Sichuan Deyang Lithium Cathode Long-Distance Conveying Case

Case Overview

This case study examines the long-distance conveying system deployed by HeadPowder for a lithium cathode material production facility in Deyang, Sichuan. The system was designed to transport fine lithium iron phosphate (LFP) powder over a distance exceeding 200 meters, from the milling stage to the blending silo, while maintaining material integrity and process cleanliness.

Customer Challenges

The customer faced several operational difficulties with their existing mechanical conveying method. Belt-based conveyors caused frequent material spillage and dust emission, resulting in a workplace environment that did not meet local air quality standards. The abrasive nature of cathode powders led to high wear rates on conveyor belts and rollers, requiring monthly replacement of key components. Additionally, the limited layout of the existing facility made it impossible to extend the mechanical conveyor to the new storage area without building a costly elevated structure.

Our Solution

HeadPowder implemented a dense-phase pneumatic conveying system specifically engineered for long‑distance transport of cohesive lithium cathode powders. The system uses a closed-loop pipeline with controlled air velocity to minimize particle attrition and avoid segregation. A series of booster nozzles placed at strategic intervals maintain a consistent flow profile along the 220‑meter route. The powder is discharged into a receiving hopper equipped with a vent filter that captures residual fines, ensuring zero emission to the atmosphere. The entire conveying process is monitored by a programmable logic controller (PLC) that adjusts air pressure and batch timing based on real‑time material level sensors.

Key Outcomes

After commissioning, the plant reported a 40% reduction in overall material waste and a 60% decrease in dust‑related maintenance downtime. The sealed pipeline eliminated airborne dust, allowing the customer to pass a surprise environmental inspection. The system has been running continuously for over 12 months with no conveyor belt replacements required, and the energy consumption per ton of material conveyed is 35% lower than the previous mechanical method.