Purpose: The purpose of this paper is to focus on predicting the pressure drop in fluidized dense phase pneumatic conveying of fine particles through pipelines by modelling the solids friction factor in terms of non-dimensional parameters using experimental data of definite pipeline configuration. Finally, the model is to be tested for a different pipeline configuration. Design/methodology/approach: Solids friction factor has been expressed in terms of certain non-dimensional parameters such as density ratio, solids loading ratio and mean particle diameter to pipe diameter ratio, and a certain number of coefficients and exponents. Experimental data of five conveying materials (two types of fly ash, two types of alumina and one type of cement meal) for a pipeline configuration of diameter 53 mm and length 173 m and another conveying material EPS dust for two pipeline configurations (69-mm diameter, 168-m long; 105-mm diameter, 168-m long) have been used to calculate the unknown coefficients or exponents of the mathematical model for solids friction factor. Findings: The developed model gives the best results in predicting the pressure drop for the pipelines that are less than 173-m long, but the model shows a large error for the pipelines more than 173-m long. Research limitations/implications: Current research will be helpful for the researchers to model the process of pneumatic conveying through long distances. Practical implications: The method will be helpful in conveying powder materials through long distances in cement or brick industry, alumina industry. Social implications: Fly ash piles over at the nearby places of thermal power plants. Pneumatic conveying is the best method for transporting the fly ash from the location of power plants to the nearby brick industries or cement industries. Originality/value: Solid friction factor has been presented in terms of four non-dimensional parameters and evaluated the accuracy in predicting the pressure drop for two different pipeline configurations. © 2020, Emerald Publishing Limited.