SYSTEM FOR TRANSPORTING PARTICLE MATERIAL, INJECTOR ASSEMBLY AND METHOD FOR TRANSPORTING PARTICLE MATERIAL

Abstract

Material transport device with shut-off valves. The present invention relates to a system and method for transporting particulate material. A plurality of injector assemblies are positioned along the transport pipeline to inject a continuous flow of transport gas into the pipeline. The continuous flow of transport gas injected by each of the injector assemblies prevents particulate material from entering any part of the injector assemblies, thereby reducing the risk of blockage of nozzles, injection path selection valves, and so on. The continuous injection of transport gas along the pipeline also maintains a degree of permeability of the particulate material in the pipeline and promotes stable transport.The pilot-operated shut-off valve of each injector assembly is operable to independently detect a large pressure drop in the pipeline, and to close in order to store pressurized carrier gas in the injector assembly and feed it.

Description

SYSTEM FOR TRANSPORTING PARTICLE MATERIAL, INJECTOR ASSEMBLY AND METHOD FOR TRANSPORTING PARTICLE MATERIAL Field of Invention

[0001] The invention relates to devices and methods for transporting particulate material through a pipeline and, in particular, to the use of pressurization or vacuum techniques for transporting dense-phase particulate material. Background of the Invention

[0002] Pneumatic conveying by pressure or vacuum are techniques used to transport particulate materials along a pipeline. These techniques are typically used to transport materials over distances usually in the range of 10 m to 500 m, and in some cases, even longer. Pneumatic conveying avoids the need for conveyor belts or similar equipment, which can be bulky and expensive to maintain.

[0003] Pneumatic conveying techniques are particularly useful where material must be transported along a complex path or to multiple distribution points. These techniques also ensure that particulate material can be fully contained within a pipeline, which can avoid the need to deal with dust or material contamination along the pipeline route.

[0004] Dense phase positive pressure or vacuum pneumatic conveying is frequently used to transport dense phase particles that are not suitable for transport via suspension in a gas stream, such as materials Petition 870260050642, dated 05 / 27 / 2026, p. 6 / 98 2 / 67 subject to aggregation or coagulation, or particularly abrasive or friable materials. In dense-phase pneumatic conveying, such materials are transported along a pipeline at relatively low velocities, often in a series of material packets. By keeping the conveying velocity low, pipe wear and energy consumption are reduced.

[0005] A conventional dense-phase pressurized pneumatic conveying system 1 is shown in Figure 1(a). A particulate material 3 is distributed from a hopper 5 to a pressure vessel 7 (commonly referred to as a conveyor) by means of a material shut-off valve 9. The pressure vessel is pressurized with compressed air fitted, for example, with a compressor 11a by means of a control valve 13. The pressurized air in the pressure vessel 7 expands into the conveying pipe 17 and the airflow propels the particulate material 15 along the pipe to a distribution point (for example, a second hopper, 19).

[0006] Dense phase vacuum conveying uses a similar principle. As shown in Figure 1(b), instead of the pressure differential between the inlet and outlet of the conveying pipeline being achieved by pressurizing the conveyor, in vacuum conveying the pipeline inlet is at ambient pressure and the pressure at the outlet (e.g., at the second hopper 19) is reduced by a vacuum pump 11b.

[0007] Some materials are unsuitable for dense phase transport without additional assistive technologies being applied directly to the transport piping. For example, some materials have low Petition 870260050642, dated 05 / 27 / 2026, page 7 / 98 3 / 67 Permeability to motive gas flow. When combined with high friction between the particulate material and the inner wall of the pipeline, the movement of the material can become erratic and unpredictable, which can lead to variable transport rate performance and / or pipeline blockages.

[0008] To try to solve these problems, it is known to inject compressed air through a plurality of distribution points positioned at intervals along the length of the pipeline. However, this approach generally requires larger volumes and / or pressures of compressed air. This additional consumption arises because air is unnecessarily injected at some points along the pipeline. In turn, the additional airflow increases the velocity of the particulate material along the pipeline, which can lead to increased wear of the pipeline or damage caused by contact with the particulate material.

[0009] One approach to minimizing air consumption has been to provide injectors along a pipeline with pressure transducers and inject compressed air through check valves only at specific injectors in response to pipeline pressure conditions. Examples of such systems are described in US documents 4,515,503, US 5,584,612 and GB2085388. Systems that trigger gas injection above an absolute pipeline pressure limit can be difficult to implement, since the required pressure limit decreases along a pipeline (requiring individual adjustment) and may be dependent on the type of material being transported. GB2085388, for example, teaches that reference values ​​for the pressure above which compressed air is injected are selected for each type of material. Petition 870260050642, dated 05 / 27 / 2026, page 8 / 98 4 / 67 material that is being transported.

[0010] These systems have several additional disadvantages. Since they operate on the principle of detecting an increased pressure characteristic in the pipeline from a material plug and pushing the plug along the pipeline by injecting additional air, the tendency is for each injector, in turn, to be switched on and remain switched on as the plug advances into the pipeline, leading to wasted air. Furthermore, the injectors and check valves are subject to blockage when not in use due to contaminated backflow from the transport pipeline.

[0011] Systems such as those described above are also prone, under certain circumstances, to exacerbate problems by injecting gas upstream of a material plug, thereby compacting it.

[0012] US patent 4861200 describes a system in which the pressure differential between a reference line, which represents an idealized predicted pressure along the pipeline, and the actual pressure in a transport pipeline is measured (Δpn) in each of a series of injector groups positioned along the pipeline. A pressure drop greater than expected along the pipeline is indicative of a blockage, and therefore differential pressure switches are positioned so that where Δpn exceeds Apn+1 in adjacent downstream injector groups by a predetermined amount, compressed air is injected through the upstream injectors. Comparison with a reference value means that each pressure difference Δρ must be calibrated to the idealized pressure drop along the pipeline, which is, again, specific to the material. Petition 870260050642, dated 05 / 27 / 2026, page 9 / 98 5 / 67

[0013] The velocity and pressure of the transport can also be limited by allowing excess pressure and volume of the transport gas to bypass a material buffer, for example, through an internal grooved pipe or bypass circuits controlled by an external pressure relief valve. Again, however, bypass assemblies can be subject to blockage and wear. In the case of internal bypass piping, repair or replacement can be particularly difficult and expensive.

[0014] The Applicant's previous application WO 2018 / 007787 describes a material transport device that addresses a number of disadvantages of previously known approaches. The device is equipped with sets of injectors along the transport pipeline that are configured to inject a continuous flow of carrier gas into the pipeline; and to switch between a lower and higher injection flow rate if a pressure differential above the limit is detected along the transport pipeline. This device reduces the total amount of carrier gas required and allows for more stable transport.

[0015] Although this device constitutes a significant improvement over the conventional transport device, in some circumstances, additional control over the injection of transport gas along the transport pipeline may still be desired. Summary of the Invention

[0016] According to a first aspect of the invention, a system for transporting particulate material is provided comprising: a transport pipeline that has an inlet Petition 870260050642, dated 05 / 27 / 2026, page 10 / 98 6 / 67 to receive a quantity of particulate material and carrier gas and an outlet; the system being configured to maintain the inlet at a higher carrier gas pressure than the outlet; a plurality of injector assemblies along the transport pipeline to inject a continuous flow of transport gas into the pipeline; wherein each set of injectors is associated with a pressure device to detect pressure conditions in the transport pipeline; and wherein each set of injectors comprises a flow adjustment mechanism operable to increase the flow rate at which the transport gas is injected into the pipeline from an injection flow rate to an increased injection flow rate when the pressure device detects pressure conditions in the transport pipeline indicative of locally reduced permeability of the material; and wherein each set of injectors comprises a pilot-operated shut-off valve positioned between the flow adjustment mechanism and the transport pipeline and operable to close in response to a received pilot signal indicative of a pressure condition in the transport pipeline below a minimum limit pressure condition.

[0017] The continuous flow of carrier gas injected by each of the injector assemblies prevents particulate matter from entering any part of the injector assemblies, thereby reducing the risk of blockage of nozzles, valves, and so on. The continuous injection of carrier gas along the pipeline also maintains a degree of permeability of the particulate matter in the pipeline and promotes transport. Petition 870260050642, dated 05 / 27 / 2026, page 11 / 98 7 / 67 stable.

[0018] In pressurized or vacuum pneumatic conveying, the conveying gas flows along the conveying pipeline at a higher velocity than the particulate material. Thus, the particulate material is, to some extent, permeable to the flow of the conveying gas. Higher permeability implies lower flow resistance and may be associated with less compaction and friction between particles. In turn, this results in a lower overall conveying pressure for a given mass flow rate. Conversely, lower permeability implies higher flow resistance and may be associated with a greater degree of particle compaction and friction against the pipeline (usually resulting in higher overall conveying pressure).

[0019] If a local reduction in the permeability of the particulate material occurs when the transported particulate material begins to compact locally, material plugs or pipe blockages may eventually form. A local reduction in permeability can cause localized changes in pressure conditions in the pipeline, such as pressure differentials along the transport pipeline. In use, when a local increase in material permeability is detected, a set of injectors (typically in the region of, or upstream of, the locally decreased permeability) increases the flow rate of the injected transport gas to maintain material permeability and prevent blockages from occurring.

[0020] The pilot-operated shut-off valve of each injector assembly is operable independently of the mechanism of Petition 870260050642, dated 05 / 27 / 2026, page 12 / 98 8 / 67 flow adjustment and pressure device. That is, the pilot signal by which each pilot-operated shut-off valve is regulated can be independent of any signals (e.g., electrical signals, pressure signals, etc., as described in this document) by which the flow adjustment mechanism and pressure device operate.

[0021] The pilot-operated shut-off valve of each injector assembly can be operated to detect a large pressure drop in the pipeline, i.e., a pressure condition below a suitable limit pressure condition, and to close in order to store pressurized carrier gas in the injector assembly and feed it thereto. Such a configuration, therefore, stores energy (in the form of pressurized gas) in an injector assembly and reduces gas consumption by reducing or eliminating the need to repressurize the parts of the system associated with the injector assemblies after a routine interruption of material transport, or due to a failure, such as a serious leak in the carrier pipeline or when insufficient carrier gas is being fed to the system.

[0022] Storing pressurized gas in an injector assembly using shut-off valves ensures that the pressure in the injector assembly is maintained above the pressure in the transport pipeline at all times, preventing any contamination of the injector assembly, for example, when the system is restarted or a given injector assembly is reactivated.

[0023] The pilot-operated shutoff valve of each injector assembly is also typically operable to open in response to a received pilot signal indicating a condition. Petition 870260050642, dated 05 / 27 / 2026, page 13 / 98 9 / 67 pressure in the transport pipeline above the minimum limit pressure condition.

[0024] The minimum limit pressure condition may be an absolute minimum limit pressure, such as a minimum transport pipeline pressure (measured, for example, at or near the entrance of the transport pipeline).

[0025] The minimum limit pressure condition may be a minimum limit pressure difference (i.e., pressure drop), such as between a pressure in one part of an injector assembly and the pressure in the transport pipeline, such as in the vicinity of the injector assembly. A minimum limit pressure difference may be a drop between an expected and an actual pipeline pressure. A minimum limit pressure difference may be a drop between the pipeline pressure at its inlet and another downstream part of the pipeline.

[0026] It will be understood that a minimum limit pressure condition will typically be related to the overall system pressure or the pressure in the transport pipeline. A minimum limit pressure condition may be between approximately 550% of the system pressure or between approximately 10-40% or 10-25% of the system pressure.

[0027] Shut-off valves can be configured to operate independently of each other and / or simultaneously. Shut-off valves can be configured to operate in groups; that is, subgroups of shut-off valves can be configured to operate simultaneously.

