PneumaticConveyingofLi-ionCarbonBlackforDeNOxinSuez

Project Title: Pneumatic Conveying of Li-ion Carbon Black for DeNOx in Suez, Egypt

This article presents a comprehensive case study of a pneumatic conveying system designed for injecting lithium-ion battery carbon black into a DeNOx process at a major industrial facility in Suez, Egypt. The project highlights the growing demand for advanced powder handling solutions in the African market, specifically for applications requiring fine, highly dispersive materials such as carbon black used in flue gas treatment systems. As environmental regulations tighten globally, the need for reliable and precise dosing of reactive powders has become critical, and this installation demonstrates how effective pneumatic conveying can meet those challenges.

Keyword Focus: pneumatic conveying case study, pneumatic conveying in Africa, lithium battery carbon black injection conveying. The entire solution was engineered and supplied by Shandong Headpowder Engineering Co., Ltd., a leading Chinese company specializing in pneumatic conveying systems, powder processing equipment, and turnkey engineering services. With a strong track record in both domestic and international projects, Headpowder brings extensive expertise in handling fine, abrasive, and cohesive powders, ensuring that even the most difficult materials are transported efficiently and safely.

In this particular project, the customer required a system capable of receiving carbon black powder from storage bags or silos and conveying it pneumatically to a DeNOx reactor, where the powder is injected as a reagent to support selective non-catalytic reduction (SNCR) or similar emission control processes. The carbon black used in lithium battery manufacturing is characterized by very fine particle size, low bulk density, and high surface area, making it prone to agglomeration and flow issues. Therefore, the design had to incorporate specialized features such as aeration pads, vibratory discharge aids, and high-velocity conveying lines to maintain consistent flow and prevent blockages.

Shandong Headpowder Engineering designed a dense-phase pneumatic conveying system with a nitrogen or dry air supply, depending on the inertness requirements of the process. Since carbon black is combustible when suspended in air, inert gas conveying was selected to ensure maximum safety in the explosive environment of the DeNOx system. The conveying line was carefully routed to minimize bends and pressure drops, with an optimized pipe diameter to achieve the required conveying rate without damaging the fragile particle structure. A pressure vessel feeder was used as the pressure source, allowing gentle yet reliable transport over the required distance.

The system operates in batch or continuous mode, with automated controls that include load cells, pressure transmitters, and flow sensors. The control logic ensures precise dosing of carbon black according to the real-time demand from the DeNOx process. This level of automation reduces manual intervention and operational variability, which is essential for meeting the strict emission limits in the Suez industrial zone. Furthermore, the entire conveying process is enclosed, preventing dust leakage and ensuring a clean working environment that complies with local occupational health and safety standards.

One of the key challenges of this project was the logistical coordination between the manufacturing facility in China and the installation site in Egypt. Shandong Headpowder Engineering provided comprehensive support, including detailed engineering drawings, equipment supply, supervision of installation, and commissioning services. The company’s project team worked closely with local contractors to ensure that all components were installed correctly and that the system was fully tested before handover. This successful collaboration proves the capability of Headpowder to execute projects across international borders, even in regions with demanding conditions such as the Middle East and Africa.

The benefits of the implemented pneumatic conveying system are numerous. It eliminated the need for manual handling of carbon black bags, significantly improving worker health and safety. The enclosed nature of the system also reduced material losses through spillage or dust generation, contributing to lower overall operating costs. Moreover, the precise control over feed rate allows for optimized reagent consumption, reducing waste and ensuring that the DeNOx process operates at peak efficiency. As a result, the customer in Suez achieved both economic and environmental benefits, demonstrating the value of investing in high-quality pneumatic conveying technology.

In addition to the core conveying equipment, Shandong Headpowder Engineering supplied accessories such as reverse-jet filter receivers, rotary valves, diverters, and a programmable logic controller (PLC) panel with remote monitoring capability. The filter receiver ensures that the conveying air is cleaned before being released, and the collected fine powder is returned to the main process. The PLC system provides real-time data acquisition and alarm management, enabling plant operators to promptly respond to any abnormal conditions. This level of integration is a hallmark of Headpowder’s engineering approach, which focuses on providing complete solutions rather than isolated components.

The successful implementation of this Li-ion carbon black injection conveying system in Suez marks an important milestone for Shandong Headpowder Engineering Co., Ltd. in the African market. It showcases the company’s ability to adapt its products and services to the specific needs of diverse industries, including environmental protection, new energy materials, and chemical processing. With the growing global shift toward cleaner production technologies, the demand for reliable powder handling systems will continue to expand, and Headpowder is well positioned to serve that demand with innovative engineering and dedicated customer support.

For any inquiries or further information about this project or other pneumatic conveying solutions, please contact the company representative: Mr. Zhang, WeChat: 15662777102. The company’s registered address is in Shandong, China, and its full legal name is Shandong Headpowder Engineering Co., Ltd. Headpowder offers a wide range of services including system design, equipment fabrication, installation supervision, commissioning, and after-sales technical support. With years of experience and a commitment to quality, the company welcomes clients from all over the world, including the growing industries in Africa, to discuss their material handling challenges and develop optimized solutions that ensure safe, efficient, and economical operation.