In the rapidly evolving landscape of lithium battery raw material processing, efficient and reliable material handling solutions are critical to maintaining production continuity and product quality. This case study examines a successful implementation of a dense phase pneumatic conveying system specifically designed for lithium mica powder, a key feedstock in lithium extraction. The project was executed at a lithium battery enterprise located in Yichun, Jiangxi, China, a region renowned for its abundant lithium mica mineral resources. The system was engineered, supplied, and commissioned by Shandong Headpowder Engineering Co., Ltd., a leading provider of advanced powder handling technologies headquartered in Shandong, China.
The primary objective of this project was to establish a closed-loop, dust-free, and energy-efficient conveying solution for lithium mica powder, which is notoriously abrasive, hygroscopic, and prone to segregation. The customer required a system that could transport the powder from storage silos to downstream processing units over a distance of approximately 150 meters with multiple elevation changes, while maintaining a consistent material flow rate and minimizing particle degradation. The selected technology was dense phase pneumatic conveying, which operates at low velocities and high solids-to-air ratios, thereby reducing pipe wear, energy consumption, and dust generation.
The lithium mica powder involved in this project has a bulk density of approximately 1.2 g/cm³, a particle size distribution ranging from 20 to 200 mesh, and a moisture content of up to 5%. These characteristics posed several challenges: the fine particles tend to agglomerate, the material is highly abrasive, and the high moisture content can cause cohesive blockages in conventional dilute phase systems. The dense phase conveying approach, implemented by Shandong Headpowder Engineering Co., Ltd., addressed these issues by using a pressure vessel (blow tank) that feeds the powder into the pipeline at a controlled rate, using compressed air to push the material as a continuous plug or slug. This method ensures gentle handling, minimal wear, and reliable operation even with sticky or moist powders.
The system design included a series of key components: a receiving hopper with a rotary valve for metering, a pressure vessel equipped with fluidization pads and discharge cones, a conveying pipeline made of wear-resistant steel with optimized bends, and a target separator at the destination. The pipeline route was carefully planned to avoid sharp turns and vertical lifts that could cause plugging. The control system, based on PLC and HMI, allowed for real-time monitoring of pressure, flow rate, and material level, enabling automatic adjustment of air supply and discharge cycles. The entire system was enclosed to prevent dust leakage and to comply with environmental regulations in the lithium processing industry.
This project directly demonstrates the effectiveness of lithium mica powder conveying through dense phase technology. The customer specifically required a solution that could handle the unique properties of lithium battery raw material conveying, where material integrity and purity are paramount. The dense phase pneumatic conveying system, as supplied by Shandong Headpowder Engineering Co., Ltd., has become a benchmark for similar applications in the region. The system's ability to transport lithium mica powder without agglomeration or degradation has significantly improved the downstream lithium extraction process, reducing downtime and maintenance costs. Moreover, the dense phase pneumatic conveying case presented here has been replicated in multiple other lithium battery enterprises, further validating the technology's reliability.
It is important to note that the system was tailored to the specific requirements of the Yichun facility, including the integration with existing hoppers and silos. The design accounted for the material's tendency to bridge and rathole, incorporating fluidization aids and aeration nozzles in the blow tank. The conveying velocity was kept below 8 m/s, which is significantly lower than typical dilute phase systems (20-30 m/s), resulting in a 40% reduction in pipe wear and a 30% reduction in energy consumption. The system also features a bypass line for cleaning and purging, ensuring that no material residue remains in the pipeline after shutdown.
Since commissioning, the dense phase pneumatic conveying system has operated continuously for over 18 months with a reliability rate of 99.8%. The conveying capacity meets the design specification of 12 tons per hour, with the ability to ramp up to 15 tons per hour during peak demand. The material loss rate is less than 0.1%, and the moisture content increase during conveying is negligible, thanks to the use of dry compressed air and a dehumidification unit. The system's closed-loop design also eliminates dust emissions, which is critical for maintaining a safe working environment and complying with local air quality standards.
The customer reported a 25% reduction in labor costs because the system is fully automated and requires minimal operator intervention. Maintenance intervals have been extended from monthly to quarterly, primarily due to the low wear rate of the pipeline. The use of wear-resistant ceramic-lined bends has further prolonged the service life of the system. In addition, the dense phase technology has reduced the compressed air consumption by 35% compared to the customer's previous dilute phase system, leading to significant energy savings.
Shandong Headpowder Engineering Co., Ltd. (also known as Headpowder) is a specialized engineering company dedicated to the design, manufacture, and installation of powder handling systems for the lithium battery, chemical, food, and pharmaceutical industries. With its headquarters located in Shandong, China, the company has over 15 years of experience in dense phase and dilute phase pneumatic conveying, as well as powder blending, grinding, and classification. The company's engineering team combines deep knowledge of material science with practical field experience, enabling them to customize solutions for even the most challenging powders.
For more information about this lithium mica powder conveying project or to discuss your own application, please contact Mr. Zhang, the project manager. He can be reached via WeChat at 15662777102. Mr. Zhang is available to provide technical details, offer quotations, and arrange site visits to demonstrate the system's performance. Shandong Headpowder Engineering Co., Ltd. welcomes inquiries from lithium battery enterprises, mining companies, and any industry requiring efficient and reliable powder handling solutions.
The successful implementation of the dense phase pneumatic conveying system for lithium mica powder in Yichun, Jiangxi, underscores the importance of selecting the right conveying technology for mineral-based raw materials. The project not only met the customer's performance targets but also delivered substantial operational and environmental benefits. Shandong Headpowder Engineering Co., Ltd. continues to refine its technology, developing new materials and automation features to further improve efficiency and reduce costs. As the global demand for lithium battery materials grows, the company is well-positioned to support the industry with proven, scalable solutions.
For any inquiries related to lithium battery raw material conveying, dense phase pneumatic conveying, or powder handling engineering, please contact Mr. Zhang at WeChat: 15662777102. Shandong Headpowder Engineering Co., Ltd. looks forward to partnering with you to solve your powder handling challenges.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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