[0028] By independently, we mean that the operation of each shut-off valve occurs independently of the configuration of any other shut-off valve and does not exclude Petition 870260050642, dated 05 / 27 / 2026, page 14 / 98 10 / 67 two or more of said shut-off valves operating independently of each other in response to corresponding pilot signals, but simultaneously or nearly simultaneously.

[0029] As described in more detail below, each pilot-operated shut-off valve can be operable to respond to more than one type of pilot signal. Consequently, in some embodiments, the shut-off valves operate simultaneously in response to one or more first pilot signals and operate independently in response to one or more second pilot signals.

[0030] The shut-off valves can be configured to receive a common pilot signal so as to operate simultaneously. Alternatively, or in addition, the shut-off valves can be configured to operate simultaneously when receiving a pilot signal through any of the pilot-operated shut-off valves.

[0031] A pilot signal may be transmitted by any suitable means including, but not limited to, wirelessly, optically, electrically, pneumatically. The shut-off valve of each injector assembly may be connected to a pilot line, such as an electrical pilot line (for transmitting electrical signals), a pneumatic pilot line, or an optical fiber. The shut-off valve of each injector assembly may comprise or be coupled to a receiver for receiving a wirelessly transmitted pilot signal.

[0032] A pilot signal may be a pressure signal, such as a decrease in pressure below a minimum limit pressure or a pressure pulse, pressure difference or similar.

[0033] For example, each pilot-operated shut-off valve can communicate with a pneumatic pilot line. The valve Petition 870260050642, dated 05 / 27 / 2026, page 15 / 98 11 / 67 The shut-off valve for each injector assembly can be pressure-operated. For example, the shut-off valve can be coupled to or comprise a diaphragm actuator or a differential pressure piston actuator or similar.

[0034] For example, each shut-off valve can be opened if the static pressure in the pilot line is above a minimum limit pressure and / or below a maximum limit pressure or between a maximum and minimum limit pressure (and closed if the relevant condition is not met).

[0035] Each pilot line can extend from a pilot collector, that is, be in fluidic communication with each other, or the pilot lines can be independent of each other.

[0036] Each shut-off valve (when present via a pilot line or pilot manifold) may be in communication (including pressure communication, directly or via a diaphragm or piston actuator or similar, electrical communication, wireless communication or optical communication, etc.) with another part of the system, such as: the transport pipeline, such as an upstream section or the inlet to the transport pipeline; an upstream part or the inlet for the respective injector assembly; a carrier; a carrier gas source for the system; a carrier gas feed manifold for the injector assemblies; a manual cutting device.

[0037] Thus, the received pilot signal may be directly or indirectly indicative of a pressure condition in Petition 870260050642, dated 05 / 27 / 2026, page 16 / 98 12 / 67 transport piping below a minimum limit pressure condition. For example, a manual shut-off device may indicate that the pressure in the piping will subsequently drop. Similarly, a drop in pressure from a transport gas source, the carrier, or another upstream part of the system may likewise precede a drop in pressure in the transport piping. In some embodiments, where shut-off valves close as a consequence of a minimum limit pressure difference, a pilot line to an injector manifold may serve as a reference for measuring said minimum limit pressure difference.

[0038] The said pneumatic pilot line or manifold may be in pressure communication with the transport piping. Each pilot-operated shut-off valve may communicate with a pilot line, wherein the pilot line is in pressure communication with the transport piping locally for each set of injectors.

[0039] A pneumatic pilot line can be in pressure communication with a pilot manifold, so that simultaneous operation of each shut-off valve can be performed.

[0040] A pilot signal can be an electrical signal. Each shut-off valve can be an electromechanical valve.

[0041] The pilot-operated shut-off valve of each injector assembly can be configured to respond to a pilot signal indicating a pressure condition in the transport pipeline below the minimum limit pressure condition; and one or more additional pilot signals.

[0042] One or more additional pilot signals may, for example, include one or more pilot signals indicating Petition 870260050642, dated 05 / 27 / 2026, page 17 / 98 13 / 67 a failure condition.

[0043] A fault condition that gives rise to another pilot signal may comprise an adverse pressure condition or an adverse flow condition.

[0044] For example, each pilot-operated shut-off valve may be operable to close in response to a received pilot signal indicating a pressure condition in the pipeline above a maximum limit pressure condition. The pilot-operated shut-off valve of each injector assembly is also typically operable to open in response to a received pilot signal indicating a pressure condition in the transport pipeline below the maximum limit pressure condition.

[0045] A maximum limit pressure condition may be indicative of a blockage in the pipeline (as opposed to such smaller pressure variations associated with locally reduced permeability) or a fault associated with the carrier gas supply (e.g., a control valve and / or compressor). A maximum limit pressure condition may be indicative of a fault associated with an injector assembly, such as a leak or a drop in the gas supply to it.

[0046] As described in this document, under normal transport conditions, the system autonomously adjusts the flow rate (between the injection flow rate and the increased injection flow rate) in each of the injector sets. Failure conditions may arise whereby the injector sets are susceptible to contamination of the material in the transport pipeline (for example, when the pressure in the transport pipeline exceeds the injection pressure in one or more of the injector sets). The shut-off valve of each set Petition 870260050642, dated 05 / 27 / 2026, page 18 / 98 14 / 67 of injectors can advantageously be closed in order to avoid such contamination and damage to the injector assembly.

[0047] The maximum limit pressure condition may be an absolute maximum limit pressure, such as a maximum pressure in the transport pipeline (measured, for example, at or near the entrance of the transport pipeline).

[0048] The maximum limit pressure condition may be a maximum limit pressure difference (i.e., pressure increase), such as between a pressure in a part of an injector assembly and a pressure in the transport piping, such as in the vicinity of the injector assembly.

[0049] A maximum limit pressure may be between approximately 105-150% of the system pressure or between approximately 110-140% or 110-125% of the system pressure. A maximum limit pressure differential may be between approximately 5-50% of the system pressure or between approximately 10-40% or 10-25% of the system pressure.

[0050] A fault condition that gives rise to an additional pilot signal may include a local pressure above another limit pressure value (for example, a value selected based on the pressure rating of a system component).

[0051] A fault condition may comprise a manifold pressure limit or an injector pressure limit. Or, indeed, a fault condition may be an adverse pressure difference, for example, between two points in the system, such as the conveyor and the transport piping or an inlet to and an outlet of an injector assembly.

[0052] A fault condition may comprise a transport gas flow rate above or below a limit flow rate, such as into or along the transport pipeline, Petition 870260050642, dated 05 / 27 / 2026, p. 19 / 98 15 / 67 into or out of a conveyor or through a set of injectors, etc. For example, if the flow rate of carrier gas exceeds a maximum limit flow rate, this may indicate a leak, while a flow rate below a minimum limit flow rate may indicate a blockage or that insufficient carrier gas is being fed to the system.

[0053] A fault condition may comprise a combination of two or more pressure or flow conditions.

[0054] A pilot-operated shut-off valve can be adapted to operate even in the presence of particulate contaminants (as might be present under certain failure conditions). For example, a pilot-operated shut-off valve can be a ball valve, a butterfly valve, a dome valve, a plug valve, a globe valve, or an angle seat valve.

[0055] The system can be configured so that the shut-off valves operate simultaneously, independently or in groups in response to a received pilot signal or signals indicating a fault condition, generally as discussed above in relation to the minimum limit pressure condition.

[0056] The nature of the pilot signal may dictate whether simultaneous, independent, or grouped operation is required. For example, some faults may require the immediate closure of all shut-off valves, while others may arise from local faults in a set of injectors, so independent closure is appropriate.

[0057] Shut-off valves can be configured to be operated manually (in groups, simultaneously and / or individually). For example, the system may include a manual device (e.g., emergency) to initiate a Petition 870260050642, dated 05 / 27 / 2026, page 20 / 98 16 / 67 pilot signal.

[0058] It should be understood that the system may comprise a fault detection device including, for example, one or more pressure and / or flow sensors, to detect a fault condition or conditions. Each set of injectors may comprise, or be associated with, such a fault detection device.

[0059] The fault detection device can communicate with each sensor electronically. The fault detection device can understand, or communicate with, a controller that has a processing module capable of detecting each fault condition based on readings received from the sensor.

[0060] Pressure conditions indicative of decreased permeability may be an absolute pressure reading at one or more points along the transport pipeline, for example, a pressure reading above an expected pressure at a point along the transport pipeline or a difference between the absolute pressure readings at two points along the transport pipeline.

[0061] Pressure conditions indicative of decreased permeability may be a pressure differential, for example, between two points along the pipeline or between two sets of injectors, such as adjacent sets of injectors.

[0062] Each set of injectors may be associated with a differential pressure device to detect whether a pressure differential in the piping between said set of injectors and an adjacent set of injectors is above or below a limit value. Petition 870260050642, dated 05 / 27 / 2026, page 21 / 98 17 / 67

[0063] In use, each set of injectors can be operated to increase the flow rate at which the carrier gas is injected into the pipeline from an injection flow rate to an increased injection flow rate when a pressure differential detected in a predetermined number of injector sets upstream or downstream of the same rises above the limit value.

[0064] Consequently, injector assemblies can respond to very small pressure differentials along the transport pipeline as a result of small decreases in the permeability of the transported material. These localized pressure differentials can also occur when a material plug forms and reaches one of the injector assemblies.

[0065] This facilitates the stable and predictable transport of particulate material, and a smaller overall amount of transport gas is required for each unit mass of particulate material transported. Thus, the system's energy requirements are reduced.

[0066] The limiting pressure differential between adjacent injector sets is also independent of the position along the transport pipeline, the material being transported, and the absolute pressure conditions within the transport pipeline.

[0067] In addition, the injector assemblies are operable independently, allowing the system to respond to two more pressure differentials detected at the same time.

[0068] It has been found to be particularly effective when each set of injectors is operable to increase the flow rate at which the carrier gas is injected into the pipeline. Petition 870260050642, dated 05 / 27 / 2026, page 22 / 98 18 / 67 when the detected pressure differential is a predetermined number of injector sets upstream of it.

[0069] This finding is contrary to the approach adopted in existing systems, in which gas is injected into or upstream of a pressure anomaly detected in a transport pipeline. Instead, the injection flow rate is preemptively increased downstream of a region of locally decreased material permeability, so that its permeability is reduced as it arrives and before a material plug or blockage properly forms.

[0070] Each set of injectors can be operated to increase the flow rate at which the carrier gas is injected into the pipeline when the detected pressure differential is between it and an adjacent set of injectors.

[0071] Alternatively or in addition, each set of injectors may be operable to increase the flow rate at which the carrier gas is injected into the pipeline when the detected pressure differential is between two adjacent sets of additional injectors.

[0072] The flow rate of the nth set of injectors can be increased based on a pressure differential between the (n+m)th set of injectors and the adjacent (n+m+1)th set of injectors - that is, based on a downstream pressure differential.

[0073] Advantageously, the flow rate of the nth set of injectors can be increased based on a pressure differential between the (nm)th set of injectors and the adjacent (nm-1)th set of injectors - that is, based on an upstream pressure differential. Petition 870260050642, dated 05 / 27 / 2026, page 23 / 98 19 / 67

[0074] The value of m can be 0, 1 or 2 and, in some cases, more than 2.

[0075] The differential pressure device can, in some embodiments, be configured to also function as a fault detection device or a component part thereof.

[0076] However, a minimum (or maximum) limiting pressure difference (or indeed any other pressure difference that gives rise to an additional pilot signal, described above) is distinct from the limiting value of a so-called pressure differential that causes an injector to switch between one flow rate and an increased flow rate. Typically, a minimum (or maximum) limiting pressure difference is much larger than the so-called limiting pressure differential, for example, 1, 2 or more orders of magnitude greater.

[0077] The device may comprise one or more sets of terminal injectors, meaning sets of injectors at or near the inlet or outlet of the piping, such that a pressure differential above the limit value cannot be detected in a predetermined number of sets of injectors upstream or downstream of the same, since the sets of terminal injectors have fewer than the predetermined number of sets of injectors upstream or downstream of the same, as the case may be.

