This article presents a comprehensive case study of a bentonite dilute phase pneumatic conveying project implemented for a building materials enterprise in Zhangjiakou, Hebei Province. The project was successfully delivered by Shandong Headpowder Engineering Co., Ltd., a leading provider of bulk material handling solutions. The core focus of this case is the application of dilute phase pneumatic conveying technology for bentonite powder, a critical raw material in the construction materials industry. The solution not only optimized the production process but also significantly improved operational efficiency and environmental compliance.
The client, a well-established building materials manufacturer located in Zhangjiakou, Hebei, faced several challenges in handling bentonite powder. Bentonite is a highly hygroscopic, fine-grained clay mineral with a tendency to agglomerate and adhere to equipment surfaces. The existing manual handling and mechanical conveying methods led to frequent blockages, dust emissions, and high maintenance costs. The client needed a reliable, enclosed, and automated conveying system that could transport bentonite from storage silos to mixing stations over a distance of approximately 80 meters, with a conveying capacity of 15 tons per hour. The system had to handle high moisture content variations (up to 12% moisture) and maintain consistent flow without segregation or degradation of the material. The primary requirement was to implement a dilute phase pneumatic conveying system that could provide dust-free operation, low energy consumption, and minimal product degradation.
After thorough site assessment and material testing, the engineering team from Shandong Headpowder Engineering Co., Ltd. (headpowder) proposed a custom-designed dilute phase pneumatic conveying system specifically tailored for bentonite powder. Dilute phase conveying operates on the principle of suspending the material in a high-velocity air stream, typically at air velocities between 20 and 30 m/s, with a low solid-to-air ratio. This method is ideal for fine, free-flowing powders like bentonite, as it prevents material buildup and ensures smooth transport through pipelines. The system incorporated a positive displacement blower, a rotary airlock feeder, a series of wear-resistant pipe bends, and a cyclone separator with a baghouse filter for dust collection. The pipeline routing was carefully designed to avoid sharp bends and long horizontal sections that could cause material accumulation. The use of a specialized building materials powder conveying approach ensured that the bentonite remained in a consistent fluidized state, reducing the risk of blockages even under variable moisture conditions.
The entire system was built around a dilute phase pneumatic conveying system that included the following major components: a high-capacity rotary airlock feeder with a variable speed drive to control the feed rate, a 75 kW Roots blower providing a pressure of 0.8 bar, and a 6-inch diameter steel pipeline with ceramic-lined bends to extend service life. The receiving station consisted of a venturi-type receiver hopper connected to a pulse-jet dust collector. The dust collector was equipped with PTFE filter bags capable of capturing particles as fine as 1 micron, ensuring zero emissions to the atmosphere. The control system utilized a PLC with HMI touchscreen, allowing operators to monitor conveying pressure, air velocity, and material flow in real time. Alarms were set for high pressure, low airflow, and motor overload to prevent system downtime. The entire system was designed to operate continuously for 16 hours per day, with a design life of more than 10 years under normal maintenance.
The installation was completed within 45 days, including civil works, equipment mounting, and pipeline erection. The commissioning phase involved a step-by-step tuning of the air velocity and feed rate to achieve optimal conveying conditions. During the initial trial, the system successfully conveyed bentonite with a moisture content of 10% without any clogging. The conveying capacity reached 15.5 tons per hour, exceeding the client's requirement by 3%. The power consumption was measured at 0.8 kWh per ton of material conveyed, which is significantly lower than the previous mechanical system that consumed 1.5 kWh per ton. The dust emissions were reduced to virtually zero, meeting the strict local environmental standards. The client reported a 40% reduction in maintenance labor and a 60% decrease in spare parts consumption. The building materials powder conveying solution provided by headpowder proved to be highly reliable and cost-effective.
This case demonstrates the significant advantages of using a dilute phase pneumatic conveying system for handling bentonite and other fine powders in the building materials sector. First, the enclosed nature of the system eliminates fugitive dust, improving worker health and safety while complying with increasingly stringent environmental regulations. Second, the flexibility of pipeline routing allows the system to adapt to existing plant layouts without major structural modifications. Third, the gentle conveying action of dilute phase prevents degradation of the bentonite particles, preserving the material's swelling and binding properties essential for applications such as cement-based mortars, tile adhesives, and drilling fluids. Fourth, the system's automated control reduces human error and ensures consistent product quality. The successful implementation in Zhangjiakou serves as a benchmark for other building materials powder conveying projects across the region.
Shandong Headpowder Engineering Co., Ltd. (headpowder) is a professional engineering company headquartered in Shandong Province, China, specializing in the design, manufacture, and installation of pneumatic conveying systems and bulk material handling equipment. With over 15 years of experience in the field, the company has completed hundreds of projects in the building materials, chemical, food, and mining industries. The company's core competency lies in providing customized solutions for challenging materials such as bentonite, cement, fly ash, and lime. The engineering team applies advanced computational fluid dynamics (CFD) simulations to optimize pipeline design and ensure reliable performance. All equipment is manufactured in the company's ISO 9001 certified factory, with strict quality control procedures. The company offers comprehensive after-sales support, including remote monitoring, spare parts supply, and on-site training. For any inquiries regarding dilute phase pneumatic conveying or building materials powder conveying solutions, please contact the project manager.
For more information about this bentonite dilute phase pneumatic conveying project or to discuss your specific conveying requirements, please contact the dedicated sales manager: Manager Zhang. You can reach Manager Zhang via WeChat at 15662777102. The team at Shandong Headpowder Engineering Co., Ltd. is ready to provide a free consultation and site assessment to help you achieve the most efficient and cost-effective powder handling solution. We look forward to partnering with you to optimize your production process.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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