In the field of powder transportation, the physical properties of PE resin powder determine that its conveying process must balance efficiency and safety. This paper takes the PE resin powder positive pressure dense phase conveying project of a chemical enterprise in Yichang, Hubei as an example to explore how technical optimization can solve conveying difficulties in actual production.

Case Summary

The project is located in Yichang, Hubei, serving a company specializing in the production and processing of PE resin powder. The company originally used traditional pneumatic conveying methods but faced multiple challenges such as dust leakage, pipeline wear, and high energy consumption, urgently needing a stable, environmentally friendly, and economical conveying system. After multiple evaluations, the system was ultimately upgraded using positive pressure dense phase conveying technology.

Customer pain points

• Dust Rises, High Environmental Pressure:PE resin powder has a small particle size, and traditional dilute phase conveying tends to generate a large amount of dust, which not only pollutes the workshop environment but also makes it difficult to meet increasingly strict local environmental emission standards.
• Severe pipeline wear and high maintenance costs:High-speed airflow carrying powder collides violently inside the pipeline, causing frequent wear of components such as elbows and valves, requiring key parts to be replaced on average once per quarter, affecting production continuity.
• High energy consumption, difficult to control operating costs:The original conveying system had high air source pressure and high gas consumption, with energy consumption per unit of material conveying remaining at a high level for a long time, making the demand for energy conservation and cost reduction by enterprises urgent.
• Limited conveying distances cannot meet the requirements for new production line layouts:With the expansion of the production line, materials had to be delivered from the storage silo to multiple usage points about 200 meters away. The original system suffered from pipe blockages and unstable speeds due to the increased conveying distance.

Product advantages

To address these pain points, Head Powder has designed and implemented a positive pressure dense phase conveying solution. This solution centers on "low speed, high concentration, low energy consumption," achieving system optimization from multiple dimensions:

• Sealed conveying enables environmentally friendly production:The entire system adopts a fully sealed pipeline design combined with an efficient dust removal device, truly achieving dust-free operation, improving workshop cleanliness, and helping enterprises easily pass environmental inspections.
• Low-speed wear, extending equipment lifespan:By accurately controlling the airflow speed (usually 2~6 m/s), materials move smoothly within the pipeline in the form of bolt flow or fluidized beds, reducing the impact of particles on the pipe wall and extending the service life of elbows and pipelines by more than double.
• Energy saving and consumption reduction, lowering operating costs:The amount of gas required for positive pressure dense phase conveying is only one-third~one-fifth that of dilute-phase conveying, reducing the air source pressure by about 30%, and overall energy consumption dropping by more than 40%, significantly reducing production electricity costs.
• Stable long-distance conveying, suitable for complex processes:The system can stably achieve horizontal and vertical combined conveying from 150 meters to 300 meters, and through automatic valve control, it accurately distributes materials to multiple downstream devices, meeting the flexible layout needs of new production lines.

Currently, the project has been operating normally for over 18 months, with no serious pipe blockages or wear leaks. The client's material transportation costs have been reduced by 35%, equipment maintenance frequency by 60%, and has become a typical reference case for powder transportation upgrades in the region.