[0078] Terminal injector assemblies can be configured differently from other non-terminal injector assemblies.

[0079] For example, where m = 2 and the system is configured so that the plurality of injector sets (not terminals) respond to pressure differentials. Petition 870260050642, dated 05 / 27 / 2026, page 24 / 98 20 / 67 detected above the upstream limit, the first and second sets of injectors along the pipeline may be terminal injector sets and may not have the capacity to increase the flow rate of the injected carrier gas. Alternatively, the second (terminal) set of injectors may increase the injection flow rate based on a pressure differential to the adjacent first (terminal) set of injectors.

[0080] The terms upstream and downstream, inlet, outlet and other related terms are expressed in relation to the direction in which the particulate material is to be transported in normal use of the system.

[0081] By permeability of the transported particulate material we refer to the resistance that is imposed against a flow of transport gas through the pipeline.

[0082] The system may comprise a conveying device for feeding a quantity of particulate material under a system pressure from a conveying gas to the inlet of the conveying pipeline. In use, the system pressure is maintained (e.g., by means of a compressor) at a pressure above the pressure at the outlet. For example, the outlet may be at ambient pressure and the system pressure may be at a higher pressure. The system may be a pressurized pneumatic conveying system.

[0083] The system may comprise a receiving vessel, such as a hopper, to receive particulate material from the transport pipeline. In use, the receiving vessel may be maintained at a pressure below the inlet pressure. The inlet may be at ambient pressure and the receiving vessel Petition 870260050642, dated 05 / 27 / 2026, page 25 / 98 21 / 67 may be at reduced pressure. For example, the receiving vessel may communicate with a vacuum pump to pump the carrier gas from the receiving vessel. The system may be a vacuum pneumatic conveying system.

[0084] For the avoidance of doubt, references in this document to the detected pressure differential refer to the detected pressure differential of a predetermined number of injector sets upstream or downstream of said injector set.

[0085] Each set of injectors can be configured to reduce the flow rate at which the carrier gas is injected into the pipeline from the increased injection flow rate to the injection flow rate when the detected pressure differential falls below the limit value.

[0086] It will be recognized that, at least temporarily, the increased injection flow rate may be associated with a local increase in carrier gas pressure as the particulate material adjusts locally to the new conditions.

[0087] In fact, the pressure at which the carrier gas is injected can increase or decrease with the injection flow rate. For example, at the injection flow rate, the injection pressure may be lower than the increased injection pressure at the increased injection flow rate. Thus, in use, each set of injectors may be operable to increase the pressure at which the carrier gas is injected into the pipeline from an injection pressure to an increased injection pressure when said pressure differential rises above the limit value.

[0088] The carrier gas can be injected at an increased injection flow rate for about 0.0001 to 5 seconds or Petition 870260050642, dated 05 / 27 / 2026, page 26 / 98 22 / 67 approximately 0.0001 to 3 seconds or approximately 0.0001 to 2 seconds or approximately 0.0001 to 1 second. In some circumstances, the carrier gas is injected at an increased injection flow rate for approximately 0.5 seconds.

[0089] The length of time during which an injector injects carrier gas at the increased injection flow rate may depend on how long it takes for the pressures within the carrier pipeline to re-equilibrate. Factors determining how long the increased injection flow rate is used include the degree to which the permeability of the particulate material has decreased (e.g., how much a plug has compacted), the position of a region of decreased permeability relative to a set of injectors, or how long it takes for a plug to be aerated or broken so as to increase permeability.

[0090] Each set of injectors can be operated to inject carrier gas into the pipeline at the injection flow rate when the detected pressure differential is below the limit value and to inject carrier gas into the pipeline at the increased injection flow rate when the detected pressure differential rises above the limit value.

[0091] Each set of injectors can be configured to reduce the flow rate at which the carrier gas is injected as soon as the detected pressure differential falls below the limit value.

[0092] Alternatively, there may be a delay between the drop in the detected pressure differential below the limit value and the reduction in the flow rate at which the carrier gas is injected. Thus, the flow rate at which the carrier gas is injected may remain at the increased injection flow rate for a period of time. Petition 870260050642, dated 05 / 27 / 2026, page 27 / 98 23 / 67 selected time as soon as the detected pressure differential falls below the limit value, in particular in relation to the modes that have a said control unit or units by which the injection flow rate of the carrier gas is controlled.

[0093] The limiting pressure differential can be on the order of millibars. For example, the limiting pressure differential can be between about 10 Pa and 100 kPa (0.1 and 1000 mbar), or between about 100 Pa and 50 kPa (1 and 500 mbar), or between about 500 Pa and 20 kPa (5 and 200 mbar), or between about 1 kPa and 10 kPa (10 and 100 mbar).

[0094] Some particulate materials can progress steadily along a transport pipeline as a series of permeable plugs without leading to blockage. Under certain circumstances, increased injection flow rates can be triggered whenever a material plug passes between adjacent sets of injectors. When the system is configured in this way, the temporarily increased injection flow rates of each set of injectors can, in turn (as the plug progresses along the pipeline), be considered again as a preventive measure against pipeline blockage or unstable transport of the particulate material.

[0095] The system pressure and / or the pressure difference between the inlet and outlet and / or the injection flow rate may vary depending on, for example, the length and diameter of the transport piping, the nature of the particulate material being transported, the ambient temperature in the piping and other factors, as known to those skilled in the art. Petition 870260050642, dated 05 / 27 / 2026, page 28 / 98 24 / 67

[0096] The system pressure (i.e., absolute pressure) may, for example, be in the range from 10 kPa to 10 MPa (0.1 to 100 bar), or between about 50 kPa to 2 MPa (0.5 to 20 bar). The injection flow rate in an injector assembly may, for example, be in the range from about 0.0001 to 100 m3 / min, or 0.01 to 100 m3 / min (based on the equivalent volume of air at atmospheric pressure), or in the range from about 0.1 to 60 or 55 m3 / min. In some embodiments, the injection flow rate may be around 0.01 Sm3 / min.

[0097] The system can be configured so that the system pressure can be the same as the injection pressure, so that the system pressure never exceeds the injection pressure, or so that the system pressure is always below the injection pressure.

[0098] The injection flow rate (and / or pressure) of one set of injectors may exceed the injection flow rate / pressure of an adjacent set of injectors downstream. For example, the flow rate of the carrier gas may progressively increase or decrease along the carrier pipeline from inlet to outlet. Alternatively, the flow rates and pressures at which the carrier gas is injected may be the same in each set of injectors.

[0099] Increased injection flow rate may cause a localized pressure increase in the transport pipeline sufficient to cause a local increase in the permeability of the particulate material. Increased injection flow rate may cause a localized pressure increase in the transport pipeline sufficient to dislodge a material plug that has become blocked in the transport pipeline. Injection of transport gas at the increased injection flow rate may rupture a Petition 870260050642, dated 05 / 27 / 2026, page 29 / 98 25 / 67 buffer material in order to reduce its size, or aerate or fluidize the buffer to a certain degree, in order to increase its permeability.

[0100] Increased injection pressure can be selected, for example, based on the nature of the material being transported, the dimensions of the piping, the system or injection pressures, temperature, and so on.

[0101] The increased injection flow rate is typically at least 2, 3, 5, 7 or 10 or more times the injection flow rate. For example, where the injection flow rate is about 0.01 Sm3 / min, the increased injection flow rate may, in some embodiments, be between about 0.02-0.1 Sm3 / min, for example, about 0.07 Sm3 / min.

[0102] In order to achieve the increased injection flow rate, the increased injection pressure at which the injector array injects the carrier gas can typically be between about 10 kPa to 300 kPa (0.1 to 3 bar) higher than the injection pressure. Alternatively, a larger flow area can be employed in order to achieve a higher flow rate for a given injection pressure.

[0103] The differential pressure device can be configured to detect whether the differential pressure in the piping between a set of injectors and an adjacent set of injectors upstream and / or downstream is above or below a limit value.

[0104] The differential pressure device can be configured to detect a pressure differential between adjacent injector assemblies, for example, between portions of injector assemblies in fluid communication with the transport piping. The differential pressure device Petition 870260050642, dated 05 / 27 / 2026, page 30 / 98 26 / 67 pressure can be configured to detect a pressure differential between the respective regions of the transport piping proximal to the adjacent injector assemblies.

[0105] The differential pressure device can be configured to detect differential pressure information.

[0106] Differential pressure information may comprise an indication that the differential pressure is above or below the limit value or may comprise a value of a differential pressure or a property related thereto. For example, differential pressure information may comprise the setting of a differential pressure sensitive device or may comprise a signal output by a differential pressure sensitive electrical or electromechanical device, such as a piezoelectric device. Such a device may also be able to detect adverse differential pressure information from which a fault condition may be identified.

[0107] Each set of injectors may comprise a differential pressure device. Advantageously, the differential pressure device may be located upstream of the continuous flow of carrier gas being injected into the pipeline. In this way, the differential pressure device is protected against contamination, damage, or wear that could result from contact with particulate material being carried in the pipeline. In turn, this facilitates the use of more sensitive differential pressure devices.

[0108] A differential pressure device of Petition 870260050642, dated 05 / 27 / 2026, page 31 / 98 27 / 67 said set of injectors may be in fluid pressure communication with an adjacent set of injectors (upstream and / or downstream of the same) or with an interior of the transport piping proximal to an adjacent set of injectors.

[0109] A differential pressure device of said injector assembly may be configured to respond to differential pressure information (such as the configuration of a differential pressure sensitive device) in order to regulate the injection flow rate in the transport piping.

[0110] A differential pressure device of said injector assembly may, alternatively or in addition, be configured to transmit differential pressure information to an additional injector assembly, a predetermined number of injector assemblies upstream and / or downstream thereof. The differential pressure information may be transmitted directly (e.g., an electrical signal) or indirectly (e.g., a pressure in a line resulting from the operation of a differential pressure-sensitive device, such as a valve).

[0111] For example, a differential pressure device may comprise a valve coupled to a differential pressure actuator, such as a diaphragm or a piston actuator. One side of the differential pressure actuator may be in fluid communication with an injector assembly (or the transport piping proximal to it) and a second side of the differential pressure actuator may be in fluid communication with an adjacent injector assembly (or the transport piping proximal to it). Petition 870260050642, dated 05 / 27 / 2026, page 32 / 98 28 / 67 same).

[0112] Upon detection of a pressure differential above the limit pressure differential between the first and second sides of the differential pressure actuator, the valve may be actuated so as to alter the flow rate at which the carrier gas is injected by the injector assembly or by an upstream or, more preferably, downstream set of injectors, as discussed further in this document. A differential pressure device may comprise an operable differential pressure transducer to emit a signal indicating that the limit pressure differential has been exceeded or indicative of or related to a pressure differential and, in some embodiments, a signal related to an adverse pressure difference or fault condition.

[0113] A differential pressure device of an injector assembly can be configured to transmit differential pressure information (and, in some embodiments, adverse pressure difference information) to two or more injector assemblies upstream and / or downstream of the same.

[0114] A pressure differential can be determined based on pressure measurements or a related property by pressure sensors associated with adjacent injector assemblies. Such pressure sensors may also, in some embodiments, be able to detect a minimum limit pressure condition or other fault condition as described herein and, consequently, may be in communication with said pilot-operated shut-off valve.

[0115] The system may comprise a unit of Petition 870260050642, dated 05 / 27 / 2026, page 33 / 98 29 / 67 control unit in communication with pressure sensors of (or associated with) adjacent operable injector sets to determine if the limit pressure differential is exceeded. The control unit may be in communication with sensors associated with more than two or each of the injector sets. The control unit may be in communication with one or more or all of the pilot-operated shut-off valves and be configured to emit one or more types of pilot signals to them.

