1. プロジェクトの背景
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.
| 仕様 | Requirement | Actual Result |
| フィードサイズ | 300 Mesh (approx45μm) | Met feed requirements |
| Product Size D97 | ≤10μm | 9.2μm |
| Product Size D50 | 17.5μm | 17.2μm |
| 容量 | 2,500 kg/h | 2,600 kg/h |
注記： の 粒子サイズ distribution (PSD) curve demonstrated an extremely narrow range, indicating superior product consistency.
3. The Solution: エピックパウダー HTS空気分級機
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.
- スケーラビリティ: 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.