Air classifier mill is a highly efficient equipment in processing carbon black and it integrates grinding and classification. The following is an analysis of its advantages and disadvantages in carbon black processing:
1. Advantages
— Precise control of particle size
The ultra-fine powder production with D97 ≤ 10μm is achieved through a high – speed rotating classifying wheel (the rotational speed can reach 10,000 – 30,000 rpm). Meanwhile, the classification efficiency is as high as 85% – 95%, reducing over-grinding and residue of coarse particles.
This can meet the application needs of carbon black in high-end fields, such as: inks and lithium battery conductive agents.
— Suitable for heat-sensitive materials
Due to the airflow cooling effect, the inlet temperature can be <60℃, preventing carbon black from high-temperature oxidation or structural damage (gentler than mechanical mills).
This makes air classifier mill suitable for heat – sensitive products, such as high-pigment carbon black and high-end sealant carbon black.
— Low contamination & high purity
① Adopting air suspension grinding eliminates direct contact between mechanical parts and materials, reducing dust generation.
② Critical components (classifying wheel and guide ring, etc), are coated with ceramic/silicon carbide to prevent metal ion contamination, and iron content can be <10ppm.
③Suitable for high-purity materials, such as lithium battery negative electrodes, electronic components and pharmaceutical intermediates.
— High processing efficiency
The screen-free design avoids the screen clogging problem of traditional mechanical mills.
2. Disadvantages
— High energy consumption
Air classifier mill relies on high-speed airflow (usually >200m/s) to achieve material suspension and classification. Compared with mechanical mills (such as ball mill and Raymond mill), the energy consumption per unit product is higher (about 1.5-2 times that of mechanical mills).
— High maintenance cost
Although ceramic/silicon carbide coatings are wear-resistant, they will still wear out after long-term operation. Their service life is about 2000-5000 hours, and the replacement cost is as high as 15%-25% of the original value of the equipment.
— Process limitations
The pretreatment requirements for raw materials are high: the carbon black must first be coarsely crushed to less than 1mm through mechanical grinding or crushing equipment, otherwise it will easily clog the classifying wheel.
3. Main application of carbon black after processed by air classifier mill
| Application Fields | Requirement Description |
| Lithium battery negative electrode materials | High purity carbon black, iron content <5ppm |
| Tire rubber | Ultra-fine carbon black (D50＜20μm), improving strength and wear resistance |
| Ink / paint | High dispersibility, uniform particle size, optimized blackness and gloss |
Qingdao Epic Powder Machinery Co., Ltd. is a powder processing equipment manufacturer with rich experience and technical accumulation. Our products cover grinding equipment, classifying equipment, modification equipment and related auxiliary equipment.
Air classifier mill is one of our products, including 5 series: MJW-W, MJW-L, MJW-A, MJL-W and Lab air classifier mill, with good quality and competitive prices. If you need air classifier mill to process carbon black or other materials, or need other powder processing equipment, please contact our staff directly, we will provide you with a one-stop solution from equipment selection, scheme design to installation and commissioning, and after-sales service.
We look forward to working with you and sincerely hope to contribute to the development of your business.
