Shandong Headpowder Engineering Co., Ltd., headquartered in Shandong, China, has recently completed a landmark dense phase pneumatic conveying system for a major glass producer located in Shijiazhuang, Hebei Province. This project specifically focuses on the efficient and reliable transportation of zircon sand, a critical raw material for high‑quality glass production. The system is designed to handle the unique challenges of conveying fine, abrasive, and high‑density zircon sand particles without degradation or segregation. By utilizing advanced dense phase conveying technology, the solution ensures minimal wear on pipelines, reduced energy consumption, and consistent material flow, which are essential for maintaining production stability in glass manufacturing.
Zircon sand, also known as zirconium silicate, is widely used in the glass industry for its superior refractory properties and ability to enhance the clarity and strength of glass products. However, its high specific gravity (approximately 4.6–4.7 g/cm³) and abrasive nature make conventional pneumatic conveying methods inefficient and prone to equipment damage. The dense phase conveying approach adopted by Headpowder operates at low gas velocities and high solid‑to‑gas ratios, which significantly reduces particle attrition and pipeline erosion. This project successfully demonstrates the application of dense phase pneumatic conveying for zircon sand, delivering a dust‑free, environmentally friendly, and cost‑effective material handling solution for the client’s glass raw material preparation line.
The primary product featured in this case is a custom‑engineered dense phase pneumatic conveying system tailored for zircon sand and other glass raw materials. The system includes a pressure vessel (blow tank), a series of diverting valves, pipeline networks, and a control unit that precisely regulates air pressure and material flow. Key design parameters such as conveying distance, pipe diameter, air consumption, and material velocity were optimized based on the specific characteristics of zircon sand. The system achieves a conveying capacity of up to 10 tons per hour over a horizontal distance of 150 meters and a vertical lift of 25 meters, while maintaining a material‑to‑air ratio exceeding 30:1, which is typical for dense phase applications.
In addition to zircon sand, the same dense phase conveying technology can be applied to other glass raw materials such as silica sand, soda ash, limestone, and feldspar. The system’s modular design allows for easy integration into existing raw material handling plants, and its low‑velocity operation minimizes dust generation and noise pollution. Headpowder’s engineers also incorporated a pressure‑balanced feeding mechanism to prevent bridging and arching in the blow tank, ensuring uninterrupted supply to the glass furnace. This project underscores the company’s expertise in supplying dense phase conveying solutions for the glass industry, particularly for challenging materials like zircon sand.
The dense phase conveying engineering employed in this project involves a series of advanced technologies that set it apart from conventional dilute phase systems. First, the system uses a high‑pressure blow tank (up to 6 bar) with a bottom discharge design, which is ideal for handling heavy and abrasive materials like zircon sand. Second, a proprietary air injection system ensures consistent fluidization of the material, preventing blockages even when conveying fine particles with high moisture content. Third, the pipeline is constructed from wear‑resistant alloy steel with a hardness of 60 HRC, extending service life by over 300% compared to standard carbon steel pipes.
Furthermore, the control system integrates real‑time monitoring of pressure, flow rate, and material level, allowing operators to adjust parameters on the fly. A touch‑screen HMI provides a user‑friendly interface for system diagnostics and maintenance scheduling. The entire system is designed to comply with international safety standards, including explosion‑proof electrical components for handling combustible dusts. Headpowder’s engineers also conducted extensive computational fluid dynamics (CFD) simulations to validate the pipeline layout and minimize pressure drops, resulting in an overall energy efficiency improvement of 15% compared to traditional dense phase designs. This project exemplifies the company’s commitment to delivering high‑performance dense phase conveying systems for the glass and ceramic industries.
In this specific case, the client, a leading glass manufacturer in Shijiazhuang, required a reliable and low‑maintenance system to transport zircon sand from storage silos to the batch mixing station. The existing dilute phase system suffered from frequent pipe blockages, high dust emissions, and excessive wear on elbows and bends. Headpowder’s team conducted a thorough site survey and material analysis, then designed a dense phase conveying solution that addressed all these issues. The new system operates at a conveying velocity of 5–8 m/s, significantly lower than the 20–25 m/s typical of dilute phase, resulting in virtually no particle breakage and a 90% reduction in pipeline wear.
After installation and commissioning, the system has been running continuously for over 12 months with zero unscheduled downtime. The customer reported a 40% reduction in energy consumption per ton of material conveyed, along with a 50% decrease in maintenance costs. The enclosed nature of the system also eliminated fugitive dust, improving workplace air quality and meeting strict environmental regulations. This successful implementation has led to additional orders from the same client for conveying other glass raw materials, including soda ash and limestone. The project serves as a benchmark for dense phase conveying of abrasive minerals in the glass industry, demonstrating the superior performance and reliability of Shandong Headpowder’s engineering solutions.
Shandong Headpowder Engineering Co., Ltd. is a professional engineering company specializing in the design, manufacturing, and installation of pneumatic conveying systems for bulk solids. With headquarters in Shandong, China, the company has served clients across the glass, ceramics, chemicals, metallurgy, and food industries for over a decade. Their core competencies include dense phase conveying, dilute phase conveying, and air‑assisted gravity conveying, with a particular focus on handling difficult materials such as zircon sand, alumina, titanium dioxide, and cement. The company’s engineering team consists of experienced mechanical, electrical, and process engineers who utilize advanced software tools for system design and simulation.
Headpowder’s commitment to quality is reflected in their ISO 9001:2015 certification and adherence to CE and ATEX standards for explosion‑proof applications. They offer turnkey solutions, from feasibility studies and system design to fabrication, installation, and commissioning. Their after‑sales support includes remote monitoring, spare parts supply, and on‑site training. For this zircon sand project, Headpowder’s project manager, Mr. Zhang (Manager Zhang), oversaw every phase of implementation, ensuring that the system met the client’s exact specifications and delivery schedule. The company’s dedication to customer satisfaction and technical innovation has made them a trusted partner for dense phase conveying projects in China and abroad.
For more information about dense phase conveying systems for zircon sand, glass raw materials, or other bulk solids, please contact the project manager directly. Manager Zhang is available to discuss your specific application requirements and provide a customized solution. You can reach Manager Zhang via WeChat at 15662777102. Shandong Headpowder Engineering Co., Ltd. looks forward to assisting you with your next material handling project, ensuring efficient, reliable, and cost‑effective conveying of even the most challenging materials.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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