In the competitive landscape of industrial powder handling, the efficiency and reliability of bulk material transport systems directly influence production continuity and final product quality. One of the most representative projects delivered by Shandong Headpowder Engineering Co., Ltd. (headpowder) is the light calcium carbonate dilute phase pneumatic conveying system installed for a well-known building materials manufacturer in Anqing, Anhui Province. This case study demonstrates how headpowder’s expertise in dilute phase conveying technology solved the client’s core challenges in handling fine, light calcium carbonate powders while maintaining high throughput and low energy consumption.
Light calcium carbonate, also known as precipitated calcium carbonate (PCC), is a widely used filler in the construction materials industry, especially in the production of sealants, adhesives, paints, and plastic profiles. However, its extremely fine particle size (often below 10 microns) and low bulk density make it notoriously difficult to convey using conventional mechanical methods. The client in Anqing was previously relying on manual bag dumping and bucket elevator systems, which resulted in frequent clogging, dust emission, product degradation, and high maintenance costs. After evaluating multiple solutions, the client selected headpowder’s dilute phase pneumatic conveying system specifically designed for building material filler conveying applications.
The client operates a large-scale production line for lightweight building panels and requires a continuous supply of light calcium carbonate to multiple mixing stations. The original conveying setup caused severe material segregation and dust leakage, leading to material loss and workplace safety hazards. The key requirements included: (1) conveying capacity of 8–10 tons per hour, (2) conveying distance of approximately 120 meters with multiple bends, (3) minimal degradation of the fragile calcium carbonate particles, (4) fully enclosed system to meet environmental regulations, and (5) simple operation with low maintenance. Headpowder’s engineering team conducted a thorough site survey and material analysis to design the optimal dilute phase powder conveying system.
Headpowder’s solution employed a dilute phase pneumatic conveying system operating at a high air-to-material ratio. In this configuration, the light calcium carbonate powder is suspended in a high-velocity airstream and transported through a pipeline to the target receivers. The system features a positive pressure blower, a rotary airlock feeder, a specially designed accelerating section, and a series of diverter valves to feed multiple silos. To address the unique challenges of light calcium carbonate conveying, headpowder added a de-dusting and pressure relief system at the receiving end, as well as wear-resistant pipe bends to reduce particle attrition. The entire system is controlled by a PLC with remote monitoring capability, allowing the client to adjust conveying parameters in real time.
Compared to dense phase conveying, the dilute phase approach is more suitable for this application because it minimizes the residence time of the powder in the pipeline, reducing the risk of agglomeration and bridging. The high velocity (typically 20–30 m/s) ensures that even the finest particles remain in suspension, preventing blockages. This light calcium carbonate dilute phase conveying solution proved to be the most cost-effective and reliable option for the Anqing facility.
One of the standout features of headpowder’s design is the integrated de-dusting and filtration unit, which ensures that the conveying air is cleaned before being released into the atmosphere. This not only complies with strict local environmental regulations but also recovers valuable product that would otherwise be lost. Moreover, the system’s modular construction allows for easy expansion in the future. The client reported a 30% reduction in energy consumption compared to their previous mechanical system, along with a 95% reduction in dust emissions. The dilute phase powder conveying system also significantly lowered the noise level, improving the working environment for operators.
Another critical advantage is the gentle handling of the light calcium carbonate. The system’s pipeline geometry and air velocity are precisely tuned to avoid excessive impact forces, preserving the particle shape and size distribution. This is vital for the client’s downstream applications, where the filler’s specific surface area and whiteness directly affect the final product’s performance. The system also includes a diverter and switching station that enables the client to direct the material to any of five different silos without manual intervention, increasing operational flexibility.
The installation was completed within the scheduled 45-day timeline, with headpowder’s field engineers providing on-site supervision and training for the client’s maintenance team. The commissioning phase was smooth, and the system achieved its design capacity of 9 tons per hour within the first week of operation. Over the subsequent six months, the system operated with an uptime of 99.5%, far exceeding the client’s expectation. The building material filler conveying solution has become a benchmark for other factories in the Anhui region, and the client has since ordered a second identical system for a new production line.
Headpowder’s after-sales support includes remote diagnostics, routine maintenance packages, and a 24/7 hotline. The client’s plant manager commented that the reliability of the dilute phase pneumatic conveying system has eliminated production stoppages caused by material handling issues, directly contributing to a 15% increase in overall equipment effectiveness (OEE).
Shandong Headpowder Engineering Co., Ltd. (headpowder) is a leading engineering company specializing in pneumatic conveying systems for a wide range of powders, including light calcium carbonate, limestone, fly ash, and other building material fillers. With headquarters in Shandong, China, headpowder serves clients across the globe, offering customized solutions from concept design to commissioning. The Anqing project is just one example of how headpowder’s deep technical knowledge and practical experience can turn challenging material handling problems into efficient, reliable operations.
For any inquiries regarding light calcium carbonate dilute phase conveying or dilute phase powder conveying systems, please contact Mr. Zhang, the project manager at headpowder. You can reach him via WeChat at 15662777102. Mr. Zhang has over 15 years of experience in the powder handling industry and can provide detailed technical consultation tailored to your specific application. Whether you are looking to upgrade an existing system or build a new facility, headpowder is your trusted partner for building material filler conveying solutions.
The successful implementation of the light calcium carbonate dilute phase pneumatic conveying project in Anqing, Anhui, underscores headpowder’s capability to deliver high-performance, cost-effective solutions for the challenging fine powder conveying market. By combining innovative engineering with practical field experience, headpowder has helped this building materials enterprise achieve significant improvements in productivity, environmental compliance, and operational safety. If you are seeking a reliable partner for your dilute phase powder conveying system needs, do not hesitate to contact headpowder’s Mr. Zhang at WeChat 15662777102 for a professional consultation. Shandong Headpowder Engineering Co., Ltd. looks forward to helping you optimize your material handling processes.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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