Antecedentes del proyecto
Polyethylene wax (PE Wax) is widely used in masterbatches, coatings, and adhesive industries, yet its ultrafine grinding process presents significant technical challenges.
Due to its low melting point and thermoplastic nature, heat generated during conventional mechanical grinding can easily cause the material to soften, adhere to equipment surfaces, agglomerate, or even melt.
To optimize the particle size distribution of its PE wax products and enhance competitiveness in the high-end coatings market, a leading chemical enterprise in India introduced the Epic Powder Air Classifier Mill (ACM) system.
Core Technical Challenges
- Heat Sensitivity Control:
Operators must control the grinding temperature carefully to avoid the softening or melting of the PE wax. - Particle Size Control:
Target particle size of 50–150 μm, with a narrow and well-controlled particle size distribution and no oversized particles. - Stable Throughput:
Maintain a stable output of 200 kg/h while preventing material build-up or blockage.
Solution: Polvo épico Molino clasificador de aire (ACM) for PE Wax Ultrafine Grinding
Epic Powder adopted a specially designed Air Classifier Mill (ACM) that integrates grinding and classification within a single system.
Its high airflow volume not only enables efficient size reduction but also provides continuous cooling during grinding, making it an ideal solution for PE wax processing.
Technical Advantages Analysis
1. Excellent Temperature Control Strategy
PE wax becomes sticky as temperature rises.
The Epic Powder ACM rapidly removes friction-generated heat through an efficient internal airflow circulation system.
Epic Powder recommended and implemented a chilled air supply to counter the relatively high ambient temperatures in India.
This ensured 24-hour continuous operation of the production line without caking or agglomeration.
2. Precise Particle Size Cut Point
The built-in high-speed classifier wheel accurately intercepts particles larger than the target size.
For the required D50 = 150 μm, the ACM system not only achieved the specified fineness but also significantly narrowed the particle size distribution, greatly improving the lubrication performance and dispersibility of PE wax in downstream applications.
3. Optimization for the Indian Market
Engineers upgraded the system based on local production conditions in India, incorporating enhanced dust protection and power stability:
- Enhanced dust-proof design
- Optimized electrical control system with improved resistance to power fluctuations
These measures ensured long-term operational stability and reliability.
Project Operation Results Summary
| Category | Parámetro | Operating Data / Technical Specification |
|---|---|---|
| Basic Information | Project Location | India |
| Processed Material | Polyethylene Wax (PE Wax) | |
| Equipment Configuration | Main System | Epic Powder Air Classifier Mill (ACM Series) |
| Core Functions | Integrated grinding, classification, and temperature control | |
| Product Specifications | Finished Particle Size | D50 = 150 μm |
| Production Capacity | 200 kg/h | |
| Product Characteristics | Good particle morphology, no thermal damage, excellent dispersibility | |
| Operational Performance | Temperature Control | Chilled air system installed at inlet; discharge temperature maintained below 40°C |
| Cleaning & Maintenance | Quick-opening design; easy removal of adhered material | |
| Automation Level | Fully automated PLC control; stable and smooth operation |