A metal silicon manufacturing company in Sanming, Fujian, needed to safely and efficiently transport metal silicon powder from the grinding workshop to downstream processes due to a production line upgrade. Metallic silicon powder has characteristics such as fine particle size, light weight, easy dust generation, and explosive exposure to open flames. Traditional mechanical conveying methods face issues such as leakage, contamination, and safety hazards, urgently requiring an explosion-proof, sealed, and dust-free conveying solution.

Customer pain points

The original conveying system used a combination of bucket elevators and screw conveyors, which had the following pain points:

• Severe material leakage, excessive dust concentration in the workshop, affecting the working environment and employee health;
• Metal silicon powder easily generates static electricity during transportation, forming explosive dust clouds when exposed to air, posing high safety risks;
• Equipment wears out quickly, frequent maintenance, and downtime affects production continuity;
• The flow rate cannot be controlled accurately during conveying, resulting in significant deviations in subsequent batching stages.

Head Powder Solution: Explosion-Proof Sealed Pneumatic Conveying System

To address these pain points, Head Powder has customized a positive pressure dense phase pneumatic conveying system for the company, featuring the following main features:

Explosion-proof safety design

The system uses explosion-proof control cabinets, anti-static pipeline materials, and grounding devices. All seals are made of flame-retardant materials, and key areas are equipped with explosion vents and automatic spark detection extinguishing devices, ensuring safe operation in flammable dust environments.

Fully sealed and dust-free transport

The entire pipeline from the feed inlet to the discharge port is sealed, combined with a high-efficiency dust collector and negative pressure balance valve, achieving zero material leakage. Workshop dust concentration is reduced to below 1mg/m³, meeting environmental protection and occupational health standards.

High-precision metering and automatic control

Integrated weighing sensors and variable frequency adjustment devices allow the conveying flow to be controlled more accurately within ±1% of the set value, and supports remote PLC automatic control, reducing manual intervention and improving production stability.

Compact structure and low energy consumption

The system occupies a small footprint and does not require large-scale civil engineering modifications; Utilizes low gas fluidization technology, reducing unit energy consumption by 30% compared to traditional dilute phase conveying, making maintenance convenient and offering a long service life.

Implementation Results

Since the system was put into operation, workshop dust monitoring data has consistently met standards, with no safety incidents occurring; Material conveying efficiency has increased to 15 tons/hour, equipment failure rates have dropped by 80%, and annual maintenance costs have been saved by about 120,000 yuan. The customer highly praised Head Powder's professional capabilities and plans to continue using similar solutions in subsequent production lines.