicals, such as fertilisers, pigments, calcium carbonate, and other compounds with physical characteristics that may block conventional systems.
Food industry: For handling powdered products such as flours, sugar, salt, or granulated ingredients that must be transported delicately yet efficiently.
Construction materials industry: For moving materials such as cement, gypsum, lime, and bulk additives, which can be abrasive and difficult to move without reinforcement systems.
Recycling and waste management: In applications where recyclable materials or solid waste, in the form of powder or fine particles, are transported.
Increased transport capacity: The booster injectors increase the air pressure, allowing large volumes of material to be moved even over long distances, without excessively increasing air consumption.
Better handling of difficult materials: The system is ideal for materials with complex characteristics, such as fine powders, highly abrasive materials, or those that tend to compact or block conventional pneumatic systems.
Energy efficiency: Although the system uses additional compressed air through the boosters, this method reduces the need for large compression systems, as the injectors optimise the use of air in key areas.
Lower equipment wear: The use of injectors allows for maintaining a controlled transport speed, minimising wear on pipes, valves, and other system components.
Flexibility: The system can be adapted to different types of materials and pipeline lengths, making it a versatile option for various industries.
Greater transport distance: Thanks to the pressure boost, this system is more effective in applications that require transport over greater distances or in systems with complex and long pipelines.
Specialised maintenance: Due to the booster injectors, more frequent maintenance is required on these parts of the system to ensure they function properly and avoid pressure losses or blockages.
Installation and operational cost: The incorporation of the booster injectors may make the initial investment higher, but the benefits in terms of transport capacity and operational efficiency often offset this additional cost in the long term.
Precise air control: To maximise efficiency, a well-designed air pressure control system is needed, which allows for regulating the action of the booster injectors according to the process requirements.
Pneumatic conveying by pressure in dense phase with booster injectors is a robust and efficient solution for the handling of bulk materials, especially in industrial applications that require the transport of difficult products or large volumes. With the help of booster injectors, the system maintains a high transport capacity over long distances, without compromising energy efficiency or significantly increasing equipment wear, making it an ideal option for companies looking to optimise their bulk material handling processes.
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