This case study details a successful dense phase pneumatic conveying system implemented for polyethylene pellets at a major petrochemical facility located in Tianjin, China. The project was executed by Shandong Headpowder Engineering Co., Ltd., a specialized engineering company headquartered in Shandong, China, known for its expertise in bulk material handling solutions. The primary objective was to replace an outdated mechanical conveying method with a modern, low-damage dense phase conveying system that could handle the delicate polyethylene pellets with minimal breakage while maintaining high throughput and energy efficiency. The project delivered a fully automated, closed-loop conveying line that significantly improved product quality and operational reliability.
At the heart of this project lies the polyethylene pellet dense phase conveying technology, which employs a high-pressure, low-velocity air stream to move the pellets through a pipeline. Unlike dilute phase systems that use high velocity and can cause particle attrition, dense phase conveying maintains a plug flow regime where the material moves as a compact slug. This method is especially critical for polyethylene pellets, which are soft and prone to deformation, surface dust generation, or even melting under high shear forces. The system designed by Headpowder achieves a conveying velocity of only 2–5 m/s, compared to 10–20 m/s in conventional dilute phase systems, thereby reducing impact energy and preserving pellet integrity. The conveying capacity exceeds 20 tons per hour over a distance of 300 meters, with a turn-down ratio of 10:1, allowing flexible operation according to production demands. The entire process is controlled by a PLC-based system with real-time pressure monitoring and automatic air pressure regulation, ensuring consistent plug formation and stable flow.
One of the most critical requirements for this project was the implementation of a low-damage conveying system specifically designed for petrochemical granules. Polyethylene pellets, being a typical petrochemical product, are extremely sensitive to mechanical stress. Even minor impacts can generate fines, dust, or rough surfaces, which directly affect the downstream processing quality and the final plastic product's appearance. The Headpowder solution incorporates a series of wear-resistant elbows with large radius curves, a specially designed feeding device that minimizes initial acceleration forces, and a gentle blow-tank discharge system. The entire pipeline is lined with a smooth, low-friction polymer coating to reduce wall friction. After commissioning, the system achieved a pellet breakage rate of less than 0.1%, measured by the weight of fines passing through a 10-mesh sieve, compared to the industry average of 0.5–1% for traditional conveying methods. This low-damage performance has been verified by independent third-party testing and has been maintained consistently over two years of continuous operation.
The project also serves as a benchmark for petrochemical granule conveying due to its comprehensive integration with upstream and downstream equipment. The dense phase system receives pellets directly from the extruder and pelletizer, passes them through a cooling and de-dusting station, and then conveys them to storage silos or bagging machines. A key innovation was the integration of a nitrogen blanketing system to prevent oxidation and moisture absorption, which is crucial for high-quality polyethylene grades used in food packaging and medical applications. The control system communicates via OPC-UA with the plant's DCS, enabling remote monitoring and predictive maintenance. Additionally, the project included a multi-point air injection system along the pipeline to prevent blockages when handling sticky or high-moisture pellets. The total energy consumption of the dense phase system is 40% lower than the previous mechanical screw conveyor and bucket elevator combination, resulting in significant annual cost savings for the client.
Shandong Headpowder Engineering Co., Ltd. (abbreviated as Headpowder) has been a leading provider of pneumatic conveying solutions for over 15 years, with a particular focus on the petrochemical sector. The company's R&D team has developed proprietary algorithms for calculating dense phase flow parameters, including pressure drop, plug velocity, and air-to-material ratio, which are fine-tuned for different pellet sizes and shapes. Headpowder's manufacturing facility in Shandong, China, is equipped with a full-scale test rig that can simulate actual plant conditions, allowing customers to witness the performance of their specific material before installation. The Tianjin project was completed within a tight timeline of 8 months from design to commissioning, including a 2-week training program for the plant's maintenance staff. Headpowder provided a full 2-year warranty on all conveying components and a 5-year extended support contract for the control system. The company's after-sales service includes annual inspection, spare parts inventory, and remote troubleshooting.
For more details about this polyethylene pellet dense phase conveying project or to discuss your own petrochemical granule conveying requirements, please contact the Headpowder team. The project manager, Mr. Zhang, is available to provide technical documentation, reference lists, and a preliminary system design based on your material properties and site layout. You can reach Mr. Zhang directly via WeChat at 15662777102. This dedicated contact handles all inquiries related to low-damage conveying systems, polyethylene pellet conveying, and other dry bulk material handling solutions. Shandong Headpowder Engineering Co., Ltd. looks forward to partnering with you to optimize your material transport process while minimizing product degradation. For any sales or engineering questions, do not hesitate to reach out to the contact person mentioned above.
The Tianjin petrochemical plant has reported a 95% reduction in dust generation inside the conveying area, a 30% increase in overall production line uptime, and a significant improvement in the final pellet quality, which now meets the strictest export standards for premium polyethylene grades. The client specifically praised the low-damage conveying system's ability to handle both LLDPE and HDPE pellets without any changeover adjustments. The success of this project has led to two additional contracts for similar dense phase conveying systems at other facilities owned by the same parent company. Headpowder continues to innovate in the field of petrochemical granule conveying, investing in new materials for pipeline linings and advanced sensor technology for real-time particle size monitoring. The company's commitment to quality and precision engineering makes it a trusted partner for the global petrochemical industry.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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