This article presents a detailed case study of a gypsum powder mixed pneumatic conveying system implemented for a building materials enterprise located in Wuhan, Hubei Province, China. The project was successfully delivered by Shandong Headpowder Engineering Co., Ltd., a leading provider of pneumatic conveying solutions headquartered in Shandong, China. The core technologies involved include gypsum powder mixed conveying, desulfurized gypsum conveying, and a complete mixed pneumatic conveying engineering system. This case demonstrates how advanced pneumatic conveying technology can significantly improve material handling efficiency, reduce dust pollution, and enhance overall production line reliability for construction material manufacturers.
The client, a well-established building materials company in Wuhan, specializes in the production of gypsum-based products such as gypsum blocks, plasterboards, and drywall compounds. Their existing material handling system relied on mechanical conveyors, which frequently caused blockages, dust leakage, and high maintenance costs. The primary products to be handled were gypsum powder and desulfurized gypsum – a byproduct of flue gas desulfurization in power plants. The client required a closed, dust-free, and energy-efficient conveying solution that could handle these fine, abrasive, and moisture-sensitive materials with minimal degradation.
After evaluating multiple suppliers, the client selected Shandong Headpowder Engineering Co., Ltd. due to its proven expertise in mixed pneumatic conveying engineering and its extensive experience with gypsum powder and desulfurized gypsum applications. The project scope included the design, fabrication, installation, and commissioning of a complete mixed pneumatic conveying system capable of transporting gypsum powder from storage silos to multiple production points simultaneously.
The mixed pneumatic conveying system designed by Headpowder combines both dilute phase and dense phase conveying principles, optimized for the specific characteristics of gypsum powder and desulfurized gypsum. The system features a custom-designed air supply unit, a rotary feeder with wear-resistant components, a dedicated conveying pipeline with smooth bends to minimize material degradation, and a cyclone separator coupled with a bag filter for efficient product recovery and air cleaning.
For the gypsum powder mixed conveying process, the material is fed into the conveying line at a controlled rate, where it is entrained by compressed air. The system operates at a conveying velocity of 8–12 m/s in the dilute phase section and reduces to 2–5 m/s in the dense phase section, ensuring gentle handling of the fragile gypsum particles. The mixed pneumatic conveying engineering approach allows the system to handle both fine powders and slightly coarser particles, making it ideal for the client's diverse raw material streams.
Special attention was paid to the desulfurized gypsum conveying segment. Desulfurized gypsum has a high moisture content (up to 15–20%) and tends to agglomerate, causing blockages in conventional conveyors. Headpowder's engineers incorporated a specialized air injection system along the pipeline to break up agglomerates and maintain a consistent flow. Additionally, the pipeline was lined with wear-resistant ceramic tiles to withstand the abrasive nature of the material, extending the system's service life by over 200% compared to standard steel pipelines.
The implemented mixed pneumatic conveying system offers several distinct advantages for the client's production operation. First, the fully enclosed design eliminates dust emissions, complying with strict environmental regulations in Wuhan. The system achieves a conveying efficiency of over 99.5%, with virtually zero material loss. Second, the modular design allows for easy expansion and integration with existing production lines. The control system, based on PLC and HMI, provides real-time monitoring of air pressure, flow rate, and material level, enabling operators to adjust parameters remotely.
Compared to traditional mechanical conveyors, the mixed pneumatic conveying system reduces energy consumption by approximately 30% due to optimized air-to-material ratios. Maintenance requirements are significantly lower, as there are no moving parts in contact with the material except the rotary feeder. The system also offers flexibility in routing – the pipeline can be installed overhead, underground, or around obstacles, without interfering with other equipment.
The entire project, from initial design to final commissioning, was completed within a 12-week timeline. Shandong Headpowder Engineering Co., Ltd. deployed a dedicated project management team that worked closely with the client's site engineers. The installation phase involved minimal disruption to ongoing production, as the system was pre-assembled in modules and tested at Headpowder's workshop in Shandong before shipment.
After commissioning, the client reported a dramatic improvement in production throughput. The system can now convey up to 15 tons of gypsum powder per hour, with a conveying distance of 200 meters horizontally and 30 meters vertically. The desulfurized gypsum conveying section handles 5 tons per hour without any clogging issues, even during high-humidity seasons. The maintenance team noted a 70% reduction in downtime related to material handling, and the overall plant cleanliness improved significantly.
Shandong Headpowder Engineering Co., Ltd. (headpowder) is a professional engineering company specializing in the design and manufacture of pneumatic conveying systems, particularly for powder and granular materials in the construction, chemical, and energy industries. With its headquarters in Shandong, China, the company has completed over 200 projects worldwide, covering gypsum, cement, fly ash, lime, and other bulk solids. Headpowder is known for its innovative approach to mixed pneumatic conveying engineering, combining robust hardware with intelligent control software to deliver reliable, energy-efficient solutions.
If you are looking for a trusted partner for your gypsum powder mixed conveying, desulfurized gypsum conveying, or any mixed pneumatic conveying engineering project, please contact Manager Zhang for detailed consultation. Manager Zhang can be reached via WeChat: 15662777102. The team at Shandong Headpowder Engineering Co., Ltd. is ready to provide customized solutions tailored to your specific material characteristics and production requirements.
For more information about this project case or to discuss your own material handling needs, please feel free to contact the responsible manager. Manager Zhang, the project lead for this Wuhan gypsum powder conveying project, is available to answer your questions. You can reach Manager Zhang directly on WeChat: 15662777102. Shandong Headpowder Engineering Co., Ltd. looks forward to assisting you with efficient, dust-free, and cost-effective pneumatic conveying systems.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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