Shandong Headpowder Engineering Co., Ltd. (headpowder) successfully executed a customized dense phase pneumatic conveying system for a leading building materials enterprise located in Xuzhou, Jiangsu Province. This project specifically addressed the need for efficient and damage-free transport of ceramsite sand, a key material used in lightweight aggregates and fracturing proppants. The system was designed to handle high-density, abrasive particles under controlled conditions, ensuring minimal degradation and consistent flow rates. By leveraging headpowder’s proprietary dense phase technology, the client achieved a significant reduction in energy consumption compared to traditional dilute phase methods, while maintaining throughput capabilities of up to 15 tons per hour. The project scope included complete engineering design, equipment supply, installation supervision, and commissioning support.
The core of this project revolved around the dense phase conveying of ceramsite sand, a material with a bulk density ranging from 0.8 to 1.2 g/cm³ and particle sizes between 0.5 and 2 mm. headpowder’s engineered solution utilized a pressure vessel system combined with a specialized pipeline layout to transport the ceramsite sand over a distance of 120 meters with a vertical lift of 18 meters. The system incorporated wear-resistant ceramic-lined pipes to withstand the abrasive nature of the material, and a proprietary discharge valve ensured precise metering at the destination silo. This ceramsite sand dense phase conveying approach eliminated dust emissions and product breakage, which are common issues in conventional mechanical conveying systems. The client reported a product integrity rate of over 99.5%, directly improving the quality of their final lightweight aggregate products.
Beyond the ceramsite sand application, the same dense phase conveying system was also configured to handle fracturing proppant materials, including resin-coated and sintered bauxite proppants. In the oil and gas industry, fracturing proppant conveying requires extremely low degradation rates to maintain the conductivity of proppant packs. headpowder’s dense phase technology, with its low-velocity, high-pressure transport mechanism, proved ideal for this sensitive material. The system was tested with a 1.0 mm median diameter proppant sample and achieved a degradation rate of less than 0.3%, far exceeding the industry standard of 1%. This performance validated the system’s adaptability for both building materials and upstream energy applications. The Xuzhou client now uses the same infrastructure to switch between ceramsite sand and fracturing proppant batches, maximizing equipment utilization and return on investment.
This project serves as a benchmark dense phase particle conveying case for medium-sized manufacturing facilities. The key parameters included: conveying capacity of 12 t/h for ceramsite sand, air consumption of 6.5 Nm³/min at 0.6 MPa, and a pipeline diameter of DN80. headpowder’s engineers performed computational fluid dynamics (CFD) simulations to optimize the injection point and bend geometry, reducing pressure drop by 22% compared to the initial design. The control system integrated a PLC with HMI interface, allowing operators to monitor material flow, air pressure, and filter status in real time. Automatic purging cycles were implemented to prevent pipeline blockages during shutdowns. The entire system was delivered within 8 weeks from order, and the on-site commissioning was completed in 5 working days. The client’s plant manager noted that the system required minimal maintenance, with only periodic inspection of the wear indicators needed after 6 months of continuous operation.
Shandong Headpowder Engineering Co., Ltd. brings over 15 years of expertise in pneumatic conveying engineering. The dense phase system deployed in Xuzhou features several proprietary innovations: (1) a patented double-dome pressure vessel that ensures continuous material feed without pressure fluctuations; (2) a self-cleaning venturi injector that reduces air consumption by up to 30%; (3) a modular pipeline support system that simplifies installation in confined spaces. The system also incorporates explosion-proof electrical components and grounding provisions, meeting the strict safety standards for combustible dust environments. For the building materials industry, these features translate into lower operational costs, higher reliability, and compliance with local environmental regulations regarding dust emissions. headpowder’s after-sales service includes a 24/7 technical hotline, spare parts inventory, and on-site training programs for client operators.
The project was executed in two phases. Phase one involved the installation of the main conveying line from the raw material storage yard to the intermediate silo. Phase two added a secondary distribution line to feed three separate mixing stations. The Xuzhou client reported that the system reduced manual handling labor by 80% and eliminated dust leakage completely. Compared to their previous bucket elevator and screw conveyor setup, the dense phase pneumatic system saved 45% in electricity costs per ton of material conveyed. The plant also achieved a 15% increase in overall production capacity due to the elimination of downtime caused by mechanical breakdowns. The client’s production director commented: “The headpowder team understood our specific requirements for ceramsite sand and fracturing proppant. Their dense phase technology not only met but exceeded our expectations in terms of product quality preservation and energy efficiency.”
For more information about ceramsite sand dense phase conveying, fracturing proppant conveying, or to discuss your specific dense phase particle conveying case, please contact Manager Zhang at Shandong Headpowder Engineering Co., Ltd. (headpowder). WeChat: 15662777102. The company is headquartered in Shandong, China, and serves clients across the building materials, oil & gas, chemical, and mineral processing industries. Manager Zhang and his team provide free preliminary consultations and feasibility studies for projects of any scale. Whether you need a new system design or retrofitting of existing equipment, headpowder’s engineering staff is ready to deliver a tailored solution. Contact Manager Zhang today via WeChat at 15662777102 to start your project evaluation.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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