Project Overview and Background:
Carbon black is an essential industrial raw material widely used in rubber, plastics, inks, coatings, and emerging new energy battery applications. In high-performance fields—especially specialty coatings and conductive materials—extremely fine particle size distribution is crucial. Precise control of product fineness (such as D97 values) directly determines end-product performance.
This case project is located in Iraq, where the customer required ultrafine grinding and precise classification of a specific carbon black feedstock.
Core Requirements and Challenges
Ultrafine Particle Size Target
The final product needed to reach D97 = 10 μm.
For carbon black—a material with strong agglomeration tendency and large specific surface area—achieving such ultrafine grinding and tight particle size control imposes high demands on grinding efficiency and classification accuracy.
Throughput Assurance
The customer required a stable production rate of 250 kg/h, ensuring continuous operation and economic productivity.
Material Characteristics
Carbon black is lightweight, easily airborne, and prone to agglomeration. These characteristics challenge equipment sealing performance, dust control, explosion protection (if flammable grades are involved), and maintenance cleanliness.
Equipment Selection
The Epic Powder engineering team conducted on-site investigation, analyzed the characteristics of the local Iraqi carbon black (such as hardness and moisture content), and performed performance simulations for the MJW-400L.
The final evaluation confirmed that this model could achieve D97 = 10 μm while maintaining throughput at 250 kg/h.
MJW-400L Advantage Analysis
| Feature | MJW-400L Advantage Explanation |
|---|---|
| Integrated Design | Integrates the grinding zone and precision classification zone within the same chamber, allowing ground material to immediately enter the classifier wheel. This avoids over-grinding and ensures accurate control of D97 particle size. |
| Ultrafine Grinding Capability | Uses impact and shear mechanisms to efficiently disperse carbon black agglomerates and grind them to micron-level fineness. |
| Classification Accuracy | Adjustable classifier wheel speed and airflow allow flexible, precise control of the particle cut point, ensuring stable achievement of D97 = 10 μm. |
| Adaptability to Carbon Black | Optimized internal flow-field design reduces material adhesion; the fully enclosed operation helps with environmental protection and minimizes dust emissions. |
Project Implementation and Results
During commissioning and production, the MJW-400L classifier mill fully achieved and exceeded customer expectations.
| Key Indicator | Target Requirement | Actual Operating Result | Achievement Level |
|---|---|---|---|
| Product Particle Size | D97 = 10 μm | Stably controlled at D97 ≤ 10 μm | Achieved |
| Production Throughput | 250 kg/h | Consistently reached or exceeded 250 kg/h | Exceeded |
| Operational Stability | Continuous and stable | Excellent continuous operation with low failure rate | Excellent |