In the industrial heartland of Longyan, Fujian Province, a prominent coal enterprise faced a critical challenge: how to efficiently and safely transport pulverized coal from storage to its boiler feeding system. Traditional mechanical conveying methods suffered from high maintenance costs, dust leakage, and inconsistent flow rates, leading to operational inefficiencies and environmental concerns. To address these issues, the company turned to Shandong Headpowder Engineering Co., Ltd. (abbreviated as headpowder), a leading provider of pneumatic conveying solutions headquartered in Shandong, China. This case study details the successful implementation of a dilute phase pneumatic conveying system tailored for pulverized coal transport and boiler feeding, showcasing the expertise of headpowder in delivering reliable, clean, and cost-effective material handling solutions.
The client, a coal enterprise operating multiple boilers for energy generation, required a continuous and dust-free method to transfer pulverized coal from its milling and storage units to the boiler burners. The existing system, based on screw conveyors and bucket elevators, experienced frequent blockages, high wear rates, and significant dust emissions, violating local environmental regulations. The client specifically needed a solution that would ensure stable feeding rates, minimize particle degradation, and eliminate fugitive dust. After evaluating several technology providers, they selected headpowder due to its proven track record in dilute phase pneumatic conveying applications for coal and other bulk solids. The project scope included the design, supply, installation, and commissioning of a complete dilute phase pneumatic conveying system for pulverized coal, covering the entire route from the storage silo to the boiler injection points.
Headpowder engineers proposed a dilute phase pneumatic conveying system specifically optimized for pulverized coal (coal powder) transport. In this configuration, the pulverized coal is entrained in a high-velocity air stream, creating a suspension that flows through a pipeline network. The dilute phase approach is ideal for this application because it offers several advantages: low capital cost, simple system layout, easy maintenance, and the ability to handle long distances and multiple discharge points. The system designed for the Longyan project consists of a rotary airlock feeder that meters the coal powder into the conveying line, a roots blower providing the motive air flow, and a series of pipelines with wear-resistant bends. To ensure reliable boiler feeding, the system incorporates a pressure control mechanism and a bypass arrangement that allows continuous operation even during partial load conditions. The conveying velocity is carefully maintained between 20 and 30 m/s to prevent settling while minimizing particle attrition. This dilute phase pneumatic conveying engineering solution successfully delivers the pulverized coal at a consistent rate of 8 tons per hour to the boiler, with a pressure drop of less than 50 kPa across the entire line.
The core of the project lies in the seamless integration of two critical product categories: boiler feed conveying and dilute phase pneumatic conveying engineering. The boiler feed conveying system is designed to handle the specific rheological properties of pulverized coal, which tends to be cohesive and prone to agglomeration. Headpowder's engineers selected a venturi-type injector at the feed point to create a homogeneous mixture of coal and air, preventing blockages. The conveying line features a 6-inch diameter schedule 40 steel pipe with ceramic-lined bends at all turning points to extend service life. A dedicated control system monitors the air pressure, flow rate, and material level in the receiving hopper, automatically adjusting the rotary feeder speed to maintain a stable feed rate. This dilute phase pneumatic conveying engineering approach ensures that the boiler receives a consistent supply of pulverized coal with minimal fluctuations, directly improving combustion efficiency and reducing emissions. The project also includes a dust collection system at the storage silo vent and the boiler receiving hopper, ensuring that the entire operation meets the strictest environmental standards.
The installation of the dilute phase pneumatic conveying system was completed within six weeks, with minimal disruption to the client's ongoing operations. During the commissioning phase, headpowder's technical team conducted a series of tests to verify the system's performance under various load conditions. The results were outstanding: the pulverized coal conveying rate reached 8.5 tons per hour, exceeding the design specification by 6%. The system maintained a consistent pressure drop of 45 kPa, with a conveying air-to-solids ratio of approximately 1.5 kg of air per kg of coal. Most importantly, the fugitive dust emissions were reduced to near zero, as confirmed by on-site monitoring. The boiler feed conveying system now operates 24/7 with a reliability of over 99%, significantly reducing unplanned downtime. The client reported a 15% reduction in overall energy consumption for material handling, thanks to the optimized air flow and reduced mechanical friction. The dilute phase pneumatic conveying engineering solution provided by headpowder has transformed the client's coal handling process, making it safer, cleaner, and more efficient.
Shandong Headpowder Engineering Co., Ltd. (headpowder) has accumulated extensive experience in designing and implementing dilute phase pneumatic conveying systems for a wide range of bulk materials, including pulverized coal, fly ash, cement, and chemical powders. The Longyan project is a testament to the company's ability to deliver customized solutions that meet the exact requirements of boiler feed applications. Headpowder's engineers utilize advanced simulation tools to model the flow behavior of the material, ensuring that the pipeline routing, fan selection, and control logic are optimized for each unique site. The company's commitment to quality is reflected in its use of high-grade components, such as wear-resistant alloys and explosion-proof electrical equipment, which are essential for handling combustible coal dust. Additionally, headpowder provides comprehensive after-sales support, including on-site training, spare parts supply, and remote monitoring services. For any coal enterprise seeking a reliable, dust-free, and energy-efficient method for pulverized coal conveying and boiler feeding, headpowder stands as a trusted partner.
For inquiries about dilute phase pneumatic conveying systems, boiler feed conveying solutions, or custom engineering for pulverized coal handling, please contact the headpowder sales team. The project manager, Mr. Zhang, is available to discuss your specific requirements and provide a preliminary design evaluation. You can reach Mr. Zhang directly via WeChat at 15662777102. Headpowder looks forward to assisting you with your next material handling project, whether it involves a small-scale retrofit or a large-scale greenfield installation. The company's address is in Shandong, China, and its expert engineers are ready to travel to your site for a thorough assessment. Contact headpowder today to learn how dilute phase pneumatic conveying engineering can improve your plant's efficiency and environmental compliance.
This case study of the coal enterprise in Longyan, Fujian Province, demonstrates the effectiveness of headpowder's dilute phase pneumatic conveying technology for boiler feed applications. By replacing outdated mechanical conveyors with a modern pneumatic system, the client achieved significant improvements in dust control, operational reliability, and energy savings. The project serves as a reference for other coal-fired power plants, industrial boilers, and chemical facilities that require safe and efficient pulverized coal transport. Headpowder's expertise in dilute phase pneumatic conveying engineering ensures that each system is tailored to the specific material properties and site constraints, delivering long-term value. For more information or to schedule a consultation, please contact Mr. Zhang via WeChat: 15662777102. Headpowder is committed to advancing the field of pneumatic conveying with innovative, customer-focused solutions.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
telephone
WeChatconsult
top