Dense-Phase Pneumatic Conveying & Slug Flow Calculator
Calculate dense-phase pneumatic conveying slug flow pressure drop, mass phase ratio, low superficial velocity, and pressure vessel transporter volume.
Conveying Route & Throughput
Material Density & Inlet Gas Velocity
Dense Phase Pressure & Air Requirements
| Mass Phase Ratio (μ = M_solids / M_air): | -- kg/kg |
| Inlet Pipe Froude Number (Fr): | -- |
| Solids Friction Pressure Drop (ΔPs): | -- bar |
| Vertical Lift Static Head (ΔPh): | -- bar |
| Compressed Air Flow Rate (Free Air): | -- SCFM |
| Transporter Vessel Volume (Blowpot): | -- L (liters) |
Recommended Tools & Equipment
Tested hardware and components for high reliability
Frequently Asked Questions
What is the fundamental difference between dilute-phase and dense-phase pneumatic conveying?
Dilute-phase conveying operates at high gas velocities (18 to 30 m/s) and low solids loading ratios (mu < 15 kg solid / kg air), keeping particles airborne in turbulent suspension. Dense-phase conveying operates at very low gas velocities (3 to 8 m/s) and high solids loading ratios (mu = 30 to 120+ kg/kg), pushing compact slugs or fluidizing dunes along the pipe at higher pressures (2 to 6 barg), virtually eliminating particle attrition and pipe wear.
What materials are ideal candidates for dense-phase pneumatic conveying?
Dense phase is specifically chosen for: (1) Highly abrasive products (silica sand, alumina, glass cullet) that would wear out dilute-phase pipe elbows within weeks, (2) Fragile friable products (roasted coffee beans, spray-dried detergent granules, pet food kibble) that shatter at high speeds, and (3) Heavy bulk density minerals.
How does a dense-phase blowpot pressure vessel transporter operate?
Instead of continuously feeding through a rotary airlock (which cannot hold 3+ bar pressure), product fills an ASME code-stamped pressure vessel (blowpot) through an open dome valve by gravity. The dome valve inflates its seal, high-pressure compressed air injects through top aerators and bottom discharge nozzles, fluidizing the batch and extruding dense slugs smoothly through the pipeline.