[0116] Each set of injectors may comprise a control unit.

[0117] The flow adjustment mechanism may comprise an adjustable device, such as an adjustable valve (for example, a needle valve, ball valve, adjustable opening valve or similar) or an adjustable flow controller or restrictor or an adjustable nozzle. In some embodiments, such adjustable devices are electromechanically actuated. In some embodiments, such adjustable devices are pressure actuated; that is, under the action of fluid pressure (for example, as a consequence of said fluid pressure differential).

[0118] In some embodiments, the injector assemblies are supplied with carrier gas from a high-pressure manifold (the manifold being at a pressure equal to or above the pressure at which the carrier gas is fed into the pipeline). Flow adjustment mechanisms can be configured to vary the setting of an adjustable device, so as to vary a pressure drop between the manifold and the gas injected into the transport pipeline and thus the flow rate of the injected carrier gas. Petition 870260050642, dated 05 / 27 / 2026, page 34 / 98 30 / 67

[0119] Each set of injectors may comprise a high-flow injection path and a low-flow injection path between a carrier gas source (e.g., manifold) and the carrier pipeline. Each flow adjustment mechanism may be configured to selectively direct the carrier gas through the high-flow injection path (e.g., comprising a large-area flow restrictor or no flow restrictor) or through the low-flow injection path (e.g., comprising a small-area flow restrictor).

[0120] The flow adjustment mechanism can be configured to selectively open only the low-flow injection path or to open both the high-flow and low-flow injection paths. The flow adjustment mechanism may comprise one or more operable injection path selection valves to regulate the flow through the high- and / or low-flow injection paths.

[0121] In some embodiments, therefore, the low-flow injection path remains open to the carrier gas source at all times. In this case, when both flow paths are open (for example, when a said injection path selection valve positioned in a bypass, as described below, is open), a greater proportion of carrier gas will flow through the bypass and thus an increase in injection flow rate occurs.

[0122] This configuration reduces the risk that the flow of carrier gas from the injector assembly to the transport pipeline may be interrupted, for example, through slow or out-of-sequence operation of an injection path selection valve or while a valve is switching. Petition 870260050642, dated 05 / 27 / 2026, page 35 / 98 31 / 67 between the positions.

[0123] Consequently, the invention extends, in a second aspect, to a system for transporting particulate material comprising: A transport pipeline that has an inlet to receive a quantity of particulate material and carrier gas and an outlet; the system being configured to maintain the inlet at a higher carrier gas pressure than the outlet; a plurality of injector sets along the transport pipeline to inject a continuous flow of carrier gas into the pipeline; and each injector set associated with a pressure device to detect pressure conditions in the transport pipeline; each set of injectors having one high-flow injection path and one low-flow injection path between a carrier gas source and the carrier pipeline; and a flow adjustment mechanism configured to selectively open only the low-flow injection path or to open both the high-flow and low-flow injection paths; In use, the operable flow adjustment mechanism opens both the high-flow and low-flow injection paths and thus increases the flow rate at which the carrier gas is injected into the pipeline from a given injection flow rate to an increased injection flow rate when the pressure device detects pressure conditions in the transport pipeline indicative of permeability. Petition 870260050642, dated 05 / 27 / 2026, page 36 / 98 32 / 67 locally reduced material; wherein each set of injectors further comprises a pilot-operated shut-off valve positioned between the flow adjustment mechanism and the transport piping and operable to close in response to a received pilot signal indicating a pressure condition in the transport piping below a minimum limit pressure condition.

[0124] The low-flow injection path may comprise a large-area flow restrictor and a small-area flow restrictor. For example, the low-flow injection path may comprise a bypass of at least a portion of the low-flow injection path (e.g., the small-area flow restrictor).

[0125] The flow adjustment mechanism can be configured to prevent flow through the bypass. For example, an injection path selection valve can be positioned in the bypass.

[0126] The shut-off valve may be positioned downstream (relative to the gas flow through the injector assembly) of said pipelines. The shut-off valve may be positioned immediately upstream of the transport pipeline relative to the direction of gas flow through the injector assembly. The shut-off valve may be positioned immediately upstream of a nozzle to inject transport gas from the nozzle into the pipeline. Consequently, the shut-off valve is operable to protect the flow adjustment mechanism (e.g., any injection pipeline selection valves present) against debris carried in the transport pipeline.

[0127] The injector assembly can optionally Petition 870260050642, dated 05 / 27 / 2026, page 37 / 98 33 / 67 include a passive (i.e., unpiloted) check valve as an additional protection against contamination of the injector assembly by materials in the transport piping. A check valve may be upstream or, more typically, downstream of the shut-off valve.

[0128] Each shut-off valve may incorporate or be operable to function as a check valve.

[0129] The flow adjustment mechanism may comprise a multi-way (e.g., 2-way or 3-way) injection path selection valve operable to select the high or low flow injection path.

[0130] The multi-way injection path selection valve may be positioned in the bypass.

[0131] The multi-way injection path selector valve may be pressure actuated. For example, the multi-way injection path selector valve may be coupled to or comprise a diaphragm actuator or a differential pressure piston actuator.

[0132] The multi-way injection path selection valve can be actuated electromechanically.

[0133] An adjustable electromechanically actuated device can understand or communicate with a control unit.

[0134] In some embodiments, each set of injectors comprises a control unit for controlling an electromechanically actuated or adjustable device based on differential pressure information received. Said control unit may be part of the flow adjustment mechanism. In some embodiments, a single control unit is configured to control more than one or all of the mechanisms. Petition 870260050642, dated 05 / 27 / 2026, page 38 / 98 34 / 67 flow adjustment.

[0135] Such a control unit may communicate with the differential pressure device and a flow adjustment mechanism (and, as mentioned above, in some embodiments, a pilot-operated shut-off valve or valves).

[0136] It will be recognized that such electronic control can be performed through a variety of ways, with signals being communicated between electromechanical devices and / or differential pressure devices, and one or more control units associated with the injector assemblies.

[0137] The system may comprise a processing element that is part of a control unit or issues control instructions to one or more of said control units based on differential pressure information and / or adverse pressure difference information. For example, the system may comprise a computer processor, or one or more computer processors communicating with each other. The system may comprise an associated computer device, such as programmable or fixed memory, and so forth.

[0138] In some circumstances, increasing the injection flow rate when a pressure differential above the limit is detected, as described above, may not be sufficient to move or break a material plug. Under such circumstances, it may be necessary to increase the injection flow rate further.

[0139] One way to achieve this is to further increase the injection flow rate locally, in said set of injectors (for example, through additional adjustment by a flow adjustment mechanism). Petition 870260050642, dated 05 / 27 / 2026, page 39 / 98 35 / 67

[0140] Alternatively, or in addition, in some circumstances, it may be necessary to increase the injection flow rate in one group or in all sets of injectors. The system can be configured to detect such circumstances and increase the injection flow rate accordingly.

[0141] The system can, for example, be configured to determine a system pressure. The system pressure can be determined based on pressure measurements from a series of pressure sensors along the transport pipeline (e.g., an average value).

[0142] System pressure can be measured by a pressure sensor at the inlet or in the conveyor device. A pressure measurement at the inlet or conveyor device can be indicative of resistance to the distribution of particulate material in the conveyor piping.

[0143] An increase in system pressure for longer than a predetermined period may indicate the need to increase injection flow rates along the pipeline. For example, if the system pressure remains elevated for longer than, for example, between approximately 1 and 180 seconds, or between 1 and 120 seconds, or between approximately 1 and 60 or 5 and 60 seconds, the flow rates along the pipeline may be increased.

[0144] Other indications may include the detection of pressure differentials above the limit at or above a certain frequency or the detection of more than a certain number of pressure differentials above the limit at a given time. The need to increase the injection flow rate may be determined based on a combination of such indications. Petition 870260050642, dated 05 / 27 / 2026, page 40 / 98 36 / 67

[0145] When a system pressure is detected above a predetermined system pressure limit, the injection flow rate in one or more, or in some cases all, injector sets may be increased (e.g., for increased injection flow rate).

[0146] In embodiments where a high carrier gas pressure is supplied to the injector assemblies, typically via a manifold, the supply pressure may be increased when a high system pressure is detected. Increasing the supply pressure in this way may cause the injection flow rate to increase (e.g., where the injector assemblies comprise flow restrictors). Indeed, increasing the supply pressure may also cause the system to operate at a generally higher pressure.

[0147] It may be preferable that injection flow rates be increased temporarily, after which the system pressure can be monitored again to determine if it returns to normal.

[0148] The feedback described above between the injection flow rate(s) and the system pressure may constitute a mechanism by which the system calibrates in order to discover the appropriate system pressure and injection flow rate for a particular type of particulate material. For example, the injection flow rate and system pressure may be progressively increased until the rate or number of pressure differentials above the limit is at an acceptable level.

[0149] As described in this document, a system pressure measurement can also lead to the identification of a fault condition, and it should be understood that the condition Petition 870260050642, dated 05 / 27 / 2026, page 41 / 98 37 / 67 maximum limit pressure will normally be above, and typically substantially above, any pressure above the limit that could cause a further increase in injection flow rate.

[0150] It should be understood that some of the operating modes described in this document are performed by means of one or more control units and / or processing elements. For example, control over multiple sets of injectors together or delays to monitor the effects of a change in injection flow rate, increased injection flow rate, system pressure and so on, can be facilitated by electronic control over said parameters.

[0151] The system may comprise any suitable type of conveying device, as known in the state of the art. For example, the conveying device may comprise: a pressure vessel having an inlet port for receiving particulate material; an outlet port extending into the conveying piping through which the particulate material may be distributed under a conveying gas pressure; and a conveying gas inlet through which the pressure vessel may be pressurized to the system pressure.

[0152] The entry port may comprise a pressure isolation valve, such as a rotary valve or a material shut-off valve.

[0153] In use, the pressure of the carrier gas in the conveyor device can be raised to the system pressure before distributing a quantity of particulate material into the pipeline. The pressure of the carrier gas in Petition 870260050642, dated 05 / 27 / 2026, page 42 / 98 38 / 67 conveyor can be maintained at system pressure.

[0154] The conveyor device can be gravity-fed with particulate material, for example, from a hopper. The system can, for example, comprise a hopper that has an outlet above the conveyor's inlet port (optionally connected via a conduit extension).

[0155] The inlet and outlet ports are normally electronically controlled, for example, by a control unit. The carrier gas inlet may also, in some embodiments, be electronically controlled in order to regulate the system pressure. The carrier gas inlet may be pneumatically controlled to regulate the system pressure. Such pneumatic control or a pneumatically controllable device may be controlled by means of a control unit.

[0156] The said control unit, or processing element that issues instructions to it, may be part of or communicate with controller(s) / processing element(s) associated with the injector assemblies, as described in this document.

[0157] The carrier gas can be supplied to the various parts of the system (the carrier device, each of the injector assemblies, a manifold, and so on) from a single source. For example, the system can be connected or connectable to a source of compressed gas, such as a compressed gas cylinder or, more commonly, a compressor.

[0158] The system may include a compressor.

[0159] The carrier gas can be any gas Petition 870260050642, dated 05 / 27 / 2026, page 43 / 98 39 / 67 suitable. Normally, the transport gas is air. However, other gases may be preferred for certain applications. For example, an inert gas, such as nitrogen or carbon dioxide, may be used to transport perishable or oxygen-sensitive materials.

[0160] The transport pipeline can have a straight, curved or convoluted path.

[0161] Injector assemblies may be equally spaced along the transport pipeline or along portions of the transport pipeline. The pipeline route may require that the spacing of the injector assemblies vary in some parts of the pipeline. For example, particulate material may be more prone to blockage in bends in the pipeline, which may therefore benefit from closer spacing of the injector assemblies in their vicinity. The spacing may be selected according to the particular application and may depend on factors such as pipeline diameter, gradient, and so on.

