This article presents a comprehensive case study on the successful implementation of a dense phase pneumatic conveying system for resin pellets at a major chemical plant located in Dalian, Liaoning Province. The project was engineered and executed by Shandong Headpowder Engineering Co., Ltd. (referred to as headpowder), a leading provider of bulk material handling solutions based in Shandong, China. The primary goal of this project was to achieve efficient, gentle, and dust-free transport of resin pellets from storage silos to downstream processing units. This case study details the technical challenges, the tailored dense phase conveying solution, and the measurable benefits achieved, highlighting the expertise of headpowder in delivering reliable dense phase pneumatic conveying systems for the chemical industry.
The client, a well-established chemical manufacturing company in Dalian, produces high-quality resin pellets used in various industrial applications. Their existing material handling system relied on mechanical conveyors, which suffered from frequent blockages, high maintenance costs, and significant product degradation. The client specifically required a new conveying system that could handle resin pellets with minimal breakage, reduce dust emissions, and operate with low energy consumption. After evaluating multiple vendors, they selected Shandong Headpowder Engineering Co., Ltd. due to our proven track record in designing dense phase pneumatic conveying systems for similar materials. The key requirements included: transporting resin pellets over a distance of 120 meters with a vertical lift of 15 meters, conveying capacity of 8 tons per hour, and maintaining pellet integrity with less than 0.5% fines generation. Additionally, the system had to be enclosed to prevent contamination and comply with strict environmental regulations.
Headpowder’s engineering team proposed a custom-designed dense phase pneumatic conveying system specifically optimized for resin pellets. Unlike dilute phase conveying, which uses high air velocity and can cause particle attrition, dense phase conveying operates at low air velocity with a high material-to-air ratio. This method is ideal for fragile materials such as resin pellets because it minimizes impact and friction, thereby preserving product quality. The system incorporates a pressure vessel (blow tank) that feeds resin pellets into the pipeline in a controlled, slug-like flow. The conveying line is designed with smooth bends and gradually expanding sections to reduce pressure drop and prevent particle damage. A key component is the proprietary nozzle configuration at the blow tank outlet, which ensures stable and uniform material discharge. The entire system is controlled by a PLC-based automation unit that monitors pressure, flow rate, and material level, allowing for precise adjustment of conveying parameters. The dense phase pneumatic conveying solution also includes a dedicated air supply unit with a screw compressor and air dryer to maintain consistent air quality. This design ensures that the resin pellets are transported gently, with minimal degradation, while achieving the required capacity and distance.
The successful deployment of this project demonstrates the effectiveness of dense phase pneumatic conveying technology for chemical granules, particularly resin pellets. Chemical granules are often irregular in shape, sticky, or prone to breakage, making them challenging to convey using conventional methods. Headpowder’s dense phase pneumatic conveying systems are specifically engineered to handle such materials. In this case, the resin pellets had an average diameter of 3-5 mm and a bulk density of 0.6 g/cm³. The system was designed with a conveying pressure of 2.5 bar and a line velocity of 6-8 m/s, which is significantly lower than typical dilute phase systems (15-25 m/s). This low-velocity approach significantly reduces particle-to-particle and particle-to-wall collisions, thereby preserving the resin pellets’ physical properties. The system also incorporates a separation cyclone and a rotary airlock at the discharge point to ensure efficient product recovery. The dense phase conveying technology proved to be the ideal solution for this chemical granule application, as it provided gentle handling, reduced dust generation, and lower energy consumption compared to alternatives. The client reported that the new system reduced product degradation by over 70% compared to their previous mechanical conveyor, and dust emissions were virtually eliminated.
The installation of the dense phase pneumatic conveying system was carried out by headpowder’s field service team in close coordination with the client’s plant personnel. The project timeline spanned 12 weeks from design to commissioning. The first phase involved site survey and pipeline routing, ensuring that the conveying line avoided existing infrastructure and could be easily maintained. The blow tank and control panel were installed in a dedicated area near the resin pellet storage silos. The pipeline was assembled using pre-fabricated sections with flanged connections to facilitate future maintenance. During commissioning, the system underwent a series of tests including air leakage checks, pressure tests, and material conveying trials with actual resin pellets. The PLC control logic was fine-tuned to optimize the conveying cycle time and minimize air consumption. The system achieved the target capacity of 8 tons per hour within the first week of operation. The client’s operators received on-site training on system operation, troubleshooting, and routine maintenance. The entire process was completed without any safety incidents, and the system was handed over to the client on schedule.
After six months of continuous operation, the dense phase pneumatic conveying system for resin pellets has delivered outstanding performance. The key metrics are as follows: The conveying capacity consistently meets the design specification of 8 tons per hour, with peaks up to 9.5 tons per hour during high-demand periods. The product quality has been maintained with less than 0.3% fines generation, well below the client’s 0.5% threshold. The system’s energy consumption is 30% lower than the client’s previous mechanical conveyor, resulting in significant cost savings. The enclosed design has eliminated dust emissions, improving the plant’s environmental compliance and worker safety. Maintenance requirements have been minimal, with only routine inspections of the blow tank seals and air filter elements. The client’s plant manager commented that the system has been “remarkably reliable and easy to operate.” The success of this project has led to a follow-up order for a second dense phase conveying line for a different resin grade. This case study clearly demonstrates headpowder’s capability in providing efficient and gentle dense phase pneumatic conveying solutions for the chemical industry.
Shandong Headpowder Engineering Co., Ltd. (headpowder) is a specialized engineering company with decades of experience in designing and manufacturing pneumatic conveying systems for diverse industries including chemicals, plastics, food, and minerals. We are headquartered in Shandong, China, and serve clients across the globe. Our dense phase pneumatic conveying systems are custom-engineered to handle a wide range of materials such as resin pellets, plastic granules, chemical powders, and other bulk solids. We combine advanced computational fluid dynamics (CFD) simulation with practical field experience to optimize system performance. Our team provides end-to-end services from feasibility study and design to installation, commissioning, and after-sales support. For this project in Dalian, our team’s deep understanding of resin pellet behavior and dense phase conveying principles was instrumental in meeting the client’s stringent requirements. We are committed to delivering high-quality, reliable, and energy-efficient solutions that help our customers improve their production efficiency and reduce operational costs.
If you are considering a dense phase pneumatic conveying system for your chemical granules or resin pellets, we invite you to reach out to our team. We can provide a free consultation and preliminary design based on your specific material properties and conveying requirements. For more information about this case study or to discuss your project, please contact Manager Zhang at Shandong Headpowder Engineering Co., Ltd. WeChat: 15662777102. Our team is ready to assist you with professional advice and tailored solutions. We look forward to helping you achieve efficient and gentle material handling for your operations.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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