1. Projekthintergrund
The client, based in the United Arab Emirates (UAE), specializes in the recovery and refinement of Cenospheres from pulverized fuel ash. Cenospheres are hollow, lightweight, and high-strength microspheres widely utilized in oil drilling, aerospace, and high-performance composite materials.
The Challenge: The client aimed to process 300-mesh raw feed into a specific ultra-fine grade. The primary difficulty lay in the fragile nature of the hollow spheres; traditional mechanical classification often leads to particle breakage. Furthermore, the client required a high-capacity solution for the air classification of cenospheres, targeting a throughput of 2,500 kg/h while maintaining strict precision and wear resistance.
2. Core Technical Specifications
Based on a thorough analysis of material characteristics, Epic Powder deployed the HTS (Horizontal Turbo Classifier) System.
| Spezifikation | Requirement | Actual Result |
| Futtergröße | 300 Mesh (approx45μm) | Met feed requirements |
| Product Size D97 | ≤10μm | 9.2μm |
| Product Size D50 | 17.5μm | 17.2μm |
| Kapazität | 2,500 kg/h | 2,600 kg/h |
Notiz: Der Partikelgröße distribution (PSD) curve demonstrated an extremely narrow range, indicating superior product consistency.
3. The Solution: Episches Pulver HTS Luftklassierer
The Epic Powder HTS Series Air Classifier outperformed competitors in this project. When it comes to the air classification of cenospheres, this equipment offers several key design features:
- Horizontal Rotor Configuration: Unlike vertical classifiers, the HTS horizontal structure manages higher air volumes while maintaining a stable flow field at ultra-fine cut points (D97 = 10μm).
- Low-Breakage Design: The material entry path into the classification zone was optimized to minimize high-velocity impacts between particles and blades, preserving the structural integrity of the “hollow shells.”
- Precision Cutting: The unique impeller design ensures an exceptionally sharp cut-off, aligning the D97 and D50 values precisely with the client’s ideal curve.
- Wear Protection: To combat potential abrasive impurities in the cenospheres and the harsh environmental conditions of the UAE, internal components were treated with ceramics and high-strength wear-resistant coatings.
4. Project Outcomes
Since the commissioning of the project, the client has achieved significant milestones:
- Product Premiumization: By producing high-end ultra-fine cenospheres (D97 < 10μm), the market value of the product increased 3 to 5 times compared to the 300-mesh raw material.
- Skalierbarkeit: The 2,500 kg/h throughput allows the client to fulfill large-scale orders for the international petroleum industry rapidly.
- Operational Stability: Even under the extreme heat and sandy conditions of the UAE, the HTS equipment has demonstrated high reliability with lower-than-expected maintenance costs.