[0162] Injector sets are typically spaced about 1 m to 20 m apart along the transport pipeline, or about 1-12 m or 1-6 m apart. The spacing may be, for example, about 6 m or 12 m between adjacent injector sets.

[0163] The transport piping may comprise more than one outlet. For example, the piping may comprise two or more outlets and be configured so that particulate material can be selectively directed to one of the outlets.

[0164] The transport piping may comprise more than one inlet and associated device, for Petition 870260050642, dated 05 / 27 / 2026, page 44 / 98 40 / 67 example, to facilitate the transport of more than one type of particulate material.

[0165] The system can be a dense phase transport system for transporting dense phase particulate materials, such as sodium sulfate, sodium carbonate, sand, gypsum, alumina, metallurgical coke, clinker, metal powder and concentrates or other inorganic salts, catalyst substrates and so on.

[0166] The system according to the first or second aspects may comprise more than one pressure device.

[0167] A pressure device may be associated with more than one set of injectors. For example, a pressure device may be associated with adjacent sets of injectors or with a series of sets of injectors.

[0168] In some embodiments, each injector device is associated with a separate pressure device.

[0169] Each injector device may comprise a pressure device.

[0170] In a third aspect of the invention, an injector assembly is provided for injecting carrier gas into a particulate material transport pipeline, the injector assembly comprising: a pressure device for detecting pressure conditions in a given transport pipeline; an injector outlet for connection to said transport pipeline through which, in use, a continuous flow of transport gas can be injected into the pipeline; the set of injectors comprising a Petition 870260050642, dated 05 / 27 / 2026, page 45 / 98 41 / 67 Operable flow adjustment mechanism to increase the flow rate at which the carrier gas is injected from the injector outlet, from an injection flow rate to an increased injection flow rate when the pressure device detects pressure conditions in the carrier pipeline indicative of locally decreased material permeability; wherein each set of injectors further comprises a pilot-operated shut-off valve positioned between the flow adjustment mechanism and an outlet for connection to a transport pipeline and operable to close in response to a received pilot signal indicating a pressure condition in the transport pipeline below a minimum limit pressure condition.

[0171] The outlet may, for example, include a nozzle for injecting gas into the transport pipeline.

[0172] The injector assembly may comprise a pilot line communicating pressure with the shut-off valve.

[0173] For example, each shut-off valve can be opened if the static pressure in the pilot line is above a minimum limit pressure and / or below a maximum limit pressure or between a maximum and minimum limit pressure (and otherwise closed).

[0174] Each pilot line can, in use, extend from a pilot collector of a transport system.

[0175] The pilot line may be in pressure communication (directly or by means of a diaphragm or piston actuator or similar) with an upstream part or the inlet to the injector assembly; or a manual shut-off device. Petition 870260050642, dated 05 / 27 / 2026, page 46 / 98 42 / 67

[0176] The pilot line may be for connection, in use, to a part of a transport system, such as an upstream part or the inlet to the transport pipeline; a manifold supplying carrier gas to the injector assembly; a carrier; a source of carrier gas for the system.

[0177] The fault detection device may include the pilot line.

[0178] The pressure device may be a differential pressure device to detect whether a pressure differential is above or below a limit value.

[0179] The injector assembly can be operated to increase the flow rate at which the carrier gas is injected from the injector outlet when the differential pressure device detects a differential pressure above the limit value.

[0180] Differential pressure information can be received from the differential pressure device. Thus, the injector assembly can be operated to increase the flow rate at which the carrier gas is injected from the injector outlet from an injection flow rate to an increased injection flow rate when said differential pressure rises above the limit value.

[0181] Differential pressure information, in use, can be received from another differential pressure device, for example, from another set of injectors. The set of injectors can therefore be connected to another differential pressure device.

[0182] In a fourth aspect of the invention, it is provided Petition 870260050642, dated 05 / 27 / 2026, page 47 / 98 43 / 67 a set of injectors for injecting carrier gas into a particulate material transport pipeline, the injector set comprising: a pressure device for detecting pressure conditions in a given transport pipeline; an injector outlet for connection to said transport pipeline through which, in use, a continuous flow of transport gas can be injected into the pipeline; a high-flow injection path and a low-flow injection path between a carrier gas source and the carrier pipeline; and a flow adjustment mechanism configured to selectively open only the low-flow injection path or to open both the high-flow and low-flow injection paths; In use, the operable flow adjustment mechanism opens both the high-flow and low-flow injection paths and thus increases the flow rate at which the carrier gas is injected into the pipeline from an injection flow rate to an increased injection flow rate when the pressure device detects pressure conditions in the carrier pipeline indicative of locally decreased material permeability; wherein each set of injectors further comprises a pilot-operated shut-off valve positioned between the flow adjustment mechanism and an outlet for connection to the transport piping, and operable to close in response to a received pilot signal indicating a condition of Petition 870260050642, dated 05 / 27 / 2026, page 48 / 98 44 / 67 pressure in the transport pipeline below a minimum limit pressure condition.

[0183] According to a fifth aspect of the invention, a method is provided for transporting particulate material along a transport pipeline, the method comprising; introduce a quantity of the particulate material into the piping; transporting the particulate material along the pipeline under the action of a carrier gas flow along the pipeline; Inject a continuous flow of carrier gas into the pipeline at a plurality of injection locations along the pipeline; Monitor the pressure conditions in the transport pipeline; To monitor the transport pipeline and / or associated device for transporting particulate material for a fault condition; and to increase the flow rate of the transport gas injected into the pipeline at said location from an injection flow rate to an increased injection flow rate, when the pressure device detects pressure conditions in the transport pipeline indicative of locally decreased material permeability; and to close a pilot-operated shut-off valve to interrupt the flow of transport gas injected at an injection location by sending a pilot signal to the shut-off valve, when a pressure condition in the transport pipeline is detected below a pressure condition. Petition 870260050642, dated 05 / 27 / 2026, page 49 / 98 45 / 67 minimum limit.

[0184] The method may comprise detecting a fault condition by detecting an adverse pressure condition or an adverse flow condition, and sending an additional pilot signal to the shut-off valve.

[0185] The method may comprise opening (or reopening) the shut-off valve when a pressure condition in the transport pipeline is detected above the minimum limit pressure condition (and / or through detection of the end of a fault condition).

[0186] The method may comprise detecting a fault condition by detecting a pressure condition in the transport pipeline above a maximum limit pressure condition. As described in this document, a fault condition may be detected by detecting a local pressure above or below a limit value, such as a pressure in a part of the injector assembly; and / or by detecting a flow rate of transport gas above or below a limit flow rate, such as into or along the transport pipeline, into or out of a carrier, or through an injector assembly, etc.

[0187] The method may comprise detecting a fault condition by detecting two or more flow or pressure conditions.

[0188] The method may comprise interrupting the flow of injected carrier gas at each injection site when pressure conditions in the carrier pipeline are detected below the minimum limit pressure condition, and / or a fault condition is detected.

[0189] The method may involve operating manually Petition 870260050642, dated 05 / 27 / 2026, page 50 / 98 46 / 67 a said shut-off valve, or more than one or each shut-off valve.

[0190] The method may comprise reducing or increasing a pressure applied to a pressure-operated device (for example, through a pilot line and / or a pilot manifold) to operate said shut-off valve.

[0191] The method may comprise increasing the flow rate of the carrier gas injected into the pipeline at said location, from an injection flow rate to an increased injection flow rate when a pressure differential that arises above a limit value is detected in the pipeline between adjacent injection locations at a predetermined number of injection locations upstream or downstream of the same.

[0192] The method may involve detecting pressure differentials between each adjacent injection site.

[0193] The flow rate at said injection site may be increased when the detected pressure differential is between said site and an adjacent injection site.

[0194] The flow rate at said injection site may be increased when the detected pressure differential is between two other injection sites adjacent to each other.

[0195] The flow rate at the nth injection site can be increased based on a pressure differential between the (n+m)th injection site and the adjacent (n+m+1)th injection site; or based on a pressure differential between the (nm)th injection site and the adjacent (nm-1)th injection site. The value of m can be 0, 1 or 2 and, in some cases, more than 2.

[0196] The method may comprise transporting the material in particles under the action of a system pressure of Petition 870260050642, dated 05 / 27 / 2026, page 51 / 98 47 / 67 carrier gas, applied, for example, at or upstream of the inlet to the pipeline. Alternatively (or additionally), the method may comprise producing a reduced pressure at the outlet of the carrier pipeline, for example, by pumping the carrier gas from a receiving vessel downstream of the outlet.

[0197] The method may comprise decreasing the flow rate of the carrier gas injected into the pipeline at said injection location from the increased injection flow rate to the injection flow rate, after a fixed period of time, for example, after about 0.0001 to 5 seconds, or about 0.0001 to 3 seconds, or about 0.0001 to 2 seconds, or about 0.0001 to 1 second, or after about 0.5 seconds.

[0198] The method may comprise decreasing the flow rate of the carrier gas to the pipeline at said injection location from the increased injection flow rate to the injection flow rate when the detected pressure differential falls below a threshold value.

[0199] The flow rate can be reduced as soon as the detected pressure differential falls below the limit value.

[0200] The method may comprise further increasing the increased injection flow rate at an injection site or at a group of injection sites.

[0201] The method may comprise injecting carrier gas into the transport pipeline at the injection flow rate along a low flow rate injection path and increasing the flow rate to an increased injection flow rate by injecting carrier gas at the transport flow rate along a high flow rate injection path. Petition 870260050642, dated 05 / 27 / 2026, page 52 / 98 48 / 67

[0202] The method may comprise injecting the carrier gas into the carrier pipeline at an increased injection flow rate along both the high-flow and low-flow injection paths simultaneously.

[0203] In a sixth aspect, the invention extends to a method of transporting particulate material along a transport pipeline, the method comprising; introduce a quantity of the particulate material into the piping; transporting the particulate material along the pipeline under the action of a carrier gas flow along the pipeline; Inject a continuous flow of carrier gas into the pipeline at a plurality of injection locations along the pipeline at a low injection flow rate along a low injection flow rate injection path; Monitor the pressure conditions in the transport pipeline; and at least one said injection site, upon detection by the pressure device of pressure conditions in the transport piping indicative of locally increased material permeability, increasing the flow rate to an increased injection flow rate by injecting transport gas at the transport flow rate along both the low-flow injection path and a high-flow injection path; and closing a pilot-operated shut-off valve to interrupt the flow of injected transport gas at an injection site by sending a pilot signal to the shut-off valve upon detection of a pressure condition in the Petition 870260050642, dated 05 / 27 / 2026, page 53 / 98 49 / 67 transport piping below a minimum limit pressure condition.

[0204] The method may involve transporting a dense-phase particulate material along the pipeline.

[0205] Other preferred and optional features of each aspect of the invention correspond to the preferred and optional features of each other aspect of the invention. For example, a method described in this document may comprise steps associated with the operation of any of the preferred or optional features of any device described in this document. Description of the Drawings

[0206] Illustrative, non-limiting forms will now be described with reference to the following drawings, in which:

[0207] Figures 1(a) and 1(b) show schematic views of (a) a prior art pressurized pneumatic conveying system and (b) a prior art vacuum pneumatic conveying system;

[0208] Figure 2 shows a schematic view of a transport system having a plurality of injector sets along a transport pipeline;

[0209] Figure 3 shows an expanded schematic view of region A from Figure 2, showing sets of adjacent injectors;

[0210] Figure 4 shows a schematic view of an alternative transport system that has a plurality of injector sets along a transport pipeline;

[0211] Figure 5 shows an expanded schematic view of region A from Figure 4; Petition 870260050642, dated 05 / 27 / 2026, page 54 / 98 50 / 67

[0212] Figures 6(a) - (f) show the operation of the injector sets in Figure 5;

[0213] Figure 7 shows an expanded schematic view of an AA region of the transport pipeline of another type of transport system, showing a series of three successive sets of injectors. Detailed Description of Modalities Examples

[0214] Figures 1(a) and (b) show a conventional pressurized dense phase and vacuum pneumatic conveying systems 1 and 2, as described above. Figure 2 shows an embodiment of a system 100 for conveying particulate material according to the invention. Elements common to systems 1 and 2 are provided with similar reference numbers, incremented by 100.

