Comparison between Lean phase pneumatic conveying system And Dense Phase pneumatic Conveying System

Pneumatic Conveying System

Pneumatic Conveying System is used to convey material from one point to another point using stream of air. In this, a blower is used to move air and Bag filter is used to separate the Air from the Solid. Material is pumped into the air stream using a Rotary Airlock Valve and Ventury.

Pneumatic Conveying systems are the most efficient way of transporting solids. They are clean and Dust Free. The maintenance of these systems is also very cheap and almost trouble-free. The bags used in these systems are very crucial in terms of efficiency and the long life of the system.

Pneumatic Conveying Systems are used in conveying Dry solids and Granular materials. They are the most efficient conveying systems used in the Industry. They are dust-free and spillage-free, providing a clean and open space for working.

Different types of bags are used in this systems viz. Pleated Polyester, Non-woven Polyester tubular bags, Nomex, Fiberglass bags.

Lean Phase

Latest, Trouble free and easy to install

Lean Phase conveying uses a low Air to material ratio, hence it’s known as the Lean phase. Almost air and material are used in equal ratios. An optimum ratio of Air to the material is decided by experience and with reference to similar such installations previously built. Parts of Lean Phase Systems are Blower, RAV, Pick up Nozzle, L.R. Bends, Dust Collector. You can use a Centrifugal Blower or a Roots Blower as the case may

Lean phase pneumatic conveying system
Lean Phase lean phase pneumatic conveying system

be. Due to a Leaner system and a lower air to material ratio the systems runs smoothly and Jamming of pipes is never an issue.

All the equipment mentioned above are totally maintenance free and have a life span of more than 15 years. You can use a Lean phase system in either a Positive system or a Negative System.

Dense Phase

Old, Robust, Expensive

Dense Phase Pneumatic Conveying is a method for moving difficult, abrasive or friable materials, at slow speed. It pushes material along an enclosed pipe, in a plug form, using small amounts of gas, at a low velocity but high pressure. The low velocity of dense phase conveying allows for less wear and tear on both the system and the materials being conveyed, thereby minimizing maintenance.

Efficient use of gas also ensures low power consumption and operating costs, whilst the enclosed pipeline means that no material escapes and is therefore not wasted.

Dense phase pneumatic conveying system
Dense Phase Pneumatic Conveying System

 Most commonly, the process will mean moving material from a single collection point to either a single or multiple reception points. In this system a

transporter is used to pump the material into the air line. It’s a closed vessel that operates at 10 kg/cm2 air pressure. It’s the most important part of the pneumatic conveying system.

Below is an example of the “Quote” style:

Dense Phase Pneumatic Conveying System is Robust, Heavy, and reliable if maintained properly. Compressor and Transporter are the main components of this system. In case, any of these are of inferior quality, it will lead to complete breakdown of the system beyond repair.

Applications of Dense systems can be very rare

  • Cement
  • Minerals
  • Iron and Steel

However, many of these sectors are now going for Lean phase systems due to cheaper price.

The dense phase uses a compressor to push the material through the pipe in batches. This happens at a slow speed and hence causes less erosion in the pipes and hence preferred in the olden days when other alternatives were not viable.

Comparison between Lean and Dense Phase Systems

Lean Phase : Cheaper, Quick deliver, Lower power consumption, Nil maintenance, Easily replaceable spares. No jamming of pipes. Wide range of MoC easily possible.

Dense Phase: Costly, High power requirement, Compressor cannot run properly in dusty surrounding. High air to material ratio may lead to occasional jamming of pipes. Batch process needs high ground clearance to accommodate 2 vessels below feeding equipment.

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