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Learn How to Improve Dense Phase Pneumatic Conveying System Performance, Efficiency, and Reliability with the Use of Air Injector Technology

Dense phase pneumatic conveying is a method for moving difficult, abrasive, mixed batch, and/or friable materials at a low velocity. The materials move through an enclosed pipe, in slug form using small amounts of gas at a low velocity and high pressure. This type of system is favored for its low operating costs, basic maintenance, and minimal material degradation and system wear. This method is typically selected for moving material from a single collection point to either single or multiple destination points

Nol-Tec will strategically place an Air Assist™ our air injector technology throughout the system to create a pressure differential to prevent back-feeding which may be experienced with low pressure manifold systems. Common materials suitable for dense phase pneumatic conveying include biomass, carbon black, cement, chemicals, food, lime & limestone, pet food, and others.

All pneumatic conveying systems use air (or other gas) as the source to transfer bulk solid materials through pipelines. The conveying gas is required to have a certain pressure differential (commonly measured in PSI) and flow (commonly measured in CFM) to provide the motive force required to transfer the material over the designated distance and required rate.

While there are many variations in the design of dense phase systems, most utilize a single point of gas introduction at the area where the bulk material enters the system. This area can be in the form of a pressure vessel, rotary airlock, screw pump, or a simple flood fed scenario (in the case of dense phase vacuum design). The concept ensures that the conveying gas is mixed with the conveyed product at this single location point. Since there is a single point of gas introduction, it is imperative that sufficient volume and pressure differential of gas be supplied, to eliminate the possibility of system plugging. The introduction of air injector technology strategically placed throughout the system allows the materials to convey longer distances, with reduced pressure and gas flow, while maintaining performance.

AIR INJECTOR TECHNOLOGY ADVANTAGES:

  • Pressure differential design prevents material back-feeding
  • Lower conveying pressures
  • Longer conveying distances
  • Lower product velocities
  • Less maintenance
  • Gentle product handling
  • Reduced system wear
  • Start/stop system with a full line of material

The occurrence of pipeline plugging is virtually eliminated. The total volume of conveying gas required is significantly reduced, thus improving efficiency, and reducing energy consumption. The reduced gas flow also results in lower material transfer velocity, which reduces product attrition and pipeline wear. Air injector technology acts as a check valve between the conveying line and the transfer gas supply manifold. Additionally, the gas flow and pressure of the air injectors are easily adjustable to meet your specific needs.

With a clear understanding of the many advantages associated with the use of air injector technology it will be helpful to know that it can be included in the design of a new system or installed during a system retrofit. A bulk material handling expert will work with you to determine if dense phase pneumatic conveying is the appropriate choice for your materials. If a system retrofit is under consideration a bulk material handling expert will conduct a site visit and recommend material lab testing to prove proof of concept prior to installing the air injectors.

Key Takeaways

The use of air injector technology improves dense phase pneumatic conveying system performance, efficiency, and reliability.

  • Dense phase pneumatic conveying is a method for moving difficult, abrasive, mixed batch, and/or friable materials at a low velocity.
  • Air injector technology strategically placed throughout the system allows the materials to convey longer distances, with reduced pressure and gas flow, while maintaining performance.
  • Air injector technology can be included in the design of a new system or installed during a system retrofit.

How can we help?

Maybe you need a new system, an upgrade to an existing system, or a retrofit. Regardless of size, industry, or material, we are here to help you get your project and product moving.

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