[0215] System 100 has a conveyor device 107, to distribute a quantity of particulate material 108 to an inlet 116 of the transport piping 117. The particulate material 103 is received in the conveyor device 107 from a hopper 105 positioned above the conveyor device, by means of a material shut-off valve 109. The conveyor device 107 is pressurized to a transport gas system pressure (in this embodiment, compressed air) which is supplied from a compressor 111 via a duct 112. The system 100 is typically coupled to a compressed air supply unit (of which the compressor 111 is a part). The compressed air pressure from the compressor is typically in the range from about 250 kPa to 1.2 MPa. Petition 870260050642, dated 05 / 27 / 2026, page 55 / 98 51 / 67 (2.5 bar to 12 bar) and therefore much higher than the required system pressure of approximately 200 kPa to 1.1 MPa (2 to 11 bar) of system 100. Consequently, a valve 113 and flow restrictor 114 regulate the flow from the compressor. The system pressure can be further adjusted by the adjustable valve 125, as described in more detail below.

[0216] Transport pipe 117 extends from inlet 116 to outlet 118, to hopper 119.

[0217] In alternative embodiments, where vacuum pneumatic conveying is employed (not shown), the conveyor is at atmospheric pressure and the pressure in a receiving vessel (instead of hopper 119 in Figure 119) 2) is reduced by a vacuum pump.

[0218] A plurality of injector assemblies 121 are positioned along the transport piping 117 and, in use, each injects a continuous flow of the transport gas into the transport piping. The injector assemblies 121 are supplied with compressed air from the compressor 111 via a high-pressure manifold 123. An additional flow restrictor 127 and adjustable valve 129 are positioned between the compressor and the manifold to provide further regulation of the injected transport gas, which will also be described in more detail below.

[0219] System 100 includes a pressure device, in this case, a differential pressure device. Each of the injector assemblies includes a differential pressure device configured to detect if there is a pressure differential between each adjacent pair of injector assemblies. Petition 870260050642, dated 05 / 27 / 2026, page 56 / 98 52 / 67 is above or below a limit value (an example of a pressure condition indicative of a locally decreased material permeability in the pipeline). Each set of injectors 121 is operable to increase the flow rate at which the carrier gas is injected into the pipeline 117 from an injection flow rate to an increased injection flow rate when said pressure differential rises above the limit value.

[0220] Figure 3 shows a detailed schematic view of a region A of system 100 which includes adjacent injector sets 121A and 121B. The downstream and upstream directions along pipe 117 are shown by arrows D and U, respectively. The reference numbers of injector set 121B are marked with an asterisk.

[0221] The injector assembly 121A has a low-flow injection path in which compressed air (or other suitable carrier gas) is routed from manifold 123, along gas lines aek, and through a narrow flow restrictor (i.e., low-flow area) 130, so that the compressed air can be directed through line d to an injection nozzle 134 and injected into the piping 117. A check valve 136 is positioned along line d to prevent backflow from the piping. The narrow flow restrictor is typically about 0.2 mm in diameter, however, the diameter can vary from about 0.01 to 3.0 mm depending on the particular application.

[0222] The injector assembly 121A also includes a high-flow injection path, which extends from the manifold 123, through the gas lines bec that bypass the line k comprising the flow restrictor 130. A wider flow restrictor 146 (i.e., high-flow areas) is Petition 870260050642, dated 05 / 27 / 2026, page 57 / 98 The 53 / 67 positioned in line be has a larger flow area than the 130 flow restrictor. The wider 146 flow restrictor typically has a diameter of about 0.7 mm, however, depending on the particular application, the diameter can vary from about 1.0 to 10.0 mm.

[0223] In alternative embodiments (not shown), no flow restrictor is present in the high-flow injection path. Alternatively, the wider flow restrictor 146 may be located elsewhere in the high-flow injection path, such as in line d. In fact, the high- and low-flow area restrictors 130, 146 may be in series, and the high-flow area flow restrictor 146 now needs to be in the bypass b, c in general and may be the high-flow area flow restrictor positioned in the line upstream of the check valve, but downstream of the junction with line k, as in the embodiment of Figure 6 discussed below.

[0224] A piston-operated injection path selection valve, the bypass valve 132, is positioned in the high-flow injection path between lines b and c. The bypass valve 132 is actuated by a piston actuator 138. The piston of the actuator 138 is connected to a gas control line e. The position of the piston actuator 138, and therefore of the bypass valve 132, is determined by the relative forces applied to the piston in the actuator by a return spring and pressures in line e.

[0225] A control line f extends between manifold 123 and a piston-operated injection path selector valve 140.

[0226] Valve 140 is actuated by a differential pressure piston actuator 142. A first side of Petition 870260050642, dated 05 / 27 / 2026, page 58 / 98 54 / 67 piston actuator 142 is connected to gas line g. A second side of actuator 142 is connected to gas line h. The position of the piston actuator 142, and therefore of the valve 140, is determined by the relative pressures in the lines g and h. The piston actuator 142 comprises a resilient element, such as a spring (not shown), which determines the limiting pressure differential required for it to change position. Optionally, the spring (or other suitable resilient element) may be adjustable, so that the limiting pressure differential can be adjusted.

[0227] Line g extends to the 4-way junction 144 and is therefore in fluid pressure communication with line d. Consequently, line g is at the same pressure as line d, thus reflecting the pressure in pipe 117 at injection point 134.

[0228] Line h extends to the corresponding 4-way junction 144* of injector assembly 121B and is therefore at line d* pressure and thus reflects the pressure in the piping at injection location 134*.

[0229] Differential pressure piston actuators 142 and 142* therefore function as the differential pressure device for the respective injector assemblies 121A and 121B.

[0230] The operation of system 100 for transporting particulate material 115 along pipe 117 is generally as described below with reference to Figures 6(a) - (f).

[0231] When the system in Figure 3 is switched off, for example, for routine maintenance, valve 113 can be closed and the compressor isolated (or switched off itself). From Petition 870260050642, dated 05 / 27 / 2026, page 59 / 98 55 / 67 In the same way, if necessary, the material shut-off valve 109 can also be closed (or a valve at the pipe inlet 116, if present).

[0232] The pressure is then purged from the piping through outlet 118. The pressure inside the manifold 123 and each of the injector assemblies 121 is also purged through the check valves 136.

[0233] Figures 4 and 5 show an alternative system 200. Elements in common with the system shown in Figure 3 are given with similar reference numbers incremented by 100.

[0234] System 200 further comprises a pilot manifold pm connected and in pressure communication with piping 217 near inlet 216. Each set of injectors 221, 222 is connected to the pilot manifold pm via a pilot line p.

[0235] In alternative embodiments (not shown), each pilot line communicates with the compressor, locally with the transport piping and / or includes a manual shut-off valve or vent to depressurize the pilot manifold or a pilot line.

[0236] As shown in Figure 5, each set of injectors 221 (and also the terminal injector sets 222, now shown in Figure 5) further includes a pressure-operated shut-off valve 250, in place of the check valve 136. The shut-off valves also function as, or incorporate, check valves.

[0237] Shut-off valves 250 are held in an open position by the nominal pressure in piping 217 near inlet 216. A minimum limit pressure for each valve Petition 870260050642, dated 05 / 27 / 2026, page 60 / 98 56 / 67 250 can be selected as needed as a proportion (e.g., 75% or 90%) of the nominal inlet pressure.

[0238] When system 200 is switched off and pressure is purged from transport piping 217, the pressure in the manifold pm also drops, causing each of the shut-off valves to close once the minimum limit pressure is reached, thus substantially preventing purging of the injector assemblies. Once the piping is pressurized again, the valves 250 will reopen and normal transport operation can be resumed.

[0239] The shut-off valves will also close automatically if the pressure in pipe 217 is lost unexpectedly, for example, due to a leak.

[0240] The normal operation of injectors 221 during material transport will now be described with reference to Figure 6.

[0241] Figure 6(a) shows the system configuration when the pressure in the piping at nozzle 234 is the same as the pressure in the piping at nozzle 234*. In this configuration, the injection path selection bypass valve 232 is closed and compressed air flows along the low-flow injection path, from manifold 223 through lines a, ked, to nozzle 234 (as indicated by the arrows).

[0242] The pressure drops from the high pressure of the manifold 223 to the pressure in the transport pipe through the flow restrictor 230.

[0243] The geh lines are at the same pressure as the respective nozzles 234 and 234*, so the actuator 242 is in a position that corresponds to the path selection valve of Petition 870260050642, dated 05 / 27 / 2026, page 61 / 98 57 / 67 injection 240 being closed.

[0244] Figure 6(b) shows the configuration of injector assembly 2 when the permeability of material 215 decreases in a region of the piping. In this situation, there is a small increase in pressure in the piping near nozzle 234. This results in an increase in pressure in lines g, so that there is a pressure differential above the limit across actuator 242. Under the action of the pressure differential, fluid from line g enters the first side of actuator 242 and the piston moves in direction B and displaces fluid from the second side of the actuator to line h.

[0245] In turn, the movement of actuator 242 causes valve 240 to open, as shown in Figure 6(c). Line f is at high pressure from manifold 223 and line a. The opening of valve 240 causes fluid to flow through the valve and displace the piston of actuator 238 in direction C.

[0246] Differential pressure information can be considered to consist of one or more of the following: - the position of the differential pressure actuator 242; - the open / closed position of valve 240; - pressure on the line and; - the position of actuator 238. 74 / 86

[0247] As shown in Figure 6(d), actuator 238 thus switches bypass valve 232 to open the high-flow path along lines b and c, between lines a and d. The low-flow path along line k remains open in general, so as to maintain Petition 870260050642, dated 05 / 27 / 2026, page 62 / 98 58 / 67 continuous airflow through nozzle 234. Due to the respective flow areas through the flow restrictors, most of the air now flows through the wider flow restrictor 246, thus allowing flow through the nozzle. 234. The injection path selection valve 232 and valve 240 are therefore part of a flow adjustment mechanism.

[0248] The increase in the flow rate of the injected carrier gas may locally increase the pressure in the pipeline, for example, if the permeability of material 215 does not increase immediately. In this case, the pressure in line g also increases, so the fluid pressure differential across the actuator 242 increases further. The pressure in line h for an adjacent upstream injector assembly (not shown) is also then increased, and thus the pressure differential across the piston actuator of the upstream injector assembly is negative and this upstream injector assembly is maintained in the configuration shown in Figure 6(a).

[0249] The effect of increasing the flow rate of air injected into the pipe 217 through the nozzle 234 is to increase the permeability of the particulate material 215, or to break, or move a plug of particulate material 215. In both cases, the pressure in the pipe equalizes and the pressure differential across the actuator 242 decreases below the limit value. As a consequence, the piston in the actuator moves in the D direction as the fluid is displaced from line he to line g (Figure 6(e)).

[0250] With reference now to Figure 6(f), when valve 240 closes under the action of actuator 242, the air is purged. Petition 870260050642, dated 05 / 27 / 2026, page 63 / 98 59 / 67 back through the valve from e to f under the action of the spring piston of the actuator 238 (in the E direction). This closes by the bypass valve 232 and therefore the high flow injection path and returns the injector assembly 221A to the configuration shown in Figure 6(a).

