UltrafineLi-ionPowderDilute-PhaseConveying,KobeJapan

Ultrafine Li-ion Powder Dilute-Phase Conveying, Kobe Japan

Subtitle: High-Performance Dilute-Phase Pneumatic Conveying Solution for Advanced Lithium Battery Materials in East Asia

Keywords: pneumatic conveying case, East Asia pneumatic conveying, dilute-phase pneumatic conveying

This article presents a landmark engineering project from Shandong Headpowder Engineering Co., Ltd., commonly known as headpowder. The project focuses on the reliable and efficient dilute-phase pneumatic conveying of ultrafine lithium-ion battery powder at a leading manufacturing facility in Kobe, Japan. As a representative pneumatic conveying case in East Asia, it demonstrates how advanced engineering, careful material testing, and robust system design can meet the strict demands of the modern lithium battery industry. The solution not only ensures high product quality but also improves plant safety, reduces material loss, and lowers operational costs.

Kobe is one of Japan’s major industrial centers, with a strong tradition in precision manufacturing, chemical processing, and high-technology materials. The city hosts numerous battery-related businesses that supply the rapidly growing electric vehicle and energy storage markets. For these companies, handling fine powder materials is one of the most difficult unit operations. The powder used in lithium-ion batteries, such as cathode materials, anode materials, and specialty additives, is often characterized by extremely small particle sizes and low bulk densities. These material characteristics can cause serious problems in traditional conveying equipment, including segregation, agglomeration, degradation, and even dust explosion hazards.

The specific project in Kobe required the transfer of a very fine and high-purity lithium battery powder from an unloading area to multiple production vessels. The conveying pipeline had to follow a complicated route through different floors and around existing equipment. The material was subject to stringent quality requirements, so any risk of contamination, particle damage, or moisture pickup had to be minimized. Headpowder’s engineering team conducted extensive feasibility studies and material tests before proposing the final solution. They evaluated several conveying technologies, including mechanical conveyors, dense-phase pneumatic conveyors, and dilute-phase pneumatic conveyors.

Mechanical conveyors were seen as unsuitable because of the long distance, multiple delivery points, and the need for a completely sealed system. Dense-phase pneumatic conveying was also considered, but it operates at lower velocities and higher pressures, which can be problematic for very fine, cohesive powders that tend to fluidize and block the line. After careful analysis, the dilute-phase pneumatic conveying method was selected as the most appropriate solution. In dilute-phase conveying, the powder is suspended in a high-velocity air stream and transported at a low solids-to-air ratio. This approach creates a turbulent flow that keeps even ultrafine particles moving and prevents them from sticking to the pipe wall or forming deposits.

Headpowder designed and supplied a complete dilute-phase conveying system for the Kobe project. The system begins with a specially engineered material feed hopper and a rotary airlock feeder. The airlock ensures that powder enters the conveying line in a controlled manner while preventing the conveying air from escaping backward. From the feeder, the powder is carried through a schedule-designed stainless steel pipeline to several receiving bins. Each receiving bin is fitted with an efficient vent filter that separates the conveying air from the collected powder. The filtered air is either exhausted to the atmosphere through a secondary bag filter or returned to the system, depending on the material’s properties and local environmental regulations.

One of the most critical elements in the design is the selection of the conveying air velocity. For ultrafine lithium-ion battery powder, the velocity must be high enough to keep the material in suspension and prevent settling, but low enough to avoid excessive particle breakage and pipeline wear. Headpowder performed a series of pneumatic conveying trials using the customer’s actual powder samples. These trials helped the team determine the optimum air velocity, solids loading, and pipeline diameter. The final design also included carefully positioned bends with large radius to reduce pressure loss and minimize the impact of particles on the inner surface of the pipe. In addition, the system was provided with a nitrogen supply option for processes that require an inert atmosphere, greatly lowering the risk of dust explosion.

Automation and safety were equipped with a central PLC control system that continuously monitored pressure transmitters, flow meters, and level sensors along the conveying line. Operators could set production parameters from a touchscreen panel and observe the status of every valve and diverter in real time. If any abnormal condition was detected, the system would automatically shut down the air supply and close the relevant valves to ensure safe operation. The control logic also allowed the operator to sequence material delivery to multiple bins, so that each process vessel received the correct amount of powder at the right time. This level of automation reduced manual labor and eliminated the risk of operator error during operation.

Commissioning is a critical phase for any pneumatic conveying case in East Asia, especially when the system is installed in a busy production environment. Headpowder provided experienced engineers who worked closely with the Japanese customer’s project team. The installation was completed within the planned schedule, and the system was then subjected to a rigorous performance test. All key indicators, such as conveying capacity, material yield, electric power consumption, and dust emission, were measured and verified. The final test confirmed that the system could handle the required throughput while maintaining a dust-free environment. After the successful commissioning, headpowder also delivered complete training to the operators and maintenance staff, ensuring that they could run the system safely and efficiently.

The dilute-phase conveying system has now been operating in Kobe for many months without major problems. The customer has reported excellent results in terms of product purity, consistency, and safety. The closed design prevents powder leakage, which not only protects the health of workers but also keeps the plant clean. Because the system uses a relatively simple pipeline and standard components, maintenance is straightforward, and the downtime is very low. The energy consumption is also favorable compared to some alternative methods, because the dilute-phase system is designed to operate efficiently at the required conveying capacity. All these advantages make this project a benchmark for similar applications in the lithium battery industry.

Shandong Headpowder Engineering Co., Ltd. is a specialized engineering company dedicated to the design, manufacturing, and supply of pneumatic conveying systems and powder processing solutions. With many years of experience, headpowder has established a strong presence in the Chinese market and has successfully expanded into East Asia and other regions. The company’s project portfolio includes numerous pneumatic conveying cases covering dilute-phase and dense-phase technologies, as well as dust collection systems, vacuum conveying systems, and automated packaging lines. The headpowder team understands the unique challenges of handling fine, abrasive, or flammable powders and is committed to providing safe, reliable, and cost-effective solutions.

The success of the Kobe project has strengthened the reputation of headpowder as a trustworthy partner in East Asia pneumatic conveying. The company continues to invest in research and development, especially in the field of lithium battery materials where powder quality is directly related to battery performance. If you are looking for a professional partner to solve difficult powder handling problems, you can directly contact the headpowder sales team. The company is located in Shandong, China. The manager responsible for this business, Mr. Zhang, is always ready to discuss your project requirements. You can reach him via WeChat at 15662777102. Whether you need a complete dilute-phase conveying system, a spare part, or a full engineering proposal, headpowder will provide you with the best possible support.