This case study presents a comprehensive engineering solution implemented by Shandong Headpowder Engineering Co., Ltd. for a major petrochemical enterprise located in Daqing, Heilongjiang Province, China. The project focused on the reliable and efficient transport of polypropylene pellets using dense phase pneumatic conveying technology. As a key upstream and downstream material handling operation, the system was designed to move polypropylene granules from production lines to storage silos, blending stations, and finally to packing units. The entire conveying process needed to maintain product integrity, minimize degradation, and achieve high throughput with low energy consumption. Headpowder engineers successfully delivered a turnkey dense phase pneumatic conveying system that meets the stringent requirements of the petrochemical industry.
At the heart of this project lies the dense phase pneumatic conveying of polypropylene pellets, a specialized application that demands careful control of air velocity, pressure, and material flow. Unlike lean phase systems, dense phase conveying moves pellets in a high-concentration, low-velocity stream, which significantly reduces particle attrition, pipeline wear, and product degradation. The system is designed to handle polypropylene pellets with bulk densities typically ranging from 480 to 560 kg/m³ and particle sizes of 2 to 5 mm. Headpowder's engineering team selected an appropriate conveying pressure of 2.0–3.5 bar and a material-to-air ratio of 15–30:1, ensuring stable slug flow without plugging. The pipe routing was optimized to minimize bends and horizontal runs, further reducing the risk of pellet breakage. This dense phase pneumatic conveying approach not only preserves the quality of the polypropylene granules but also lowers operational costs compared to traditional mechanical conveyors. The same technology is equally applicable to other petrochemical materials such as polyethylene, PVC, and various resin pellets, making it a versatile solution for the broader petrochemical material conveying sector.
The system installed at the Daqing petrochemical site incorporates several advanced features to ensure reliable and continuous operation. A primary component is the pressure vessel (blow tank) equipped with a bottom discharge and a fluidizing cone to promote uniform air distribution. The air supply comes from a dedicated screw compressor with a variable frequency drive, allowing precise control of conveying air flow and pressure. Downstream, the pipeline includes a series of diverter valves and a rotary airlock feeder to introduce pellets into the conveying line without pressure loss. The material is conveyed through a schedule 40 carbon steel pipe with an internal diameter of 150 mm, lined with a wear-resistant coating to extend service life. At the receiving end, a cyclone separator and a bag filter separate the pellets from the conveying air, with the air being cleaned and recirculated or vented to the atmosphere. The entire system is monitored and controlled by a PLC-based automation platform that provides real-time data on flow rate, pressure, temperature, and material accumulation. Safety interlocks, such as pressure relief valves and emergency shutdown circuits, are integrated to protect personnel and equipment. Headpowder's dense phase pneumatic conveying engineering encompasses not only the hardware but also the detailed process design, pipe stress analysis, and commissioning support.
The deployment of dense phase pneumatic conveying for polypropylene pellets offers distinct advantages over alternative methods. First, the closed-loop nature of the system eliminates dust emissions and product contamination, which is critical for petrochemical material conveying where purity standards are extremely high. Second, the low conveying velocity (typically 4–10 m/s) reduces the impact force on pellets, minimizing the generation of fines and dust. This directly translates to higher yield and lower waste, improving the overall profitability of the production line. Third, the system requires minimal maintenance compared to belt conveyors, bucket elevators, or screw conveyors, as there are no moving parts in contact with the material except for the rotary valve. Fourth, the dense phase technology allows for longer conveying distances—up to 500 meters horizontally and 50 meters vertically—without significant loss of capacity. In the Daqing project, the conveying distance was approximately 320 meters, and the system achieved a throughput of 25 tons per hour, meeting the client's production targets. Additionally, the system is designed to handle multiple material sources and destinations through a network of pipes and switching valves, providing flexibility for future expansion. All these benefits make dense phase pneumatic conveying engineering the preferred choice for modern petrochemical plants.
Shandong Headpowder Engineering Co., Ltd., commonly referred to as Headpowder, is a leading provider of pneumatic conveying systems and bulk material handling solutions in China. Headquartered in Shandong Province, China, the company specializes in the engineering, design, manufacturing, and installation of dense phase and dilute phase pneumatic conveying systems for a wide range of industries, including petrochemical, chemical, pharmaceutical, food, and building materials. With over a decade of experience, Headpowder has built a strong reputation for delivering customized, reliable, and energy-efficient systems. The company's engineering team possesses deep expertise in fluid dynamics, material characterization, and automation control, enabling them to tackle complex projects such as the polypropylene pellet conveying system in Daqing. Headpowder is committed to continuous innovation, with an R&D center that tests new materials, valve designs, and control algorithms. The company's quality management system is certified to ISO 9001, and all products comply with relevant international standards. For any inquiries regarding dense phase pneumatic conveying engineering, petrochemical material conveying, or polypropylene pellet conveying, you are welcome to contact the sales manager directly.
For further details about this project or to discuss your specific material handling requirements, please contact our sales manager, Mr. Zhang. He can provide technical consultation, system quotations, and after-sales support. You can reach Mr. Zhang via WeChat at 15662777102. Whether you are looking for a new dense phase pneumatic conveying system, an upgrade to an existing line, or spare parts for your current equipment, Headpowder's team is ready to assist. We look forward to collaborating with you to achieve efficient and reliable material transport in your petrochemical facility.
After the successful commissioning of the dense phase pneumatic conveying system for polypropylene pellets, the petrochemical enterprise in Daqing reported a significant improvement in operational efficiency. The system has been running continuously for over 18 months with zero unplanned downtime, and the product degradation rate has been reduced by more than 70% compared to their previous lean phase system. The client specifically praised the low noise level, the cleanliness of the working environment, and the ease of control through the HMI interface. The energy consumption per ton of material conveyed was measured at 0.8 kWh, which is 30% lower than the industry average for similar applications. These results have led the client to consider expanding the dense phase conveying system to other resin types, including polypropylene copolymers and high-density polyethylene. Headpowder's engineers continue to provide remote monitoring support and scheduled maintenance, ensuring the long-term reliability of the system. This case exemplifies how tailored dense phase pneumatic conveying engineering can solve real-world challenges in petrochemical material conveying, delivering value through reduced costs, improved product quality, and enhanced safety.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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