Jiangsu Wuxi Catalyst Pellet Low-Breakage Conveying Case

Case Overview

In a catalyst pellet production facility located in Wuxi, Jiangsu Province, the plant faced considerable material loss during the conveying stage. Headpowder was engaged to evaluate the existing system and propose a tailored solution for low-breakage transfer of fragile catalyst pellets.

Client Challenge

The client observed that conventional pneumatic conveying equipment caused high impact forces on the catalyst pellets, leading to a breakage rate exceeding 5%. This resulted in frequent production stoppages for cleaning fines, increased raw material costs, and inconsistent catalyst performance downstream. The plant required a conveying method that could maintain pellet integrity while sustaining a throughput of 8 tons per hour.

Solution Delivered

Headpowder designed a closed-loop dilute-phase conveying system with multiple impact-reduction features. Key elements included a curved inlet section to avoid direct pellet-to-wall collision, internal rubber-lined bends, and a velocity-controlled air supply that maintains conveying speed below 10 m/s at the pickup point. A cyclone separator with a soft discharge valve further reduces mechanical stress on the pellets. After installation, the on-site breakage rate dropped to below 1%, and the system has operated without clogging for over 6 months.