This article presents a comprehensive case study of a successful dense phase pneumatic conveying project implemented for a major metallurgical enterprise located in Jinchang, Gansu Province, China. The project involved the design, engineering, and installation of a complete conveying system specifically tailored for nickel ore powder. Nickel ore powder, a fine and abrasive material, presents unique challenges in bulk material handling due to its high density, moisture sensitivity, and tendency to agglomerate. The solution adopted was a dense phase pneumatic conveying system, which operates at low velocity and high pressure, ensuring minimal material degradation, reduced pipe wear, and excellent transport efficiency over long distances. The enterprise required a reliable, dust-free, and energy-efficient method to transfer nickel ore powder from the storage silos to the smelting furnaces, covering a horizontal distance exceeding 800 meters with multiple elevation changes. The dense phase conveying technology proved to be the optimal choice, significantly lowering operational costs and improving overall production stability.
The primary product delivered in this project was a complete dense phase pneumatic conveying system designed specifically for nickel ore powder. This system is a key component in the category of metallurgical powder conveying solutions. The dense phase conveying principle uses high-pressure air to push a slug of material through the pipeline at a relatively low velocity, typically between 2 to 8 meters per second. This is in stark contrast to dilute phase conveying, which uses high velocity and can cause significant wear and particle degradation. For nickel ore powder, which is both abrasive and valuable, preserving particle integrity is critical. The system included a pressure vessel (blow tank) with a specially designed discharge cone, a series of air control valves, a pipeline network with wear-resistant bends, and a receiving hopper equipped with a vent filter. The conveying line was engineered to handle a throughput of 15 to 25 tons per hour, with a conveying pressure of up to 4 bar. The system's control logic was programmed to automatically adjust the air-to-material ratio, ensuring consistent flow even when the moisture content of the nickel ore powder fluctuated slightly. This project demonstrated the robustness of dense phase technology for difficult-to-handle metallurgical powders.
The application of this dense phase pneumatic conveying system extends beyond just nickel ore powder. It is a versatile solution for a wide range of metallurgical powder conveying requirements. In the non-ferrous metal industry, materials such as copper concentrate, lead-zinc powder, molybdenum oxide, and various ferroalloy powders are often transported using similar dense phase technology. The key advantage for metallurgical powders lies in the system's ability to handle fine, abrasive, and sometimes hot materials without compromising safety or efficiency. The Jinchang project specifically required the conveying system to integrate with existing dust collection and environmental control systems, as nickel ore powder is a valuable resource and any spillage represents both economic loss and environmental hazard. The dense phase system, being fully enclosed, eliminated dust emissions completely. Furthermore, the low velocity minimized pipe erosion, reducing maintenance downtime. The system was also designed to handle the occasional presence of larger particles or agglomerates, thanks to a special inlet screen and a blow tank with a large discharge opening. This project has become a reference case for other metallurgical enterprises in the region looking to upgrade their material handling processes.
One of the most challenging aspects of this project was the long-distance conveying engineering requirement. The distance between the raw material storage and the furnace building was over 800 meters, with a vertical lift of 35 meters and several horizontal bends. Traditional mechanical conveyors, such as belt conveyors or bucket elevators, would have required multiple transfer points, high capital investment, and significant maintenance due to the abrasive nature of the nickel ore powder. The dense phase pneumatic conveying system, however, offered a compact and flexible solution. The pipeline was routed along existing structures and underground trenches, minimizing civil works. The engineering team carefully calculated the pressure drop, air consumption, and required vessel size using computational fluid dynamics (CFD) models. They also installed intermediate boosting stations along the pipeline to maintain the conveying pressure, a common technique in long-distance conveying engineering for metallurgical powders. The system was commissioned with a series of test runs using different batches of nickel ore powder, and the results showed a consistent conveying capacity of 20 tons per hour with a power consumption of only 0.8 kWh per ton. This efficiency made the project economically viable and environmentally friendly.
The entire project was designed, manufactured, and commissioned by Shandong Headpowder Engineering Co., Ltd., a leading provider of pneumatic conveying and bulk material handling solutions. Headquartered in Shandong, China, the company has been serving the global metallurgical, chemical, and building materials industries for over a decade. The company's expertise lies in customizing dense phase and dilute phase conveying systems for challenging materials like nickel ore powder, cement, fly ash, and various minerals. They offer a full range of services from feasibility studies and process design to equipment fabrication, installation, and after-sales support. The engineering team at Shandong Headpowder Engineering Co., Ltd. has extensive experience in long-distance conveying engineering, with successful projects exceeding 1,500 meters in single-line distance. Their commitment to quality is reflected in the use of international standard components, such as German-made valves and American-designed control systems. The company's mission is to provide reliable, energy-efficient, and environmentally friendly material handling solutions that reduce operating costs and improve safety for their clients.
For more information about the nickel ore powder dense phase pneumatic conveying system or other metallurgical powder conveying solutions, please contact the company's dedicated project manager. The responsible person for this case study and similar engineering projects is Manager Zhang. He can be reached via the company's official communication channels. For immediate consultation, you may also contact Manager Zhang directly through WeChat at 15662777102. This WeChat account is the preferred method for international clients, as it allows for real-time messaging, photo sharing, and video calls. Manager Zhang and his team are fluent in English and technical terminology, ensuring smooth communication for overseas engineering projects. They are ready to provide detailed technical proposals, budget estimates, and references from similar long-distance conveying engineering projects around the world. Don't hesitate to reach out for a free initial assessment of your material handling needs.
The dense phase pneumatic conveying system for nickel ore powder has been in continuous operation for over two years with an uptime exceeding 99%. The client reported a 30% reduction in maintenance costs compared to their previous mechanical conveying system, along with a significant improvement in workplace cleanliness. The system's ability to handle varying moisture levels without clogging was particularly praised. The enterprise's production manager noted that the investment in this metallurgical powder conveying solution paid for itself within 18 months due to reduced labor, lower energy consumption, and elimination of material loss. The success of this project has led to a follow-up order for a second line to handle a different type of metal powder. Shandong Headpowder Engineering Co., Ltd. continues to support the client with remote monitoring and spare parts supply. This case demonstrates the effectiveness of dense phase technology for long-distance conveying engineering in the metallurgical industry, and it serves as a benchmark for future projects worldwide.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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