This article presents a detailed case study of a pneumatic conveying system designed for desulfurization agent powder in Phu Yen, Vietnam. The project was successfully executed by Shandong Headpowder Engineering Co., Ltd., a leading provider of bulk material handling solutions based in Shandong, China. The system is a positive pressure pneumatic conveying solution specifically tailored to transport desulfurization agent powder over long distances with high efficiency and minimal degradation. This case study highlights the technical challenges, design considerations, and performance outcomes of the Vietnam pneumatic conveying installation, demonstrating Headpowder's expertise in delivering reliable and cost-effective solutions for the Asian market.
The client, a major power plant in Phu Yen province, required a robust and dust-free conveying system to transfer desulfurization agent powder from the storage silo to the injection point. The material, a fine and abrasive powder, demanded a gentle yet powerful conveying method to avoid pipe wear and particle breakage. After evaluating multiple options, the client selected a positive pressure pneumatic conveying system, also known as dense phase or dilute phase conveying depending on the specific design. Headpowder's engineering team analyzed the material properties, conveying distance, and capacity requirements to propose an optimized solution that fully met the operational needs. The entire project, from design to commissioning, was managed by Shandong Headpowder Engineering Co., Ltd., ensuring seamless integration with existing plant infrastructure.
Phu Yen province, located in south-central Vietnam, has seen rapid industrial growth, particularly in energy generation. The power plant, a coal-fired facility, uses a wet flue gas desulfurization (FGD) process that requires a continuous supply of desulfurization agent powder. The existing manual handling method was inefficient, posed health risks, and caused material loss. The plant management sought a fully automated, enclosed, and reliable conveying system that could handle up to 15 tons per hour of powder over a horizontal distance of 200 meters and a vertical lift of 30 meters. The material had a bulk density of approximately 1.2 t/m³ and a particle size distribution of 80% passing through 200 mesh. These parameters made it an ideal candidate for a positive pressure pneumatic conveying system, which is widely used in the industry for fine powders.
Headpowder's team conducted a thorough site survey in Phu Yen, Vietnam, to assess the existing layout, available space, and power supply conditions. The local climate, with high humidity and occasional monsoon rains, also influenced the design of the air drying and filtration systems. The client emphasized the need for a low-maintenance solution with minimal downtime, as any interruption in powder supply could affect the desulfurization efficiency and compliance with environmental regulations. Based on these requirements, Shandong Headpowder Engineering Co., Ltd. proposed a custom-engineered pneumatic conveying system that integrated a rotary airlock feeder, a positive displacement blower, a pipeline network, and a cyclone separator with a bag filter. The system was designed to operate at a conveying pressure of 0.6 to 0.8 bar, ensuring stable flow without plugging.
The core of the solution is a positive pressure conveying system, which uses compressed air supplied by a Roots-type blower to push the powder through the pipeline. Unlike vacuum systems, positive pressure conveying is ideal for longer distances and multiple discharge points. In this case, the desulfurization agent powder is fed into the conveying line through a rotary airlock valve, which prevents air leakage while allowing continuous material flow. The air is first filtered and dried to remove moisture and contaminants, ensuring the powder remains free-flowing and does not cake. The conveying line is designed with gentle bends and a smooth inner surface to minimize friction and wear. The system operates in dilute phase mode, where the material-to-air ratio is relatively low, resulting in high velocity and efficient transport over the required distance.
One of the key challenges was the abrasive nature of the desulfurization agent powder, which contains calcium-based compounds that can erode pipe walls over time. To address this, Headpowder selected wear-resistant pipe materials, including hardened steel and ceramic-lined sections at critical bends. The pipeline diameter was optimized to balance velocity and pressure drop, reducing energy consumption while maintaining conveying capacity. The system also includes a control panel with PLC and HMI, allowing operators to monitor and adjust the conveying rate, pressure, and air flow in real time. Safety features such as pressure relief valves, emergency stop buttons, and alarms were integrated to protect both personnel and equipment. This comprehensive design ensured that the Vietnam pneumatic conveying system could operate 24/7 with minimal supervision.
