In the industrial heart of Prachuap Khiri Khan, Thailand, a specialized metal silicon powder production facility faced a critical challenge: how to safely and efficiently transport fine, abrasive, and highly combustible metal silicon powder from one processing stage to another without risking dust explosions or environmental leakage. The solution came from Shandong Headpowder Engineering Co., Ltd. (company abbreviation: headpowder), a leading provider of pneumatic conveying systems headquartered in Shandong, China. This case study details the successful implementation of an explosion-proof and airtight pneumatic conveying system tailored for metal silicon powder, demonstrating how headpowder’s engineering expertise solved a real-world industrial problem in Southeast Asia.
The customer in Prachuap Khiri Khan, Thailand, required a robust pneumatic conveying system to move metal silicon powder (also known as silicon metal powder) with particle sizes ranging from 10 to 100 microns. Metal silicon powder is widely used in the photovoltaic, semiconductor, and refractory industries, but its fine, abrasive nature and low ignition energy make it prone to dust explosions. The existing manual handling and mechanical conveying methods were inefficient, produced excessive dust, and posed serious safety hazards. The plant needed a metal silicon powder pneumatic conveying solution that was both explosion-proof and airtight, ensuring zero dust emission and complete operational safety. After evaluating several international suppliers, the client selected Shandong Headpowder Engineering Co., Ltd. due to its proven track record in handling hazardous powders and its ability to deliver a fully customized system for the specific conditions of the Prachuap Khiri Khan site.
The system designed by headpowder is a dense-phase explosion-proof airtight pneumatic conveying system operating under inert gas (nitrogen) atmosphere. The key components include a pressurized feed vessel, explosion-proof rotary valves, stainless steel pipelines with antistatic lining, and a dedicated baghouse filter equipped with explosion vent panels. The entire conveying loop is sealed to prevent any ingress of oxygen, which is critical for suppressing combustion and explosion risks. The pneumatic conveying system uses a low-velocity, high-pressure approach to minimize wear on the pipes and reduce particle attrition. For the metal silicon powder pneumatic conveying application, the system achieves a conveying capacity of 8 tons per hour over a distance of 120 meters, with a vertical lift of 25 meters. The inert gas consumption is optimized through a closed-loop control system that monitors oxygen concentration in real time, automatically adjusting the nitrogen purge rate to maintain oxygen levels below 8%—the safe limit for metal silicon powder.
The explosion-proof airtight pneumatic conveying solution offers several distinct advantages over traditional open or mechanical conveying methods. First, the airtight design eliminates fugitive dust emissions, protecting worker health and meeting Thailand’s strict environmental regulations. Second, the use of explosion-proof electrical components—such as flameproof motors, intrinsically safe sensors, and Ex-certified valves—ensures that the system can operate safely even in the presence of explosive dust clouds. Third, the dense-phase conveying mode reduces the velocity of the metal silicon powder pneumatic conveying stream, which significantly lowers the risk of electrostatic discharge—a common ignition source for metal dusts. The system also incorporates a dedicated explosion suppression system (active suppression) and pressure relief vents, providing multi-layered protection. This case study from Prachuap Khiri Khan, Thailand exemplifies how headpowder integrates advanced safety features into every pneumatic conveying system it delivers.
The installation and commissioning of the explosion-proof airtight pneumatic conveying system at the Prachuap Khiri Khan facility took six weeks, during which headpowder’s engineering team worked closely with the client’s local staff. The system was fully automated, with a Siemens PLC controlling all conveying parameters, including feed rate, nitrogen pressure, and filter cleaning cycles. During the first month of operation, the system achieved 99.5% uptime, with zero dust leakage incidents. The client reported a 40% reduction in labor costs compared to the previous manual handling process, and the pneumatic conveying system also improved product quality by eliminating contamination from manual transfer. The metal silicon powder pneumatic conveying performance was consistent, with the powder’s chemical composition and particle size distribution remaining unchanged after conveying. The success of this Thailand pneumatic conveying project has led to follow-up inquiries from other factories in the region, confirming headpowder’s reputation as a reliable partner for hazardous powder handling.
Based in Shandong, China, Shandong Headpowder Engineering Co., Ltd. (headpowder) has been engineering and manufacturing pneumatic conveying systems for over a decade, with a focus on difficult-to-handle materials such as metal silicon powder, silicon carbide, aluminum powder, and other metal dusts. The company’s in-house R&D team develops customized explosion-proof airtight pneumatic conveying solutions for clients across Asia, Europe, and the Americas. Every system is designed to meet international explosion protection standards (ATEX, IECEx, NFPA) and is rigorously tested before shipment. The company’s headquarters in Shandong, China is equipped with a full-scale test facility where clients can validate their material’s conveying behavior before committing to a full system. For inquiries about metal silicon powder pneumatic conveying or any other pneumatic conveying system needs, please contact Manager Zhang (Manager Zhang) via WeChat: 15662777102. Manager Zhang is the dedicated project coordinator for international projects and can provide detailed technical proposals, case studies, and pricing information.
The explosion-proof airtight pneumatic conveying system installed in Prachuap Khiri Khan, Thailand has been running reliably for over 18 months, with only routine maintenance required. The client has reported a significant improvement in workplace safety and a reduction in insurance premiums due to the elimination of explosion hazards. The successful pneumatic conveying case has been documented and shared with other potential clients in the region, further establishing headpowder’s presence in the Thailand pneumatic conveying market. For any company handling metal silicon powder pneumatic conveying or other explosive powders, this project serves as a benchmark for best practices. Shandong Headpowder Engineering Co., Ltd. is ready to provide similar solutions worldwide. To discuss your specific requirements, please reach out to Manager Zhang (Manager Zhang) on WeChat: 15662777102. The team in Shandong, China looks forward to helping you achieve safe, efficient, and environmentally friendly material handling.
For readers interested in the detailed engineering behind this pneumatic conveying system, the following technical parameters are provided: conveying mode – dense phase, nitrogen inert; material – metal silicon powder (density 2.33 g/cm³, bulk density 1.0–1.2 g/cm³, particle size d50 = 45 µm); conveying distance – 120 m horizontal, 25 m vertical; capacity – 8 t/h; pipeline material – 304SS with internal antistatic coating; pressure rating – 0.6 MPa; nitrogen purity – 99.9%; explosion protection – Ex d IIB T4 for electrical components, Ex e for non-sparking equipment; control system – Siemens S7-1200 with remote monitoring capability. The explosion-proof airtight pneumatic conveying design also includes a proprietary headpowder patented rotary valve with a self-cleaning mechanism to prevent material buildup. These features, combined with the airtight sealing, make the system ideal for metal silicon powder pneumatic conveying in tropical climates like Prachuap Khiri Khan, Thailand. For more detailed specifications, contact Manager Zhang via WeChat: 15662777102.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Manager Zhang） 
0531-83386006 
Jinan, Shandong Province, China 
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