Example of Wear-resistant Pipe Transportation for Desulfurization Agent in South Kalimantan, Indonesia

Shandong Headpowder Engineering Co., Ltd., headquartered in Shandong, China, successfully delivered a specialized pneumatic conveying system for desulfurization agent powder in South Kalimantan, Indonesia. This project serves as a benchmark example of how engineered bulk material handling solutions can overcome extreme abrasive conditions while maintaining high reliability and efficiency. The client, a major power generation facility in South Kalimantan, required a robust system to transport fine desulfurization agent powder from storage silos to the injection points inside the flue gas desulfurization (FGD) unit. The primary challenge was the highly abrasive nature of the calcium-based desulfurization agent, which can rapidly erode standard conveying pipelines. Headpowder’s team designed and installed a complete wear-resistant pipeline pneumatic conveying system tailored to the site’s specific layout, material properties, and operational demands.

Core Product Application: Pneumatic Conveying Case for Indonesia

This Indonesia pneumatic conveying case demonstrates the full lifecycle capability of Headpowder in handling abrasive bulk solids. The system incorporates dense phase pneumatic conveying technology, which minimizes particle velocity and reduces wear on the pipeline interior. The material, a fine desulfurization agent powder with a bulk density of approximately 1.2 t/m³ and a particle size D50 of 60 microns, was conveyed over a distance of 180 meters with a vertical lift of 25 meters. The design capacity reached 8 tons per hour, meeting the continuous dosing requirements of the FGD process. The South Kalimantan pneumatic conveying installation features a centralized control system that monitors pressure, flow rate, and material level in real time, ensuring stable operation even under fluctuating feed conditions. This project is a typical example of how Headpowder integrates local site conditions with advanced pneumatic conveying engineering to deliver a reliable solution for Indonesian industrial clients.

Wear-Resistant Pipeline Pneumatic Conveying Technology

The wear-resistant pipeline pneumatic conveying system is the cornerstone of this project. Standard carbon steel pipelines would suffer from severe erosion within weeks when conveying desulfurization agent powder. Headpowder selected high-chromium alloy wear-resistant pipes with a hardness of HRC 55-60 and a ceramic-lined composite structure for the most critical sections, including bends, reducer sections, and the injection lance. The ceramic lining, made of 95% alumina, provides a smooth inner surface that reduces friction and material buildup. Additionally, the pipeline network was designed with a gradual radius of curvature (R ≥ 10D) at all bends to minimize impact wear. The wear-resistant pipeline pneumatic conveying approach extended the service life of the entire conveying line to over 5 years under continuous 24/7 operation, drastically reducing maintenance downtime and replacement costs for the client. Headpowder also supplied a set of wear-resistant diverter valves and a rotary airlock feeder specifically engineered for abrasive powders, ensuring consistent material flow without leakage.

Desulfurization Agent Powder Pneumatic Conveying: Process and Performance

The desulfurization agent powder pneumatic conveying system operates on a closed-loop pressure vessel principle. The material is fed from a storage silo into a pressure vessel, then pressurized with compressed air and conveyed through the wear-resistant pipeline to the injection point. The control system automatically adjusts the conveying air pressure and velocity based on real-time feedback from pressure transmitters and flow meters. During the commissioning phase in South Kalimantan, the system achieved a conveying ratio (material-to-air) of 18:1, significantly higher than conventional dilute phase systems, which translates to lower energy consumption and reduced compressed air usage. The system also features a built-in dehumidification unit to prevent moisture absorption by the hygroscopic desulfurization agent, which could cause clogging and caking. Performance tests showed that the system maintained a conveying accuracy of ±1.5%, crucial for the precise dosing required in the FGD process. This desulfurization agent powder pneumatic conveying solution has been praised by the client for its stability, low maintenance, and consistent output.

Project Implementation and Site Adaptations

The South Kalimantan site presented unique challenges, including high ambient humidity (average 85%), frequent tropical rain, and limited space for equipment installation. Headpowder’s engineering team conducted a detailed site survey and designed a compact layout that fits within the existing power plant infrastructure. All electrical components were housed in IP65-rated enclosures to withstand the humid environment. The pipeline routing was optimized to avoid obstacles and reduce the number of bends, further enhancing wear resistance. The installation was completed in 45 days, with a team of 8 local technicians supervised by Headpowder’s senior engineers. Training was provided to the client’s operational staff on system start-up, shutdown, and emergency procedures. The project also included a one-year warranty and a spare parts package for the wear-resistant pipeline sections. This Indonesia pneumatic conveying case demonstrates Headpowder’s ability to adapt standard pneumatic conveying technology to challenging tropical conditions while maintaining high performance.

Customer Feedback and Long-Term Cooperation

Since the system went into operation in early 2023, the client has reported zero unscheduled downtime related to the pneumatic conveying system. The wear-resistant pipeline has shown minimal wear after 18 months of continuous operation, with only the injection lance requiring replacement due to the extreme thermal environment. The client’s plant manager stated that the system exceeded their expectations in terms of reliability and ease of use. Headpowder’s after-sales service team conducts quarterly remote inspections and provides prompt technical support. The success of this project has led to a follow-up order for a second conveying line for a sister plant in the same region. For inquiries about similar pneumatic conveying systems for desulfurization agent powder or other abrasive materials, please contact the project manager: Manager Zhang, WeChat: 15662777102. Shandong Headpowder Engineering Co., Ltd. is ready to provide customized solutions for clients in Indonesia, South Kalimantan, and beyond.

Why Choose Headpowder for Your Pneumatic Conveying Project

Shandong Headpowder Engineering Co., Ltd. has been a leading provider of pneumatic conveying systems for over 15 years, with a focus on handling abrasive, hygroscopic, and fragile powders. The company’s expertise covers the entire project lifecycle, from material testing and system design to fabrication, installation, and commissioning. The South Kalimantan desulfurization agent case is just one of many successful projects completed in Indonesia, the Philippines, Vietnam, and other Southeast Asian countries. Headpowder holds multiple patents in wear-resistant pipeline technology and dense phase conveying control. All systems are manufactured in the company’s Shandong factory, which is ISO 9001 certified. The company’s engineering team can simulate the conveying process using computational fluid dynamics (CFD) to optimize pipeline diameter, bend radius, and air velocity before manufacturing, ensuring the highest efficiency and longest service life. For more information or to discuss your specific requirements, please contact Manager Zhang via WeChat: 15662777102. Headpowder—your reliable partner in pneumatic conveying engineering.