At a desulfurizer manufacturer in Huizhou, Guangdong, traditional powder conveying methods have long faced issues such as low efficiency, dust leakage, and high maintenance costs. To solve this problem, Head Powder customized a positive pressure conveying system for them, achieving safe, efficient, and environmentally friendly delivery of desulfurizer powder, thereby improving the overall operation level of the production line.

Case Summary

The client of this case is a desulfurizer manufacturer located in Huizhou, Guangdong, mainly producing limestone powder for flue gas desulfurization in coal-fired power plants. The company's original conveying process combined mechanical lifting with negative pressure pneumatic conveying, but many shortcomings were exposed in actual operation, urgently requiring a better conveying solution. Head Powder conducted in-depth on-site research, combined with the company's material characteristics and capacity requirements, and designed and installed a positive pressure dense phase conveying system. After commissioning, it operated stably and gained customer recognition.

Customer pain points

The customer encountered the following core issues during the original conveying process:

• Severe dust pollution:The negative pressure conveying system lacks sealing, with obvious dust leakage at pipeline joints and discharge points, harsh workshop environments, and high health risks for workers.
• Low conveying efficiency:The original system suffered from frequent pipeline blockages requiring manual cleaning, with actual conveying capacity only 60% of the design value, severely limiting capacity improvement.
• High energy consumption costs:The negative pressure system must maintain a high vacuum level, and the supporting vacuum pump operates under high load for extended periods, resulting in a high proportion of electricity consumption in the total product cost.
• Heavy maintenance workload:Mechanical hoisting equipment wears out quickly, and consumable parts such as chain plates and bearings are frequently replaced. Spare parts costs and downtime significantly impact normal production.

Product advantages

To address these pain points, Head Powder offers positive pressure conveying system solutions with the following application features:

• Fully sealed and dust-free:The system uses sealed pipelines throughout the entire process from feeding to discharge, paired with high-efficiency dust removal devices. This ensures no dust escapes during operation, improves workshop cleanliness, and meets environmental protection and occupational hygiene requirements.
• High conveying efficiency and low energy consumption:Uses dense phase positive pressure conveying technology, resulting in a high gas-solid ratio, stable conveying speed, minimal pipeline wear, and low system resistance. Compared to the original negative pressure system, energy consumption is reduced by about 30%, and the actual delivery capacity is increased to over 95% of the design value.
• High degree of automation:Equipped with a PLC control system, it can achieve one-touch start/stop, remote monitoring, fault alarms, and other functions. The system automatically adjusts conveying parameters based on material level and pressure, reducing manual intervention and improving operational reliability.
• Easy maintenance and long service life:Core components are made of wear-resistant materials, with optimized designs for rotary feeders and pipeline elbows for long service life. Daily maintenance workload is minimal, requiring only regular inspection of seals and filters, effectively reducing operation and maintenance costs.

Since the system was put into operation, the customer's desulfurizer powder transportation has achieved stable, efficient, and clean operation, with annual maintenance costs reduced by about 40% and overall operational efficiency improved. Head Powder will continue to be customer-oriented, providing reliable positive pressure conveying solutions for more industries.