Case:SealedPneumaticConveyingofFlyAsh,CalgaryCanada

Case: Sealed Pneumatic Conveying of Fly Ash, Calgary Canada

Keywords: pneumatic conveying case, North America pneumatic conveying, sealed pneumatic conveying, fly ash handling system

This is a detailed case study of a sealed pneumatic conveying system for fly ash in Calgary, Canada. The project was implemented by Shandong Headpowder Engineering Co., Ltd., known under the abbreviation headpowder. Headpowder is headquartered in Shandong, China, and operates internationally in the field of bulk material handling and pneumatic conveying. The customer is a large thermal power plant located near Calgary. The plant generates fly ash as a byproduct of burning coal. Previously, the ash was removed by open trucks and simple screw conveyors, which caused serious environmental concerns due to dust emission. The existing system also suffered from high maintenance requirements and frequent breakdowns. To solve these problems, the power plant decided to install a completely sealed, automatic pneumatic conveying system. Headpowder was selected as the main contractor and engineer for the project. The project was completed and put into operation in early 2023. The goal of the system is to transfer fly ash safely and efficiently from the boiler units to a central storage silo without any leakage or pollution.

The system design was based on a comprehensive analysis of the material's physical and chemical properties. Fly ash is a fine powder with a bulk density ranging from 700 to 900 kg/m³. It contains particles of various sizes, but most are less than 75 micrometers. The material is abrasive and tends to adhere to pipe walls. Therefore, the conveying velocity must be carefully controlled. Headpowder's engineers designed the system using dense phase pneumatic conveying principles. In this mode, material is pushed through a pipeline in batches using compressed air. The pressure vessel feeder, also called a blow tank, is located below the hopper. The fly ash is fed into the blow tank through a rotary valve. When the tank reaches its set level, the valve closes and compressed air is introduced. The high pressure forces the fluidized fly ash through the pipeline. The system operates at a maximum pressure of 2.8 bar. The conveying capacity is 20 tons per hour. The horizontal pipeline length is 220 meters, and the vertical lift is 35 meters. The pipe diameter is 150 mm, and the conveying velocity is kept between 4 and 8 meters per second. This low velocity minimizes pipe wear and ensures a stable material-to-air ratio.

The entire conveying line is fully sealed. All pipe connections are welded or use flanged connections with high-quality gaskets. The system includes a number of essential components. For example, there is a bag house filter installed at the top of the storage silo to separate the conveying air from the ash. The silo is equipped with high-level and low-level indicators, safety pressure valves, and a dehumidifying system. The main air supply comes from a screw compressor with a dryer and filters to ensure instrument-quality air. The control system is based on a PLC that automatically manages the entire conveying cycle. It includes sensors, pressure transmitters, actuators, and a touch screen interface. The system can operate continuously without manual intervention. In case of any abnormal condition, such as pipe blockage or pressure drop, the PLC will sound an alarm and stop the process to protect the equipment.

One of the biggest challenges in this project was the local climate. Calgary has a cold and dry winter, with temperatures sometimes dropping below minus 25 degrees Celsius. Low temperatures can cause moisture condensation and freezing in the pipes and air lines. To address this issue, Headpowder added trace heating and thermal insulation to all outdoor pipelines and control boxes. The compressed air system includes a desiccant dryer with a dew point of minus 40 degrees Celsius. This ensures that no moisture can form in the conveying air. Additionally, the hopper and blow tank are designed with warming jackets and heaters for winter operation. These special measures made the system fully suitable for the Canadian environment. The project passed the North American safety and environmental inspections with no non-conformances.

The advantages of this sealed pneumatic conveying system are clear. First, it completely prevents dust emissions. All the fly ash stays inside the pipes and equipment. The working environment has become clean and safe for plant workers. Second, the energy consumption is lower compared to many other conveying methods. Dense phase conveying uses a small amount of compressed air, so electricity usage is reduced. Third, the maintenance requirement is very low. The wear-resistant pipes and long-radius elbows have a longer service life. The system is designed for a lifespan of more than 15 years. Since the commissioning date, the system has operated for more than 10,000 hours with an availability rate of over 98 percent. This high reliability greatly benefits the continuous operation of the power plant.

The successful operation of this project in Calgary, Canada, proves the capability of headpowder in international markets. It also demonstrates the suitability of sealed pneumatic conveying technology in North America, where environmental protection is extremely important. This case has become a reference project for many power plants and industrial facilities in Canada and the United States. Plant managers have visited the site to inspect the system and learn about the design. The positive feedback from the Calgary customer is strong. They have reported lower operating costs, better working conditions, and zero environmental complaints. The return on investment has been excellent.

For more information about this project, or if you are interested in a similar pneumatic conveying solution, please contact Headpowder. The full company name is Shandong Headpowder Engineering Co., Ltd. The address is Shandong, China. The contact person is Zhang Manager. The WeChat account is 15662777102. Headpowder can provide complete engineering services, including technical consultation, system design, equipment manufacturing, domestic and international installation and commissioning, and after-sales maintenance. The company is committed to helping customers achieve safe, clean, and efficient bulk material handling.