Dense Phase Pneumatic Conveying System

Engineered For Performance. Designed For Reliability.

AERONIX Systems LLP specializes in the design, engineering, manufacturing, installation, and commissioning of Dense Phase Pneumatic Conveying Systems for efficient handling of powders, granules, pellets, and bulk solids.

Our engineering team brings more than 17 years of practical experience in designing dense phase conveying systems for food, dairy, pharmaceutical, chemical, plastic, mineral, pigment, recycling, and specialty material applications.

Dense phase conveying is one of the most efficient and reliable methods for transporting difficult materials while minimizing product degradation, pipeline wear, dust generation, and energy consumption.

Dense phase conveying is a pneumatic conveying method where bulk materials are transported through pipelines at relatively low conveying velocities and higher operating pressures.

Unlike lean phase conveying, where particles remain suspended in the air stream, dense phase conveying transports material in compact plugs, dunes, or slug formations.

Because material velocity remains low, particle breakage, attrition, segregation, and pipeline erosion are significantly reduced.

This makes dense phase technology ideal for fragile, abrasive, friable, and difficult-to-handle materials.

Material enters a pressure vessel or blow tank.

Compressed air is introduced into the vessel.

Material is pushed into the conveying pipeline.

Material moves through the pipeline in dense plugs or dunes.

At the destination, the material is separated from conveying air using:

• Cyclone Separator
• Dust Collector
• Bag Filter
• Product Receiver

The system automatically repeats the sequence.

Low conveying velocities reduce particle damage.

• Rice
• Malt
• Plastic Pellets
• Food Ingredients
• Masterbatch
• Specialty Chemicals

Lower material velocity dramatically reduces erosion.

• Fly Ash
• Silica
• Talc
• Calcium Carbonate
• Titanium Dioxide

• Longer pipeline life
• Lower replacement costs
• Reduced shutdowns
• Increased system availability

Dense phase systems often operate with lower air volumes compared to conventional lean phase systems.

This can significantly reduce operating costs.

• Clean operation
• Environmental compliance
• Reduced product loss
• Improved housekeeping

• Short distances
• Medium distances
• Long-distance conveying applications

depending on material characteristics and system design.

The most common dense phase technology.

Material is loaded into a pressure vessel and discharged using compressed air.

• Fly Ash
• Carbon Black
• Calcium Carbonate
• Cement
• Pigments

Material is transported using controlled pulses of compressed air.

• Extremely low velocity
• Gentle handling
• Lower air consumption

Designed for processes requiring uninterrupted material flow.

• Continuous production lines
• Process plants
• High-capacity operations

Pressure vessel used for material loading and discharge.

Provides compressed air required for conveying.

• Capacity
• Distance
• Material characteristics
• Wear considerations

• Pressurization
• Fluidization
• Material discharge
• Sequence control

• Bag Filters
• Cartridge Filters
• Cyclone Separators

PLC-based automation controls the complete conveying sequence.

Engineered for Reliability

• Malt
• Rice
• Milk Powder
• Whey Powder
• Sugar
• Starch

• Titanium Dioxide
• Pigments
• Additives
• Resins
• Specialty Chemicals

• PVC Resin
• CPVC Compounds
• Polymer Pellets
• Masterbatch
• PET Chips

• Talc
• Silica
• Calcium Carbonate
• Bentonite
• Fly Ash

Dense phase conveying is widely used for carbon black because it minimizes:

• Product degradation
• Dust generation
• Material loss
• Filter loading

Every dense phase conveying system must be designed based on:

• Pipeline blockage
• Product degradation
• Excessive air consumption
• Poor system performance

Therefore, engineering evaluation is critical before system selection.

Yes. Dense phase conveying minimizes particle breakage due to low conveying velocity.

Yes. It significantly reduces pipeline wear compared to lean phase conveying.

Distances depend on material characteristics and system design. Both short and long-distance applications can be achieved.

In many cases, existing systems can be modified or upgraded after engineering evaluation.

Carbon black, fly ash, talc, calcium carbonate, pigments, polymers, food ingredients, and many specialty powders.

Whether you need a dense phase conveying system for carbon black, fly ash, calcium carbonate, pigments, polymers, food ingredients, or specialty powders, AERONIX Systems LLP can provide a customized and technically optimized solution tailored to your process requirements.

Contact our engineering team to discuss your material, capacity, conveying distance, and application requirements.