This case study presents a detailed technical overview of a successful catalyst particle positive pressure pneumatic conveying system implemented for a major petrochemical enterprise located in Lanzhou, Gansu Province, China. The project was designed and executed by Shandong Headpowder Engineering Co., Ltd., a leading engineering firm headquartered in Shandong, China, specializing in advanced bulk material handling solutions. The core objective of this project was to establish a reliable, efficient, and safe method for transporting catalyst particles from the storage area to the reactor feeding point within the petrochemical facility. Traditional mechanical conveying methods, such as belt conveyors or bucket elevators, were deemed unsuitable due to the abrasive nature of the catalyst particles, the need for complete containment to prevent dust emission, and the requirement for a flexible routing path across the plant layout. Positive pressure pneumatic conveying emerged as the optimal solution, offering enclosed pipeline transport, low maintenance demands, and the ability to handle high-temperature and friable materials without degradation.
This project serves as a benchmark catalyst conveying case study within the petrochemical industry, demonstrating the effectiveness of headpowder engineering’s proprietary technology. The system specifically handles zeolite-based catalyst particles with an average particle size ranging from 50 to 150 microns, a bulk density of approximately 0.7 to 0.9 g/cm³, and a moisture content below 1%. The catalyst material is highly sensitive to breakage, meaning that any mechanical impact or excessive velocity during transport could lead to fines generation, reducing catalytic activity and increasing operational costs. headpowder engineering addressed this challenge by employing a dense-phase positive pressure pneumatic conveying regime, which operates at relatively low gas velocities (typically 4–8 m/s) and high solid-to-gas ratios. This approach minimizes particle attrition while maintaining a consistent flow rate of up to 8 tons per hour. The conveying distance in this installation measures approximately 320 meters horizontally, with a vertical lift of 18 meters, and includes six 90-degree bends. The pipeline is constructed from wear-resistant stainless steel (304L) with a wall thickness of 6 mm, and the bends are equipped with replaceable ceramic liners to extend service life. The system is controlled by a programmable logic controller (PLC) integrated with a human-machine interface (HMI) that provides real-time monitoring of pressure, flow velocity, and material level. This catalyst conveying case study has been documented and shared with industry peers to illustrate the feasibility of dense-phase conveying for fragile, abrasive catalytic materials.
The positive pressure pneumatic conveying system employed in this Lanzhou project is a flagship example of headpowder engineering’s capability in handling granular materials for the petrochemical sector. Unlike vacuum or negative pressure systems, a positive pressure system uses compressed air (or inert gas, where required) to push the material through the pipeline from a single feed point to multiple discharge destinations. In this installation, the air source is a screw compressor with a capacity of 45 m³/min at 0.6 MPa, equipped with a refrigerated air dryer and a multi-stage filtration system to ensure oil-free, dry compressed air. The feeding device is a rotary airlock valve with a specially designed rotor profile that minimizes air leakage and material backflow, coupled with a venturi-type injector to accelerate the material into the pipeline. The system is designed for continuous operation, with a maximum conveying pressure of 0.3 MPa at the pipeline inlet. One of the key advantages of positive pressure granular conveying is the ability to maintain a sealed environment, preventing dust leakage into the plant atmosphere and ensuring compliance with strict environmental regulations. Additionally, the system incorporates a pressure relief valve and an emergency shutdown mechanism to protect against overpressure events. The conveying line is routed through a series of support structures and expansion joints to accommodate thermal expansion during operation. The system also includes a downstream cyclone separator and a bag filter at the receiving end to separate the catalyst particles from the conveying air, achieving a separation efficiency of over 99.9%. This positive pressure granular conveying solution has significantly reduced manual handling risks and improved overall plant productivity.
The petrochemical material conveying engineering provided by headpowder engineering for this Lanzhou facility extends beyond the catalyst transport system. The company conducted a comprehensive site survey, feasibility study, and process design to integrate the pneumatic conveying line with the existing plant infrastructure. The material handling system includes a storage silo with a capacity of 200 m³, a discharge hopper equipped with a vibrating feeder, and a series of diverter valves that allow the catalyst to be directed to one of three reactor vessels. The entire system is designed to operate in a hazardous area classified as Zone 1 (Group IIB, T3) due to the presence of flammable gases in the vicinity. Consequently, all electrical components are explosion-proof, and the pneumatic system uses nitrogen as the conveying gas to eliminate any risk of oxidation or combustion. The pipeline is also equipped with static grounding straps to dissipate electrostatic charges generated during the transport of fine particles. headpowder engineering provided full turnkey services, including detailed engineering design, equipment fabrication, installation supervision, commissioning, and operator training. The project was completed within a 12-month timeline, and the system has been in continuous operation for over three years with minimal downtime. The petrochemical material conveying engineering expertise demonstrated in this project has been recognized by several other clients in the refining and chemical sectors, leading to repeat orders for similar systems in other regions of China.
Shandong Headpowder Engineering Co., Ltd. (headpowder) is a professional engineering company headquartered in Shandong, China, with a dedicated focus on the design, manufacture, and installation of pneumatic conveying systems for powder and granular materials. The company’s technical team has extensive experience in the petrochemical, chemical, pharmaceutical, food, and building materials industries. headpowder engineering offers customized solutions that address specific material characteristics, conveying distances, and environmental constraints. The successful completion of the Lanzhou catalyst particle positive pressure pneumatic conveying project underscores the company’s capability to deliver high-quality, reliable, and safe bulk material handling systems. For further inquiries about catalyst conveying solutions, positive pressure granular conveying systems, or petrochemical material conveying engineering, please contact the project manager Mr. Zhang (Manager Zhang) directly via WeChat at 15662777102. Mr. Zhang is available to discuss technical specifications, project references, and potential collaboration opportunities. headpowder engineering looks forward to providing tailored solutions for your material conveying needs.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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