In the field of industrial powder processing, activated carbon is widely used in industries such as environmental protection, chemical, and food due to its porous structure and high adsorption properties. However, during transportation, activated carbon powder often affects production efficiency and environmental safety due to issues such as dust swirling, pipeline blockages, and excessive energy consumption. Head Powder designed and implemented a continuous activated carbon powder conveying project to meet the actual needs of an activated carbon producer in Yancheng, Jiangsu, addressing the above challenges.

Case Summary

This project serves an activated carbon manufacturing enterprise in Yancheng, Jiangsu, which requires a large amount of activated carbon powder to be steadily transported daily from storage warehouses to downstream processing sections. The original conveying method combined manual transfer with simple mechanical conveyors, resulting in serious dust emissions, discontinuous conveying, and frequent equipment shutdowns for cleaning. After receiving the material, Head Powder custom-built a fully enclosed pneumatic conveying system, achieving fully automated continuous operation from feeding to discharging.

Customer pain points

• Severe dust pollution:The particle size of activated carbon powder is fine (usually 100~200 mesh), and traditional open conveying causes excessive dust concentrations in workshops, which not only endangers employee health but also increases environmental management costs.
• Discontinuous conveying leads to low efficiency:Frequent issues of materials being overhead or hanging on pipe walls in the original equipment require manual periodic cleaning, causing unplanned shutdowns of the production line and limiting overall capacity.
• High energy consumption and maintenance costs:Traditional conveying equipment has high motor power and frequent clogging, resulting in extra energy consumption; At the same time, seals wear out quickly, spare parts are frequently replaced, and operating costs remain high.
• Lack of automation:Lack of remote monitoring and automatic adjustment capabilities, relying on on-site personnel to be on duty, unable to respond promptly to changes in working conditions, resulting in low management efficiency.

Product advantages and solutions

To address these pain points, Head Powder leverages years of pneumatic conveying technology to launch a continuous conveying solution tailored to the characteristics of activated carbon powder. This solution uses positive pressure dilute phase or dense phase pneumatic conveying methods, combined with dedicated fluidization devices and anti-blocking structures, to achieve stable, sealed, and intelligent material transfer.

• Fully enclosed system, zero dust leakage:All conveying pipelines and silo interfaces are sealed with a slight negative or positive pressure sealed state, preventing dust from escaping at the source. The factory environment has been significantly improved, meeting environmental emission requirements.
• Continuous normal operation:Equipped with an automatic back-blowing blocking device and fluidized plates, it effectively solves the problems of activated carbon powder bridging and wall adhesion. The system supports 24-hour uninterrupted conveying, requiring no manual intervention during a single conveying process, significantly increasing production capacity.
• Energy saving and consumption reduction:By optimizing air source matching and delivery parameters, unit energy consumption is reduced. At the same time, the system uses wear-resistant elbows and sealing components to extend equipment service life and reduce downtime and maintenance time.
• Intelligent control:Integrated PLC control system monitors conveying pressure, speed, and material level data in real time, automatically adjusting air volume and replenishment rhythm. The user interface is simple, supports remote monitoring and anomaly alarms, and reduces manual operation intensity.

After the project was put into operation, customers reported that workshop dust concentration dropped by over 90%, conveying efficiency improved by about 40%, and overall operating costs decreased by about 25%. Head Powder will continue to focus on customized design, providing reliable and efficient conveying solutions for more users in the powder industry.