Application
Dense Phase Conveying of Abrasive Minerals
Answer in brief
With abrasive minerals the conveying velocity is the wear budget.
Erosion rises steeply with velocity, so halving the speed buys far more than half the bend life, which is why dense phase is the default for these materials.
- Set velocity from the wear target, then size the line.
- Protect the bends that remain.
- Prove the material conveys in dense phase before committing.
Reviewed October 21, 2026 · Updated October 21, 2026
The problem
Angular mineral particles erode bends and valve seats, and in dilute phase a bend can need replacing within months.
Not every mineral forms stable dense phase flow, which is why trials come before design.
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
Pressure vessel systems with controlled air injection move material as a bed at low velocity, with the solids loading set by the available pressure.
Bends are protected with hardened or ceramic inserts at the remaining impact points, and wall thickness is monitored at known positions.
- Conveying trials to confirm dense phase behavior.
- Hardened or ceramic bend protection.
- Scheduled wall thickness measurement.
Selection factors
- Particle hardness, shape and size distribution.
- Required rate and distance.
- Available air pressure and volume.
- Wear target and the inspection plan.
- Dust control at the receiving end.
Common failure modes
- Velocity chosen for rate, with wear discovered later
- Material that does not form stable dense phase flow
- Bends unprotected at direction changes
- Wall thickness never measured until a line failed
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