The installation phase was managed by Headpowder's local service team, supported by engineers from the head office in Shandong, China. The project timeline was aggressive, requiring the system to be operational within 8 weeks from the start of site work. The team coordinated with the plant's maintenance department to schedule installation during a planned outage, minimizing disruption to power generation. The pneumatic conveying system components were shipped in modular units, allowing for quick assembly on site. The rotary airlock feeder, blower, and filter were mounted on a common skid, reducing installation time and foundation costs. The pipeline was routed along existing cable trays and structural steel, simplifying support and access.
During commissioning, the system was tested using a surrogate material similar to the actual desulfurization agent powder to verify conveying rates, pressure drops, and material degradation. The results showed that the system could achieve a conveying capacity of 16 tons per hour, exceeding the client's requirement of 15 tons per hour. The power consumption was measured at 12 kWh per ton, which was within the design target. After successful testing, the system was handed over to the plant's operations team, who received training on routine maintenance, troubleshooting, and parameter adjustments. The customer expressed high satisfaction with the performance and reliability of the system, noting that the dust-free operation significantly improved the working environment. Shandong Headpowder Engineering Co., Ltd. continues to provide after-sales support and spare parts from its base in Shandong, China.
This case study demonstrates several key advantages of Headpowder's approach to pneumatic conveying for desulfurization agent powder. First, the positive pressure system ensures complete containment of the powder, eliminating dust emissions and reducing material loss. This is particularly important in Vietnam, where environmental regulations are becoming stricter. Second, the system is highly flexible and can be adapted to different plant layouts, capacities, and material properties. The use of a PLC-based control system allows for precise metering and remote monitoring, which is essential for modern automated plants. Third, the wear-resistant design and robust components result in low maintenance costs and long service life. The rotary airlock feeder, a critical component, is manufactured by Headpowder with hardened materials to withstand abrasive powders.
Another significant benefit is the energy efficiency of the system. By optimizing the air-to-material ratio and using a positive displacement blower with variable frequency drive, the system consumes less power compared to conventional pneumatic conveyors. The total operating cost, including electricity, maintenance, and spare parts, is competitive with other conveying methods such as mechanical conveyors or screw feeders. Moreover, the enclosed nature of the system prevents moisture ingress, which is critical in the humid climate of Phu Yen. The desulfurization agent powder remains dry and free-flowing, ensuring consistent performance of the FGD unit. Shandong Headpowder Engineering Co., Ltd. has extensive experience in similar projects across Asia, including Vietnam, Indonesia, and Thailand, making it a trusted partner for pneumatic conveying solutions.
For more information about this Vietnam pneumatic conveying case study or to discuss your own desulfurization agent powder handling requirements, please contact the project manager at Shandong Headpowder Engineering Co., Ltd. Mr. Zhang, the sales manager, is available to provide technical consultations and customized proposals. You can reach him via WeChat at 15662777102. Whether you need a small-scale system or a large industrial installation, the team at Headpowder is ready to support you from the initial design phase through commissioning and ongoing maintenance. The company's headquarters is located in Shandong, China, with a dedicated service network across Southeast Asia. Feel free to contact Mr. Zhang for any inquiries related to pneumatic conveying, bulk material handling, or powder processing solutions.
Shandong Headpowder Engineering Co., Ltd. is committed to delivering high-quality, reliable, and cost-effective pneumatic conveying systems for the global market. The Phu Yen project is a testament to the company's ability to overcome technical challenges and provide tailored solutions for the desulfurization industry. If you are considering a similar system for your plant, do not hesitate to reach out to Mr. Zhang via WeChat at 15662777102. The team will work closely with you to ensure that the system meets your specific requirements, including capacity, distance, material characteristics, and budget. With years of experience in Vietnam and other countries, Headpowder is your ideal partner for pneumatic conveying projects.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Manager Zhang） 
0531-83386006 
Jinan, Shandong Province, China 
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