An activated carbon processing company located in Anyang, Henan, mainly produces activated carbon powder for environmental desulfurization and denitrification. During production, activated carbon powder with a fineness of over 200 mesh must be transported from the storage silo to the reactor for injection operations. Because activated carbon powder is lightweight, easily lifted, and easily absorbs moisture, traditional open conveying methods not only cause significant material loss but also seriously pollute the workshop environment, affecting operator health. Head Powder designed and implemented a complete sealed activated carbon powder injection system for this condition, achieving full sealed and automated processes from storage, conveying, metering to injection.

Customer pain points

The original operating methods had three core pain points: First, severe dust flying, excessive PM2.5 concentrations in workshops, frequent rectification during environmental inspections, and material waste rates exceeding 8%; Second, manual feeding and measurement rely on experience, resulting in large batch-to-batch deviations, leading to unstable downstream reaction efficiency and product quality fluctuations; Third, equipment pipelines wear out quickly due to powder erosion, requiring monthly shutdowns to replace elbows and seals, which leads to high maintenance costs and affects production capacity. In addition, workers are exposed to activated carbon dust for extended periods, posing significant occupational health risks and making recruitment difficult.

Product advantages

The sealed injection solution provided by Head Powder addresses the above issues from the source:

• Fully enclosed negative pressure conveying: Uses a combination of Roots fans and rotary feeders to form a negative-pressure sealed circuit, ensuring no powder leakage throughout the pipeline, reducing workshop dust concentration below national standard limits, and controlling material loss within 0.5%.
• High-precision quantitative feeding: Equipped with a weightless-type weighing scale and variable frequency speed control system, real-time monitoring of feed volume and closed-loop adjustment, with metering accuracy better than ±1%, helping to stabilize activated carbon dosing and improving reaction efficiency by 15%.
• Wear-resistant and low-maintenance design: The pipeline elbows are lined with ceramics, and the rotary feeder rotor is hardened, extending the machine's service life to over 36 months. The daily maintenance cycle has been extended from monthly to quarterly.
• Intelligent automated control: Integrates PLC and host computer systems, supports one-button start/stop, remote monitoring, fault self-diagnosis, and historical data traceability, reducing operator personnel by 60% while avoiding direct human-machine contact with dust.

After the system was put into operation, the customer's on-site working environment improved significantly, saving over 300,000 yuan in material and maintenance costs annually, and increasing overall production capacity by 20%, making it a demonstration project for sealed activated carbon conveying in the region.