Jiangsu Xuzhou Coal Chemical Coke Powder Long-Distance Case

Case Overview

A coal chemical enterprise in Xuzhou, Jiangsu, required a reliable solution for transporting coke powder over long distances. The material needed to be moved from the processing area to a storage facility located more than 2 kilometers away, with strict requirements for dust control and energy efficiency. Headpowder was engaged to design and implement a customized pneumatic conveying system that addressed these challenges.

Customer Challenges

The customer faced several operational difficulties. First, the coke powder had a fine particle size that caused significant dust emissions during conventional transport, leading to environmental compliance risks. Second, the long distance of over 2 km required a system that could maintain consistent flow without clogging or excessive pressure drop. Third, the existing mechanical conveyor system consumed high energy and required frequent maintenance due to abrasive wear from the coke powder. Finally, the customer needed a solution that could integrate with their existing plant layout without major structural modifications.

Headpowder Solution

Headpowder provided a dense-phase pneumatic conveying system specifically designed for long-distance transport of abrasive, fine powders. The system uses a controlled air-to-material ratio to move coke powder at low velocity, reducing pipe wear and energy consumption. Key components included wear-resistant pipe bends, a variable-speed rotary feeder, and a dedicated dust collection unit to ensure zero fugitive emissions. The system was engineered to handle a capacity of 15 tons per hour across the 2.1-kilometer route with a pressure drop within safe limits. Headpowder also supplied a PLC-based control system for real-time monitoring and automatic adjustment of conveying parameters.

Implementation Results

After installation, the customer achieved a 40% reduction in energy consumption compared to the previous mechanical conveyor. Dust emissions were eliminated, helping the plant meet local environmental standards. Maintenance intervals were extended from monthly to quarterly due to the reduced abrasion from low-velocity flow. The system has been operating reliably for over 18 months with no major downtime, proving its suitability for long-distance coke powder transport.