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Calcium Carbonate Separation Equipment

Industrial separation equipment encapsulates the separation process which is to separate components of a liquid mixture, for recovering dissolved solids from liquids. The choice of a suitable technology depends on the identification of the key physical or chemical property, such as size, mass, density, or boiling point, which sets the product of interest apart from the rest of the components. Separation technology is widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high-purity chemicals. As well as in waste management and recycling industries.

Separation

Calcium carbonate makes up almost one-twentieth of the earth’s crust. But the abundant mineral is found in many living things, including the human body. However, processing calcium carbonate extracts the multi-purpose material from inorganic sediments, namely limestone, chalk, and marble.

Calcium carbonate

When a saturated slurry or sludge must be dehydrated in a continuous process municipal waste water treatment facilities and industrial waste processing plants often turn to belt press filtration.  Customers in these industries need automatic equipment that does not demand constant attention from operators, the peace of mind that comes with robust and industry proven design, and low investment and operating costs.


<h2>Continuous, automatic sludge dehydration from a leader in industrial filtration</h2>
Tefsa has been providing belt press filters that meet these needs for more than 30 years.  Over 2,000 belt filter press models are installed in over 1,000 customer facilities worldwide.  The belt filter press distinguishes itself from competitors'belt filter presses by an effective pre-dehydration phase that includes a turning of the filtrate bed to enhance initial water extraction, as well as overall robustness and reliability.  Careful attention has been paid to the gradual application of pressure between the belts and shearing action caused by forcing the filtrate material through rollers of varying sized to optimize the efficiency of the filtration and dehydration process.  Several variants are available to most efficiently meet the needs of your process and the belt width of any model can be selected to achieve capacities from 10 to 35  cubic meters per hour.

Belt filter press

For large scale production processes in the chemicals or food industries that require the coarse or fine screening of difficult materials, traditional sieves do not provide sufficient throughput. A high volume rectangular sieve can process large quantities consistently, and the addition of multifrequency vibration makes them capable of extremely high efficiency.


<h2>Specialist heavy-duty sieve for large scale industrial processes</h2>
The RS 2010.1 from Virto has been conceived specifically for the coarse to fine separation of particles from large volumes of dry materials and powders, but is also available in a special version for use with liquid slurries. Designed to be robust enough to handle heavy industrial and mining/quarry use, the RS 2010.1 is also suitable for lighter and more delicate materials such as metal powders and fine particulate slurries.

Driven by a single energy efficient motor consuming only 2.8kW, the RS 2010.1 uses patented MFVexcite technology to create multifrequency vibrations. This accelerates the particle impact to the mesh from the typical 5G found in standard equipment to 500G. As well as increasing screening effectiveness this also eliminates clogging of the 1.6m2 mesh surface.

Constructed of solid carbon steel as standard, it is also available in stainless steel for speciality operations. The RS 2010.1 has been built to withstand extreme operating conditions and environments with minimal maintenance and downtime.

High volume particles separation sieve

Industrial production of high-quality powder materials often requires precise control over particle size and composition. Challenges include maintaining consistent quality in mass production and achieving specific material characteristics tailored to end-use applications.
<h2>Optimizes powder synthesis and particle coating</h2>
The Glatt ProAPP® series reactors are advanced synthesis reactors designed to meet the diverse requirements of producing, modifying, or coating powder particles in the nanometer and micrometer range. Utilizing pulsating gas flow in a continuous vertical reaction tube, these reactors allow for tailored adjustments to raw material feed rates and process temperatures. Reactor options range in diameter from 80 mm for small-scale production to 500 mm for larger quantities. The reactors can achieve process temperatures up to 1300°C with electric or gas heating options, and allow for precise product separation via filters and samplers. Suitable for various materials such as battery powders, ceramic powders, catalytic powders, and pigments, the ProAPP® reactors are customizable to fit specific industrial applications. Glatt’s facilities offer lab-scale options for research and pilot-scale reactors for scaling-up production, ensuring flexibility for both small and large campaigns.

Powder synthesis reactors for nanometer and micrometer particles

In industrial applications, achieving ultrafine particle sizes in mineral slurries, such as calcium carbonate, often presents challenges. Traditional grinding methods may not provide the necessary fineness, consistency, or continuous operation required, leading to high maintenance and operational costs.
<h2>Achieve ultrafine particle sizes in continuous mode</h2>
The ANR from Hosokawa Alpine is an open-design vertical agitated media mill. It excels in the ultrafine grinding of highly concentrated limestone slurries. The mill's design permits continuous operation with minimal maintenance. Operating in a bottom-to-top flow pattern, the feed material is ground with ceramic grinding beads, such as zirconium silicate or zirconium oxide, ensuring high whiteness and low abrasiveness. The low-speed agitator reduces energy consumption while providing durable wear rates and high service life. The mill includes a mechanical and dynamic separating element to effectively separate the grinding beads from the product suspension. Efficient cooling of the mill stator prevents overheating, and the system can scale from 45 kW pilot machines to large production mills in the MW range, making it versatile for various production needs.

