Dense conveying system

Dense Conveying system

A dense conveying system is a method of transporting bulk materials, typically powders or granular substances, through pipelines using compressed air or other gas under pressure.

Dense conveying system : Dense conveying system operates at low velocities and high pressures to move materials in a more concentrated or “dense” form, unlike dilute phase conveying systems that use high velocities and low pressures to carry materials in a dispersed form.

Here are the key components and working of a dense conveying system :

1. Material Storage Hopper: Bulk material is stored in a hopper before being fed into the conveying system.
2. Pressure Vessel (Blow Tank): The material is loaded into a pressure vessel or blow tank, which is sealed and pressurized. This vessel controls the flow of material into the pipeline.
3. Compressed Air Supply: Air or gas is injected into the pipeline under pressure. This forces the material through the pipe at a slow rate, ensuring it remains in a dense, compact form rather than becoming airborne or dispersed.
4. Pipelines: The material travels through pipelines in either a plug or slug flow. In plug flow, the material moves in compact plugs separated by air, while in slug flow, it forms slugs or waves.
5. Air Control Valves: Air control valves and pressure sensors help regulate the flow of material by adjusting the air pressure and ensuring smooth, consistent movement.
6. Discharge Point: The material is discharged into a storage silo or directly into the process where it’s needed.

Features:

• Low Velocity: The system operates at low air velocity, typically 1–5 meters per second. Reducing wear and tear on the materials and pipelines.
• High Pressure: Dense systems require higher air pressure, often ranging from 1–6 bar, to push the material through the pipe.
• Reduced Material Degradation: The slow-moving, concentrated flow minimizes damage to delicate or friable materials.
• Energy Efficiency: Since it moves materials slowly and with less energy compared to dilute phase systems. It can be more efficient, especially for abrasive or fragile materials.

Applications:

Dense conveying is used in below industries :

• • Cement (transporting dry cement, limestone, sand)
  • Food Processing (moving powdered or granular food ingredients)
  • Pharmaceuticals (delicate powders)
  • Chemicals (handling fine, toxic, or hazardous materials)
  • Plastics (resins and powder