Jordan possesses world-class high-purity limestone and calcium carbonate mineral resources, with finished products exported extensively to Middle Eastern and European markets. A leading local mineral processing enterprise, which previously focused on coarse sand production, faced increasing market demand for fine coatings, plastic fillers, and dry-mix mortar. The client needed to integrate a high-efficiency classification system at the end of their existing crushing line. The core challenge: how to accurately extract high-value fine powder within the 32-250 μm range from high-speed crushing streams while maintaining a stable output of 6t/h.
Technical Solution: CTC Series Air Classifier
To meet these specific requirements, the production line was equipped with the Epic Powder CTC Series Air Classifier. Unlike traditional ultra-fine classifiers, the CTC series is specifically engineered for “coarse-to-fine precision separation.”
Key Equipment Specifications
- Model: CTC Series Air Classifier
- Target Range: 32-250μm (Adjustable)
- Capacity: 6t/h (Finished product output)
- Application: Ground Calcium Carbonate (GCC), Quartz sand, Dry-mix mortar
Solution Advantages
- Precise Cut Point: The CTC classifier utilizes an optimized rotor design to effectively eliminate “oversize leakage” (the presence of large particles in the fine powder), ensuring a clean top-cut.
- High Airflow & Low Pressure Drop: The system is designed for high-volume air circulation, which rapidly carries away the 32-250μm target powder, reducing energy waste caused by over-grinding.
- Wear-Resistant Customization: Considering the hardness of Jordanian calcium carbonate and the demands of 24/7 operation, the internal components feature specialized anti-wear treatments to extend the maintenance cycle.
Process Workflow
The production line utilizes a closed-loop circulation system to ensure zero dust leakage, meeting local environmental standards:
- Feeding: Crushed calcium carbonate is transported via a bucket elevator into the inlet of the CTC classifier.
- Classification: Under the joint action of the centrifugal force (generated by the high-speed rotor) and the radial suction (from the system fan), the material is precisely sorted.
- Coarse Sand: Particles > 250μm fall due to gravity and are discharged for re-grinding or sold as coarse sand.
- Target Powder: Particles within the 32-250μm range are carried by the airflow into the cyclone collector.
- Collection: A secondary pulse jet bag filter ensures a recovery rate of over 99%.
Operational Results
Since commissioning in Jordan, the production line has consistently met and exceeded expectations:
- Narrow Particle Size Distribution (PSD): The output powder is highly uniform, significantly increasing the client’s competitiveness in the high-end coating and filler industries.
- Stable Throughput: It maintains a steady 6 t/h output with operational noise levels far below industry standards.
- Economic Value: By converting “sand” into “high-end powder,” the product’s added value has increased by approximately 40% – 60%.
Expert Insight:
In the calcium carbonate industry, classification efficiency directly dictates profit margins. For particle sizes above 32μm, the CTC classifier offers significantly higher efficiency and lower specific energy consumption compared to conventional ultra-fine classifiers.