Application
Dense Phase Conveying in Building Materials Plants
Answer in brief
In cement and lime plants dense phase conveying is chosen to protect the pipe, not the product.
Low velocity means a bend that lasts years rather than months, and that is the whole economic argument at these tonnages.
- Use low velocity where abrasion is the cost driver.
- Establish the material behavior by trial, not by assumption.
- Size the receiving filter for the surges dense phase delivers.
Reviewed October 21, 2026 · Updated October 21, 2026
The problem
Fine abrasive mineral erodes bends quickly in dilute phase, and the replacement cost and downtime dominate the operating budget.
Cement and lime also deaerate at different rates, which decides whether stable dense phase flow is possible.
Desired outcome
A conveying line that reaches the rate over the required distance while keeping the product and the pipework in the condition the process needs.
Process approach
Dense phase systems use a pressure vessel, a controlled air supply and a line sized for the intended solids loading.
Material permeability and deaeration rate decide whether the powder forms stable plugs or long unstable slugs, which is established by conveying trials.
The receiving filter has to absorb the surges, because dense phase delivers material unevenly by design.
- Conveying trials on the actual material.
- Bend protection at the few remaining impact points.
- Receiving filter sized for surge rather than average flow.
Selection factors
- Permeability and deaeration behavior of the powder.
- Distance, rate and available air pressure.
- Expected wear at bends and the inspection interval.
- Receiving vessel and filter capacity for surges.
- Temperature of the material, especially after milling.
Common failure modes
- Line designed from bulk density alone without conveying trials
- Receiving filter sized for average rather than surge flow
- Bends unprotected at the few high impact points
- Air supply undersized, causing line blockages at start-up
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