Carbon black, as a high-performance reinforcing agent and pigment, is widely used in the tire, rubber products, plastics, and high-end coatings industries. This is due to its extremely strong adhesion, tendency to agglomerate, and lightweight, porous physical properties. When it comes to ultra-fine grinding at the micron or even submicron level, technical challenges such as equipment clogging, low production efficiency, and uneven particle size distribution often arise.
The client in this collaboration is a renowned chemical materials supplier based in India. To expand into high-end application markets, the client urgently needed to consistently control the final particle size of its carbon black raw material to D97 ≤ 10μm. Additionally, given the stringent environmental requirements for ultrafine carbon black powders, the equipment had to feature excellent dust containment, high-efficiency classificação, and the ability to operate continuously and stably.
After comparing multiple global powder processing equipment manufacturers, the Indian client ultimately selected Epic Powder’s MJW Series Air Classifier Mill.
Key Challenges and Solutions
During the ultra-fine grinding of carbon black, the client primarily faced the following three major challenges. Leveraging its deep technical expertise, Epic Powder provided targeted engineering solutions:
Challenge 1: Carbon Black Adhesion and Clogging
Solution: The MJW Moinho Classificador de Ar features an optimized internal flow field design. Through intense impact, shearing, and friction, the high-speed rotating hammers (or blades) rapidly break down carbon black agglomerates. The liner plates further enhance the grinding effect. At the same time, the system’s high-velocity induced draft quickly carries the material away. This prevents carbon black from sticking to the chamber walls or accumulating inside.
Challenge 2: Extremely stringent finished product particle size requirements (D97 ≤ 10 μm)
Solution: This equipment integrates grinding and classification into a single unit. It features a built-in high-precision horizontal (or vertical) turbine classifier. Variable frequency speed control allows for precise adjustment of the classification cut-off point. Only qualified fine powder meeting the D97 ≤ 10μm standard passes through the classifier, while non-compliant coarse particles automatically fall back into the grinding zone for re-grinding. This ensures an extremely narrow particle size distribution.
Challenge 3: Production Environment and Safety Risks
Solution: To address the characteristics of carbon black—which is lightweight and prone to dust generation—the entire grinding production line employs a fully negative-pressure design. The system features excellent sealing performance, completely preventing dust leakage during production. The integrated high-efficiency pulse dust collector achieves a capture efficiency of over 99.9%, ensuring emissions meet regulatory standards and creating a green, clean workshop environment.
Technical Project Parameters
Below are the actual equipment and process parameters from the operational production line in India:
| Parâmetro | Detalhes |
| Client Location | India |
| Processed Material | Carbono negro |
| Core Equipment | Epic Powder MJW Series Air Classifier Mill |
| Tamanho da ração | ≤ 2 mm |
| Finished Product Requirement | D97≤ μm(Narrow Distribution) |
| System Configuration | Automatic Feeding System + MJW Classifier Mill + Cyclone Collector + Pulse Bag Filter + Induced Draft Fan + Automated Control Cabinet |
Client Feedback
Once the equipment was installed, commissioned, and put into production at the client’s facility in India, all performance indicators exceeded expectations. The site manager highly commended the system.
Sobre Pó épico
Qingdao Epic Powder Machinery Co., Ltd. is a global leader in ultra-fine grinding and classification solutions. Epic Powder can customize the optimal grinding process for different materials. These include industrial minerals such as calcium carbonate, quartz, and talc. They also include new energy battery materials such as LFP/ternary materials and anode materials. In addition, Epic Powder provides solutions for the chemical and comida industries, including matcha and ultra-fine sugar.
