Application
Dense Phase Conveying in Chemical Production
Answer in brief
In chemical production dense phase is chosen for three different reasons, and it pays to know which one applies.
It protects friable crystals, it limits erosion with hard powders, and it keeps a hazardous product in a closed pipe at low velocity.
- Name the reason before sizing the system.
- Run trials, because dense phase behavior is material specific.
- Size the receiving filter for surges.
Reviewed October 21, 2026 · Updated October 21, 2026
The problem
Chemical powders vary from soft crystals that shatter to hard abrasives that erode pipework, and both are poorly served by high velocity dilute phase.
Hazardous products add the requirement that the line stays closed and leak free.
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
A pressure vessel system with controlled air injection moves the material as a slow bed, with solids loading set by the pressure available.
Conveying trials establish whether the powder forms stable plugs, what rate is achievable and at what velocity damage begins.
For hazardous products the line design includes the connections, the receiving filter and the discharge valve, since those are where containment is usually lost.
- Trials on the actual powder, including the worst grade.
- Line and vessel materials selected against the chemistry.
- Receiving filter sized for surge flow and for the dust class.
Selection factors
- Permeability and deaeration behavior of the powder.
- Friability and the acceptable particle degradation.
- Abrasiveness and the resulting wear budget.
- Containment requirement and the exposure limit.
- Available air pressure, volume and its dryness.
Common failure modes
- System designed without conveying trials on the real powder
- Receiving filter undersized for the surge
- Moist air introducing caking in a hygroscopic product
- Containment lost at the receiving vessel rather than in the line
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