Dense Phase Conveying Systems

Pneumatic Conveying for High Capacity and Long Distances

DENSPLUS dense-phase pneumatic conveying tanks are pressure vessel systems that enable bulk solid materials to be conveyed through pipelines at a high solids ratio. In the dense-phase pneumatic conveying method, the material does not disperse sparsely within the air stream; it moves through the pipeline in a dense state. Because the ratio of material to air is high, this method is called dense phase.

| Dense-Phase Pneumatic Conveying Principle

The DENSPLUS dense-phase pneumatic conveying system is one of the most suitable methods, particularly for conveying abrasive, fragile materials or materials whose particle size must be preserved. Thanks to the low-velocity principle, wear on the pipeline and equipment is significantly reduced, the product structure is preserved, and the system operates with lower energy consumption.

The AIRPLUS support-air technology used in VOLDE dense-phase systems helps keep the flow stable throughout the pipeline, contributing to reliable, energy-efficient conveying performance over long distances.

In dense-phase pneumatic conveying systems, conveying air is kept to a minimum, creating a flow with a high material-to-air ratio in the pipeline. For this reason, this conveying method is called 'dense phase.' In this principle, also referred to as 'densveyor,' material is not conveyed by being flung at high speed through the pipeline. Instead, the material moves through the pipeline in dense blocks, transported without fully mixing with the air.

Thanks to this operating principle:

• Conveying speeds are low
• The amount of air used per unit of material is reduced
• Wear on the pipeline and elbows is reduced to a minimum
• The physical structure of fragile or sensitive products is preserved

| Slug Flow

In dense-phase pneumatic conveying systems, material does not move by dispersing continuously through the pipeline. Instead, it moves in dense blocks. This flow form is called slug flow or plug flow.

In this flow form:

• The material forms dense blocks inside the pipeline
• Air pockets exist between the blocks
• These blocks progress in sequence along the pipeline

Thanks to slug flow:

• Conveying speeds generally remain in the range of 5–10 m/s
• Pipeline wear is significantly reduced
• Energy consumption decreases
• Material quality is preserved

For this flow to form stably, air management within the pipeline is just as critical as proper tank design. This is where the AIRPLUS support-air system comes into play.

DENSPLUS ⇢

| Support Air Technology

When long distances or materials with difficult flow characteristics are involved in dense-phase pneumatic conveying lines, support-air systems are used to keep the flow stable throughout the pipeline. The AIRPLUS support-air technology used by VOLDE enables controlled air injection at specific points along the pipeline. This technology:

• Helps keep slug flow stable
• Prevents potential blockages in the pipeline
• Increases conveying performance over long distances
• Enables the system to operate at lower pressure

AIRPLUS ⇢

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Pneumatic Conveying Systems

| Technology That Makes a Difference, the Right Application

The support-air systems used in dense-phase pneumatic conveying lines are a critical engineering matter that directly affects system performance. However, this technology is often misunderstood and thought to simply consist of placing equipment along the pipeline at certain intervals. In reality, achieving stable dense-phase flow depends on delivering air injection at the right point, in the right amount, and at the right pressure level. These parameters vary depending on the properties of the material being conveyed, the pipeline length, line geometry, and system capacity.

The AIRPLUS support-air technology developed by VOLDE is designed to keep slug flow stable in dense-phase pneumatic conveying lines. This system, which provides controlled air support along the pipeline, helps achieve more reliable conveying performance over long distances. Properly designing and implementing support-air systems requires serious field experience and process knowledge in dense-phase pneumatic conveying engineering. Thanks to the experience gained from applications across different sectors, VOLDE optimizes AIRPLUS systems specifically for each project, delivering stable and efficient dense-phase conveying solutions.

| Advantages of Dense-Phase Conveying

_ Suitable for Fragile and Abrasive Materials

The dense-phase pneumatic conveying system enables sensitive or fragile products to be conveyed without damage. Thanks to low-speed, dense conveying, breakage, dust generation, and product loss are minimized for granular or sensitive materials.

_ Energy-Efficient Long-Distance Conveying

The amount of air used per unit of material is lower compared to other pneumatic conveying methods. This makes dense-phase systems an energy-efficient solution for long-distance conveying lines and provides stable performance in applications requiring high capacity.

_ Low Wear and Minimal Maintenance

Thanks to conveying at low speeds, wear on pipelines and elbows is much lower. This extends the lifespan of system equipment and significantly reduces maintenance needs. As a result, dense-phase pneumatic conveying systems offer long-lasting solutions with low operating costs.

| Typical Industrial Applications of Dense-Phase Conveying

Dense-phase pneumatic conveying is widely used, particularly for transferring fine and abrasive materials. VOLDE systems operate reliably across many sectors, including energy, chemicals, plastics, environmental technologies, and mineral processing.

Typical applications include:

• Fly ash pneumatic conveying systems
• Hydrated lime and sorbent dosing systems
• Conveying of PVC and mineral filler powders
• Transfer of activated carbon and process chemicals
• Conveying of biomass and fuel powders

In every application, pipe diameter, tank volume, air consumption, and conveying cycle times are calculated according to the flow properties of the material, and the system is designed for optimum performance.