[0251] Consequently, injector assemblies 221 are configured to increase the flow rate at which compressed air is injected into the piping from an injection flow rate to an increased injection flow rate when said pressure differential rises above the limit value and to decrease the flow rate of compressed air injected into the piping back to the injection flow rate as soon as the detected pressure differential falls below the limit value. The limit value is set at approximately 1 kPa (10 mbar) (although, in some circumstances, this may be set up to approximately 9 kPa (90 mbar)), so as to ensure that air is flowing through the nozzles and in the piping at all times. This continuous flow prevents blockage or damage to the nozzles or any other part of the injector assembly by particulate material.

[0252] By incorporating the check valve functionality, the 250 valves are also operable to close in response to a fault condition in the form of a pressure in the transport pipeline above a maximum limit pressure. The maximum pressure limit in this mode is defined in relation to the pressure in line d. A small increase in pressure in the pipeline will not overcome the low flow rate through nozzle 134. Furthermore, such a pressure increase may also be associated with an increase in flow rate along line d, and a concomitant pressure increase, so that any potential blockage can be avoided. Petition 870260050642, dated 05 / 27 / 2026, page 64 / 98 60 / 67

[0253] However, if the pressure, for any reason (for example, blockage, malfunction in the air supply), increases further, enough to overcome the flow through d, then the valves 250 will close.

[0254] Referring again to Figure 2, the conveyor device 107 is equipped with a pressure gauge 106 to measure the system pressure in the conveyor device. As mentioned above, the system pressure setpoint, i.e., the pressure at which the carrier gas is delivered to the conveyor 107, is regulated by the solenoid valve 125. The adjustment of the solenoid valve can be controlled by a controller 140 that receives pressure readings from the gauge 106.

[0255] In alternative embodiments (not shown), the system may comprise a pneumatically adjustable valve in place of the solenoid valve 125. Alternatively, the valve may be manually adjustable.

[0256] System 100 can also be configured for controller 140 to regulate the setpoint of air pressure in the manifold, for example, to maintain the manifold pressure within a predefined range (or equal to) the system pressure. In system 100, 200, an increased manifold pressure has the effect of increasing the injection flow rate and the increased injection flow rate. The pressures at which the carrier gas is injected increase or decrease proportionally.

[0257] In alternative embodiments, this can be achieved by means of variable flow restrictors in each of the injector sets, or in selected injector sets, as mentioned below.

[0258] The 100 system, in addition, includes sets Petition 870260050642, dated 05 / 27 / 2026, page 65 / 98 61 / 67 of terminal injectors 122 near the inlet and outlet. Since these do not have adjacent upstream and downstream injector sets, respectively, they differ from injector sets 121. The terminal injector set 122 closest to the inlet 116 may, for example, not have an h-line, while the terminal injector set 122 closest to the outlet does not need to be equipped with a pressure differential device or means to adjust the injection flow rate. However, it will be understood that, in practice, it may be convenient for all terminal and non-terminal injector sets to be structurally identical, with redundant features of the terminal injector sets being deactivated.

[0259] System 200 includes corresponding resources (reference numbers incremented by 100).

[0260] Figure 7 shows an alternative embodiment of a series of injector assemblies 1021A, 1021B and 1021C of a system 1000 for transporting particulate material according to the invention. Features in common with system 200 are provided with similar reference numbers incremented by 800.

[0261] The downstream and upstream directions along pipeline 1017 are shown by arrows D and U, respectively. The reference numbers for injector assembly 1021B are marked with * and those for injector assembly 1021C are marked with **.

[0262] As described above in relation to injector assembly 121A of system 100, injector assembly 1021A has a low-flow injection path in which compressed air (or other suitable carrier gas) is Petition 870260050642, dated 05 / 27 / 2026, page 66 / 98 62 / 67 is routed from manifold 1023, along gas lines a, ked, to an injection nozzle 1034 and injected into pipe 1017. A narrow flow restrictor 1030 is positioned on line k. A check valve 1036 is positioned along line d to prevent backflow from the pipe.

[0263] The injector assembly 1021A also includes a high-flow injection path extending from the manifold 1023 through the bypass lines be c. An injection path selection valve, the bypass valve 1032, is positioned between the lines be c, so that the narrow flow restrictor 1030 can be selectively bypassed by opening the valve 1032, generally as described above.

[0264] A shut-off valve 1050 is positioned in line ke and maintained in an open position by pressure in a pilot line p. Together, the pilot line p and the associated manifold in pressure communication with the system pressure function as a fault detection device.

[0265] A wide flow restrictor 1046 is, in this example, positioned upstream of the check valve 1036, but downstream of the junction with line k. Thus, the air injected along both the high-flow and low-flow paths passes through the flow restrictor 1046. However, when the bypass valve is closed and only the low-flow path is in use, the narrow flow restrictor 1036 is the restricting parameter and thus the wide flow restrictor 1046 has a negligible additional influence on the injection flow rate.

[0266] The bypass valve 1032 is actuated by a piston actuator 1038. The piston of the actuator 1038 is Petition 870260050642, dated 05 / 27 / 2026, page 67 / 98 63 / 67 connected to a gas control line and running from an injector assembly to two injection locations upstream of injector assembly 1021A (not shown in the figure). Similarly, injector assembly 1021B has a piston actuator 1038* connected to a line and from an injector assembly to two injection locations upstream (and therefore only at the upstream location of injector assembly 1021A), while the line and from injector assembly 1021A extends to actuator 1038** of injector assembly 1021C, two injection locations downstream.

[0267] The open or closed position of the piston actuator 1038 and therefore of the bypass valve 1032 is determined by the relative forces applied to the piston in the actuator by a return spring and pressures in the line and extending from the upstream injector assembly.

[0268] A control line f extends between the manifold 1023 and a piston-operated injection path selector valve 1040.

[0269] Valve 1040 is actuated by a differential pressure piston actuator 1042. One side of the piston actuator 1042 is connected to the gas line g. A second side of the actuator 1042 is connected to the gas line h. The position of the piston of actuator 1042, and therefore of valve 1040, is determined by the relative pressures of lines g and h. The piston actuator 1042 comprises a resilient element, such as a spring (not shown), which determines the limiting pressure differential required for it to change position, as described above.

[0270] Line g extends to the 4-way junction 1044 and is therefore in fluid pressure communication with Petition 870260050642, dated 05 / 27 / 2026, pages 68 / 98 64 / 67 line d. Consequently, line g is at the same pressure as line de, thus reflecting the pressure in pipe 1017 at injection point 1034.

[0271] Line h extends to the corresponding 4-way junction 1044* and is therefore at line d* pressure and therefore reflects the pressure in the piping at injection location 1034*.

[0272] Differential pressure piston actuators 1042, 1042* and 1042** function as the differential pressure device for their respective injector assemblies.

[0273] The operation of system 1000 is generally analogous to the operation of system 100. When the pressure in the piping at nozzle 1034 is the same as the pressure in the piping at nozzle 1034*, compressed air flows along the low-flow injection path of each of the injector sets 1021A-C through their respective lines a,k, d (and a*, k*, d* and a**, k**, d**, respectively) to nozzles 1034-1034**.

[0274] Valve 1032 of injector assembly 1021A is closed by default, to close the bypass along lines be c. Lines geh are at the same pressure as the respective nozzles 1034 and 1034*, so actuator 1042 is in a position that corresponds to valve 1040 being closed. The corresponding valves of the other injector assemblies are in the same configuration.

[0275] When a portion of locally reduced permeability material 1015 passes or occurs between nozzles 1034 and 1034*, a pressure differential above the limit may occur across actuator 1042. Under the action of this detected pressure differential, fluid from line g enters the first side of actuator 1042 and the fluid is displaced. Petition 870260050642, dated 05 / 27 / 2026, p. 69 / 98 65 / 67 for line h.

[0276] This causes valve 1040 to open. In system 1000 injector assemblies, the valve opening 1040 exposes line e to high pressure on line f (which is on the high pressure of manifold 1023 and line a).

[0277] Unlike injector assembly 221A of system 200, when using injector assembly 1021A, opening valve 1040 causes fluid to flow through the valve via line ee and displace the actuator piston 1038** of injector assembly 1021C, two injector assemblies downstream.

[0278] This tells the bypass valve 1032** to open the high-flow path between lines b** and c**, of the injector assembly 1021C. The flow through nozzle 1034** is then the increased injection flow. The low-flow path along line k** remains open at all times.

[0279] It should be understood that the injection flow rate through each set of injectors 1021 of the system 1000 is regulated in a similar manner based on pressure differentials detected between two other sets of injectors adjacent upstream of the same (with the exception of terminal sets of injectors near the inlet or outlet of the transport pipeline 1017).

[0280] In this way, system 1000 ensures that the reduced permeability material passes through the injection site at an increased injection flow rate as it progresses downstream along the transport pipeline 1017. The possibility of the reduced permeability region having progressed downstream from where the injection flow rate is increased (as may happen during the period required for the Petition 870260050642, dated 05 / 27 / 2026, pp. 70 / 98 66 / 67 (the system responds to the detected pressure differential) is therefore significantly reduced. In turn, this reduces the likelihood of exacerbating the reduction in permeability of the particulate material or forming or further compressing a material plug.

[0281] In common with systems 100, 200, in use of system 1000, once the pressure differential detected between injector sets 1021A and 1021B (or any two adjacent injector sets) falls below the limit value, the differential pressure actuator 1042 returns to its original position, the valve 1040 closes and the pressure in the line drops, until injector set 1021C reverts to low injection flow.

[0282] It should also be recognized that sets of injectors further upstream or downstream of the system region 1000 shown in Figure 7 (and, in fact, region A of the system) 100) are capable of operating independently in this manner. Thus, multiple transient variations in the permeability of the particulate material can be addressed simultaneously in order to maintain stable transport.

[0283] When a fault condition is detected (in the form of a loss of pressure in the upstream system, in the conveyor or near the inlet of the transport pipeline), the pressure in the pilot lines p, p* and p** is reduced and the respective shut-off valves 1050, 1050* and 1050** are all closed. The 1000 system generally responds as described above in relation to Figure 3, with injection through the injector assemblies at that moment conjured to be done through the low-flow injection path at the injection pressure stopping immediately, followed shortly afterwards by any assemblies of Petition 870260050642, dated 05 / 27 / 2026, pp. 71 / 98 67 / 67 injectors at that moment of injection at the increased injection flow rate, as their respective differential pressure switches 1042 cause the valves to close.

[0284] Although the invention has been described in relation to the previous illustrative embodiments, various modifications, additions and alterations may be made to the invention by those skilled in the art without departing from the scope of the claimed invention.

Claims

1. SYSTEM (200, 1000) FOR TRANSPORTING PARTICULATE MATERIAL comprising: a transport pipe (217, 1017) having an inlet (216) for receiving a quantity of particulate material (215, 1015) and carrier gas, and an outlet (218); the system being configured to maintain the inlet at a higher carrier gas pressure than the outlet; a plurality of injector sets (221, 22 IA, 221B, 102 IA, 1021B, 1021C) along the transport pipe (217, 1017) for injecting a continuous flow of carrier gas into the pipe; wherein each set of injectors (221, 22 IA, 221B, 102 IA, 1021B, 1021C) is associated with a pressure device (242, 242*, 1042, 1042*, 1042**) for detecting pressure conditions in the transport pipeline (217, 1017); and wherein each set of injectors (221, 22 IA, 221B, 102 IA, 1021B, 1021C) comprises an operable flow adjustment mechanism (232, 240; 232*, 240*; 1032, 1040; 1032*, 1040*;1040*) to increase the flow rate at which the carrier gas is injected into the pipeline from an injection flow rate to an increased injection flow rate, when the pressure device (242, 242*, 1042, 1042*, 1042**) detects pressure conditions in the carrier pipeline indicative of locally decreased material permeability; characterized in that each set of injectors (221, 22 IA, 221B, 102 IA, 1021B, 1021C) comprises a pilot-operated shut-off valve (250, 250*, 1050, 1050*, 1050**) positioned between the flow adjustment mechanism and the pipeline. Petition 870260050642, dated 05 / 27 / 2026, page. 73 / 98 2 / 10 transport (217, 1017) and operable to close in response to a received pilot signal indicating a pressure condition in the transport pipeline (217, 1017) below a minimum limit pressure condition.

