Dense phase transport, whether by pneumatic conveying or vacuum, is 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.
Forced dense phase
Characteristics:
Pressure: Pressure (Approx. 4 kg/cm²)
Phase: Dense
Average velocity: Between 5 and 10 m/s
Transfer: Irregular batches
Observations:
Normally for NON-fluidizable products
No fluidization
No injector
Continuous transport with two pulsers in parallel
Pneumatic conveying by pressure in forced dense phase is an advanced technology used to move bulk materials through pipes using compressed air or gas as the transport medium. Unlike other pneumatic conveying systems, this method is characterised by the movement of the material in a dense air flow, where the particles of the material are kept at a low velocity, which minimises wear and improves energy efficiency.
This system is particularly suitable for heavy or granular materials that require delicate and efficient handling without damaging the particles. It is also ideal for applications where long transport distances are needed or obstacles along the route must be overcome.
Generation of the Air Flow: In this system, the transport of the raw material is carried out through a compressed air flow generated by a compressor or turbine. Unlike dilute phase conveying, in forced dense phase, the material is in constant contact with the compressed air, but at a lower velocity.
Movement of the Material: The bulk material is introduced into the compressed air stream through controlled feeding and is propelled by the air pressure through pipes or ducts. Due to the low air velocity, the particles remain in a dense phase, where the air does not exceed the critical transport velocity, resulting in a stabilised flow that is less prone to causing turbulence or material wear.
Material Recovery: Upon reaching the destination, the material is separated from the air through a system of filters and cyclones that capture the particles, allowing the recovery of the material and the separation of any residue or dust that may have remained suspended. The remaining air is filtered to prevent the dispersion of particles into the environment.
Lower Material Damage: Due to the low air velocity in the dense phase, the material is transported with minimal agitation, reducing the risk of damage or wear to the particles. This makes it ideal for fragile or delicate materials, such as food, chemicals, minerals, among others.
Energy Efficiency: Although compressed air is required for transport, the forced dense phase system is more efficient compared to other methods, as the material moves at a controlled speed, reducing energy consumption and improving operational efficiency.
Lower Risk of Blockages: Unlike dilute phase systems, where the material is conveyed at high speeds and may get trapped in points along the pipe, forced dense phase transport reduces the risk of blockages and clogs, as the particles are kept in a more stable flow.
Transport over Long Distances: This system is ideal for transporting bulk materials over long distances or when complex changes in direction are required along the route, such as in industrial plants with multiple processes.
Reduction of Dust and Emissions: Operating in a dense phase significantly reduces the risk of particles being released into the environment as dust, contributing to improved air quality and compliance with stricter environmental regulations.
Pneumatic conveying in forced dense phase is used in a wide range of industries where the efficient and delicate handling of bulk raw materials is crucial. Some of the most common applications include:
Food Industry: In the food industry, pneumatic conveying in forced dense phase is used to move flours, sugar, coffee, granules, and other sensitive products. This system ensures that the materials do not suffer alterations in their structure or quality during the transport process.
Chemical Industry: Bulk chemicals, such as powders and granules, are safely transported without compromising their purity. Additionally, the system helps minimise the risk of contamination or dispersion of volatile products.
Pharmaceutical Industry: In the pharmaceutical sector, where precision and purity are essential, pneumatic conveying in dense phase is ideal for transporting active ingredients, powders, and granules, preventing cross-contamination and ensuring the integrity of the products.
Cement and Mineral Industry: This system is also used to transport cement, clay, limestone, and other materials in the construction and mining sectors. Dense phase transport is especially useful in these industries due to the high volume demands and the need to maintain efficiency over long distances.
Plastic Industry: In the plastic industry, pneumatic conveying in forced dense phase is used to move materials such as polymers, plastic pellets, and other compounds without generating dust, which is crucial for clean and efficient production.
Recycling Plants: This system is ideal for transporting recyclable materials, such as glass, paper, or metals in granules or small pieces. Additionally, it helps maintain an efficient and contamination-free recycling process.
Conclusion
Pneumatic conveying by pressure in forced dense phase is an ideal solution for the efficient and safe transport of bulk raw materials across a wide range of industrial sectors. Its ability to move materials over long distances without causing damage, its energy efficiency, and the minimisation of blockage risks make it the preferred choice for applications where delicate and reliable transport is required.
We are experts in the design and supply of pneumatic conveying systems by pressure in forced dense phase, tailored to the specific needs of each industry. Contact us for more information and to find the perfect solution for your bulk transport process.
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