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Dense Phase Conveying Systems
Dense Phase Conveying Systems
Low-Velocity Pneumatic Conveying for High Capacity and Long Distances
DENSPLUS Dense Phase Conveying Systems are engineered for the pneumatic transfer of powders and granules at high solids loading and low conveying velocities. Material is transported through the pipeline using controlled compressed air, with substantially less conveying air than conventional dilute-phase systems. The low-velocity conveying principle makes DENSPLUS particularly suitable for abrasive, fragile and degradation-sensitive materials, as well as demanding applications involving long conveying distances and complex pipeline routes. Each system is engineered according to the material characteristics, required capacity, conveying distance and pipeline geometry to achieve stable material flow with controlled air consumption and reduced mechanical wear.
| Dense Phase Conveying Principle
Unlike dilute phase conveying, where particles are suspended in a relatively high velocity air stream, dense phase conveying operates with a significantly higher material-to-air ratio. Depending on the material and operating conditions, the product moves through the pipeline in a dense, compact flow pattern rather than being fully suspended in the conveying air.
This lower conveying velocity reduces particle impact against the pipeline and elbows, making dense phase particularly advantageous where product integrity and equipment life are important.
• High solids-to-air ratio
• Low conveying velocities
• Reduced pipeline and elbow wear
• Lower risk of particle degradation
• Reduced conveying air requirement
• Suitable for abrasive and fragile materials
• Reliable conveying over demanding routes
| Controlled Dense Flow
Stable dense phase conveying depends on maintaining the correct relationship between material loading, conveying pressure, air volume and pipeline conditions.
For suitable materials and system configurations, the material may travel through the pipeline as dense plugs or slugs separated by air pockets. This flow regime is commonly referred to as plug flow or slug flow.
The objective is not simply to minimize conveying velocity, but to establish and maintain a controlled flow regime throughout the conveying cycle. Pressure vessel sizing, pipeline diameter, conveying air management and system control must therefore be engineered as an integrated system.
| Conveying Air Control
Long conveying distances, complex pipeline routes and poor flowing materials can require additional air management to maintain stable dense phase flow. VOLDE AIRPLUS introduces controlled supplementary air at engineered locations along the conveying pipeline. Rather than simply adding more air to the system, each injection point is selected and regulated according to the material characteristics, pipeline geometry and pressure profile
AIRPLUS can help:
• Maintain stable material movement through the pipeline
• Control plug and slug behavior
• Reduce the risk of pipeline blockage
• Support demanding long-distance conveying routes
• Improve pressure distribution along the conveying line
• Extend the operating flexibility of the dense-phase system
Explore our page to see other Pneumatic Conveying Systems and alternative solutions
| Optimized Air Control for Stable Conveying
The performance of a dense phase conveying system depends not only on the pressure vessel, but on how compressed air is introduced, distributed and controlled throughout the complete conveying cycle. The number, position and operating parameters of AIRPLUS injection points are therefore determined specifically for each application. Material flowability, bulk density, particle characteristics, conveying capacity, pipeline diameter, vertical lift, number of bends and total conveying distance are considered during system engineering.
This application-specific approach distinguishes an engineered air-assist system from simply installing air injection points at fixed intervals along the pipeline. Combined with DENSPLUS pressure vessel technology and process control, AIRPLUS enables VOLDE to engineer the complete conveying system around the behavior of the material and the requirements of the process.
| Advantages of Dense Phase Conveying
| Typical Applications
VOLDE Dense Phase Conveying Systems are engineered for a wide range of powders, granules and industrial bulk solids where low conveying velocity, reduced wear or product integrity is important.
Typical applications include:
• Fly ash and cementitious materials
• Hydrated lime and mineral powders
• PVC, compounds and polymer raw materials
• Calcium carbonate and mineral fillers
• Activated carbon and process chemicals
• Abrasive powders and minerals
• Fragile granules and pellets
• Selected food and specialty powders
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