2. SYSTEM (200, 1000), according to claim 1, characterized in that the pilot-operated shut-off valve (250, 250*, 1050, 1050*, 1050**) of each set of injectors (221, 22 IA, 221B, 102 IA, 1021B, 1021C) is operable to open in response to a received pilot signal indicating a pressure condition in the transport piping (217, 1017) above the minimum limit pressure condition.

3. SYSTEM (200, 1000), according to claim 1 or 2, characterized in that the minimum limit pressure condition is an absolute minimum limit pressure.

4. SYSTEM (200, 1000), according to claim 3, characterized in that the minimum limit pressure is a minimum pressure of the transport pipeline (217, 1017).

5. SYSTEM (200, 1000), according to claim 1 or 2, characterized in that the minimum limit pressure condition is a minimum limit pressure difference.

6. SYSTEM (200, 1000), according to claim 5, characterized in that the minimum limit pressure difference is a pressure difference: between the pressure in a part of said injector assembly (221, 22 IA, 221B, 102 IA, 1021B, 1021C) and the pressure in the transport pipeline (217, 1017); between the expected and actual pressure in the transport pipeline (217, 1017); or between the pressure of the transport pipeline (217, 1017) at its inlet and another part, downstream, of the transport pipeline (217, 1017). Petition 870260050642, dated 05 / 27 / 2026, page 74 / 98 3 / 10 7. SYSTEM (200, 1000), according to any one of claims 1 to 6, characterized in that the minimum limit pressure condition is related to the overall system pressure or to the pressure in the transport pipeline (217, 1017).

8. SYSTEM (200, 1000), according to any one of claims 1 to 7, characterized in that the shut-off valves (250, 250*, 1050, 1050*, 1050**) are configured to operate simultaneously.

9. SYSTEM (200, 1000), according to claim 8, characterized in that the shut-off valves (250, 250*, 1050, 1050*, 1050**) are configured to receive a common pilot signal and / or in that the shut-off valves (250, 250*, 1050, 1050*, 1050**) can be configured to operate simultaneously when receiving a pilot signal by any of the shut-off valves (250, 250*, 1050, 1050*, 1050**).

10. SYSTEM (200, 1000), according to any one of claims 1 to 9, characterized in that the shut-off valve (250, 250*, 1050, 1050*, 1050**) of each set of injectors (221, 22 IA, 221B, 102 IA, 1021B, 1021C) is connected to an electric or pneumatic pilot line (p, p*, p**).

11. SYSTEM (200, 1000), according to any one of claims 1 to 10, characterized in that each pilot-operated shut-off valve (250, 250*, 1050, 1050*, 1050**) communicates with a pneumatic pilot line (p, p*, p**), and wherein the pilot signal is a pressure signal selected from a decrease in pressure below a minimum limit pressure, a pressure pulse, or a pressure difference.

12. SYSTEM (200, 1000), according to claim 11, characterized in that each pilot-operated shut-off valve (250, 250*, 1050, 1050*, 1050**) is a pressure-operated valve, optionally each valve comprising or being coupled to a diaphragm actuator or a differential pressure piston actuator.

13. SYSTEM (200, 1000), according to claim 11 or 12, characterized in that each pilot line (p, p*, p**) extends from a pilot collector.

14. SYSTEM (200, 1000), according to any one of claims 1 to 13, characterized in that each shut-off valve (250, 250*, 1050, 1050*, 1050**) is in communication with another part of the system selected from: the transport piping (217, 1017), optionally an upstream part or the inlet to the transport piping (217, 1017); an upstream part or the inlet to the respective injector assembly (221, 22 IA, 221B, 102 IA, 1021B, 1021C); a conveyor (207); a source (211) of transport gas for the system; a manifold (223, 1023) supplying transport gas to the injector assemblies; and / or a manual shut-off device.

15. SYSTEM (200, 1000), according to any one of claims 1 to 14, characterized in that each shut-off valve (250, 250*, 1050, 1050*, 1050**) is operable to close in response to one or more additional pilot signals, wherein one or more additional pilot signals are indicative of one or more fault conditions.

16. SYSTEM (200, 1000), according to claim 15, characterized in that each pilot-operated shut-off valve (250, 250*, Petition 870260050642, dated 05 / 27 / 2026, page 76 / 98 5 / 10 1050, 1050*, 1050**) is operable to close in response to a received pilot signal indicating a pressure condition in the pipeline above a maximum limit pressure condition and, optionally, to open in response to a received pilot signal indicating a pressure condition in the transport pipeline below the maximum limit pressure condition.

17. SYSTEM (200, 1000), according to claim 15 or 16, characterized by comprising a fault detection device, the fault detection device optionally comprising one or more pressure and / or flow sensors, operable to detect a fault condition or conditions.

18. SYSTEM (200, 1000), according to any one of claims 1 to 17, characterized in that the pressure conditions indicative of decreased permeability comprise a pressure differential between two points along the pipeline (217, 1017) or between two sets of injectors (221, 22 IA, 221B, 102 IA, 1021B, 1021C), such as adjacent sets of injectors.

19. SYSTEM (200, 1000), according to claim 18, characterized by comprising a differential pressure device for detecting whether a differential pressure in the pipeline between said injector set (221, 22 IA, 221B, 102 IA, 1021B, 1021C) and an adjacent injector set is above or below a limit value; wherein each injector set (221, 22 IA, 221B, 102 IA, 1021B, 1021C) is operable to increase the flow rate at which the carrier gas is injected into the pipeline from an injection flow rate to an increased injection flow rate when a differential pressure Petition 870260050642, dated 05 / 27 / 2026, p. 77 / 98 6 / 10 detected, in a predetermined number of injector sets (221, 22 IA, 221B, 102 IA, 1021B, 1021C) upstream or downstream of the same, rises above the limit value.

20. SYSTEM (200, 1000), according to claim 19, characterized in that each set of injectors (221, 22 IA, 221B, 102 IA, 1021B, 1021C) comprises a differential pressure device, each differential pressure device comprising an injection path selection valve coupled to a differential pressure actuator, wherein a first side of the differential pressure actuator is in fluid communication with the set of injectors (221, 22 IA, 221B, 102 IA, 1021B, 1021C), and a second side of the differential pressure actuator is in fluid communication with an upstream or downstream set of injectors.

21. SYSTEM (200, 1000), according to any one of claims 1 to 20, characterized in that each set of injectors (221, 22 IA, 221B, 102 IA, 1021B, 1021C) comprises a high flow injection path (b, c; b*, c*; b**, c**) and a low flow injection path (k, k*, k**) between a transport gas source and the transport pipeline (217, 1017).

22. SYSTEM (200, 1000), according to claim 21, characterized in that the flow adjustment mechanism is configured to selectively open only the low flow injection path (k, k*, k**) or to open both the high flow injection path (b, c; b*, c*; b**, c**) and the low flow injection path.

23. SYSTEM (200, 1000), according to claim 22, characterized in that the low flow injection path (k, k*, k**) comprises a large area flow restrictor and a small area flow restrictor, and in that the high flow injection path (b, c; b*, c*; b**, c**) comprises a bypass of the small area flow restrictor.

24. SYSTEM (200, 1000), according to any one of claims 1 to 23, characterized in that the shut-off valve (250, 250*, 1050, 1050*, 1050**) of each injector assembly (221, 22 IA, 221B, 102 IA, 1021B, 1021C) is positioned immediately upstream of the transport piping (217, 1017) relative to the direction of gas flow through the injector assembly (221, 22 IA, 221B, 102 IA, 1021B, 1021C).

25. INJECTOR ASSEMBLY (221, 221A, 221B, 1021A, 1021B, 1021C) FOR INJECTING CARRIER GAS INTO A PARTICULATE MATERIAL TRANSPORT PIPELINE (217, 1017), as defined in claim 1, comprising: a pressure device (242, 242*, 1042, 1042*, 1042**) for detecting pressure conditions in said transport pipeline (217, 1017); an injector outlet for connection to said transport pipeline (217, 1017) through which, in use, a continuous flow of carrier gas can be injected into the pipeline (217, 1017); the set of injectors comprising a flow adjustment mechanism (232, 240; 232*, 240*; 1032, 1040; 1032*, 1040*;1032**) operable to increase the flow rate at which the carrier gas is injected from the injector outlet, from an injection flow rate to an increased injection flow rate, when the pressure device (242, 242*, 1042, 1042* 1042**) detects pressure conditions in the carrier pipeline (217, 1017) indicative of locally decreased material permeability; Petition 870260050642, dated 05 / 27 / 2026, page. 79 / 98 8 / 10 characterized in that each set of injectors further comprises a pilot-operated shut-off valve (250, 250*, 1050, 1050*, 1050**) positioned between the flow adjustment mechanism and an outlet for connection to a transport pipe (217, 1017) and operable to close in response to a received pilot signal indicating a pressure condition in the transport pipe (217, 1017) below a minimum limit pressure condition.

26. INJECTOR ASSEMBLY (221, 221A, 221B, 1021A, 1021B, 1021C), according to claim 25, characterized by comprising: a high-flow injection path (b, c; b*, c*; b**, c**) and a low-flow injection path (k, k*, k**) between a carrier gas source and the carrier pipeline; and wherein the flow adjustment mechanism is configured to selectively open only the low-flow injection path (k, k*, k**), or to open both the high-flow injection path (b, c; b*, c*; b**, c**) and the low-flow injection path; in use, the operable flow adjustment mechanism opens both the high-flow injection path (b, c; b*, c*;b**, c**) as low flow rate and thus increases the flow rate at which the carrier gas is injected into the pipeline from an injection flow rate to an increased injection flow rate, when the pressure device (242, 242*, 1042, 1042* 1042**) detects pressure conditions in the carrier pipeline (217, 1017) indicative of locally decreased material permeability.; 27. METHOD FOR TRANSPORTING PARTICLE MATERIAL (215, 1015) ALONG A TRANSPORT PIPELINE (217, 1017), as defined in claim 1, characterized by Petition 870260050642, dated 05 / 27 / 2026, page 80 / 98 9 / 10 comprising: introducing a quantity of the particulate material into the pipeline; transporting the particulate material along the pipeline under the action of a flow of a carrier gas along the transport pipeline; injecting a continuous flow of carrier gas into the pipeline at a plurality of injection locations (234, 234*, 1034, 1034*, 1034**) along the pipeline; monitoring the pressure conditions in the transport pipeline; monitoring the transport pipeline and / or associated device for transporting the particulate material for a failure condition;and increase the flow rate of the carrier gas injected into the pipeline at said location, from an injection flow rate to an increased injection flow rate, when the pressure device (242, 242*, 1042, 1042*, 1042**) detects pressure conditions in the carrier pipeline indicative of locally decreased material permeability; and close a pilot-operated shut-off valve (250, 250*, 1050, 1050*, 1050**) to interrupt the flow of carrier gas injected at an injection location by sending a pilot signal to the shut-off valve when a pressure condition in the carrier pipeline is detected below a minimum limit pressure condition.

28. METHOD, according to claim 27, characterized by comprising detecting a fault condition by detecting an adverse pressure condition or an adverse flow condition, and sending an additional pilot signal to the shut-off valve (250, 250*, 1050, 1050*, 1050**).

29. METHOD, according to claim 28, characterized by comprising detecting a fault condition by detecting a pressure condition in the transport piping (217, 1017) above a maximum limit pressure condition.

30. METHOD, according to any one of claims 27 to 29, characterized by comprising opening or reopening the shut-off valve (250, 250*, 1050, 1050*, 1050**) when a pressure condition is detected in the transport piping (217, 1017) above the minimum limit pressure condition and / or, when dependent on claim 28 or 29, by detecting the end of a fault condition.

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