Ultrafine grinding mill for calcium carbonate slurries

In industries such as mining and chemical processing, precise particle size distribution is crucial. When dealing with materials like limestone, talc, and calcium carbonate, achieving consistent particle sizes can be challenging due to the varying nature of raw materials.
<h2>Achieve precise particle size distribution</h2>
The Hosokawa Alpine Stratoplex ASP II is an air classifier designed to deliver high accuracy in fine to medium-fine separations. This classifier can handle particle sizes in the range of d97 = 10 - 150 µm with high throughput and efficiency. It operates with low energy consumption, making it cost-effective for large scale applications. The ASP II is particularly suited for the classification of minerals including limestone, talc, dolomite, and calcium carbonate. The system ensures a high yield of fine particles while maintaining minimal oversize. Its robust design and low-maintenance requirements are tailored to both industrial and laboratory environments, offering versatility across different applications.

Air classifier for classifying industrial minerals

When processing fine powders, achieving consistent particle size distribution is crucial. Traditional methods often lack precision and throughput needed in modern industry applications, which can result in inefficiencies and material wastage.
<h2>Ensure accurate particle separation and control</h2>
The MS ultrafine classifier by Hosokawa Alpine is designed to provide precise particle separation with pneumatic product feed. This classifier operates within a working range of approximately d97 = 15 to 150 micrometers, ensuring high throughput while saving energy due to its low classifier speed. Unique features include a belt-driven classifying wheel and steplessly adjustable speed controlled by a frequency converter, enabling easy in-operation adjustments to particle size. Fine particles are gathered via rotor blades and discharged through the main air flow, while coarse particles are rejected and discharged separately, improving cut precision and fines yield. The MS classifier is suitable for processing talc, calcium carbonate, bentonite, kaolin, loam, dolomite, quartz, kieselguhr, and fine-grade chemicals. Available in wear-protected designs for abrasive materials and stainless steel for food and pharmaceutical applications, it can also be operated with a table roller mill or in circuit operation with a ball mill.

Ultrafine classifier for precise particle separation

When you need to produce ultra-fine powders, the milling and drying process employed is what ensures the consistency of your product. To process minerals and chemicals, you need a machine which is powerful, flexible, simple to maintain.


<h2>Versatile and highly efficient milling and drying</h2>
Atritor’s cell mill has been constructed to produce ultra-fine powders. It is able to grind, flash dry, classify and surface coat powders at the same time. Its capacity ranges from 50 kilograms per hour to 15 tonnes per hour, with evaporation rates up to 3,000 kilograms per hour.

The feed can be dosed directly into the machine via a screw feeder or via the inlet air duct. It is then ground in a vertically mounted, multi-stage rotating rotor. Each of the rotor sections is constructed with up to 200 quick-change blades. There is also the possibility for a classifier which is mounted at the discharge section to ensure that oversized feed particles are either discarded or recirculated.

The mill acts as an efficient dryer when the process air is heated using a hot air generator or even waste heat from another process. It can reach an inlet temperature of up to 450ºC. Heat energy from the process can be recovered from the heated air stream and utilized to preheat the intake air. After flash drying, the product is kept cool due to evaporative cooling via the constant exposure of new surface areas of the product created during attrition.

In the case of minerals that require surface treatment, the cell mill provides a range of coatings and surface modifiers that can be added on the side of the machine during the milling process. It has a wide range of applications, from minerals like GCC, clay and limestone to chemicals, dyes, pigments and a wide range of food ingredients and by-products.

Milling and drying machine for fine powders

Drying and grinding can be an important feature when trying to process products such as raw and refined minerals, organic and inorganic chemicals, food ingredients and waste streams. It is crucial to maintain particle size and consistent quality of the finished product during such processes. You will need an efficient and abrasion resistant attrition solution to pulverise and dry your product into your required particle size.


<h2>A simplified process while drying and grinding ensuring high product quality</h2>
Atritor’s Dryer-Pulveriser is able to grind and dry the product simultaneously. It is an air-swept mill that uses an air stream to efficiently process the product and controls the final particle size. It is able to process feedstocks of up to 50+mm and production capacities from 100kg/h up to 30t/h with evaporation rates up to 6,000 kilograms per hour.

The mill acts as an efficient dryer when the process air is heated using a hot air generator or waste heat from another process. It can reach an inlet temperature of up to 550ºC. Heat energy from the process can be recovered from the heated air stream. After flash drying, the product is kept cool due to evaporative cooling. The output temperature of the product is maintained accordingly to control the moisture content of the product.

The Flash drying grinder for powders is configured with a combination of variable speed rotor, hammer arrangement and fixed pins. Turbulence inside the grinding area creates attrition to reduce the particle size, which can be controlled for simple deagglomeration of the product. An internal classifier configuration can also be used to further control particle size.

The ‘A’-series is constructed with internals that are resistant to abrasion for applications that can cause high amounts of wearing to the equipment. Where the desired amount of evaporation required far exceeds the grinding duty, the ‘B’-series machine of a lighter weight, fully fabricated configuration permitting higher airflows can be used for non-wearing product or duties, as well as for for applications in which stainless steel contact parts may be necessary.

Flash drying grinder for powders

Atritor (https://www.atritor.com/) has more than 90 years of experience in simultaneous drying and milling solutions for fine powders.

We eat it; we wear it; we plaster it. But, most importantly, we grind it. Calcium carbonate is a pervasive material found in a raft of everyday products. Virtually all industries depend on it, either as a final or an intermediary product. But GCC is not all of a size, and a plurality of applications means different preparation requirements.

Ground calcium carbonate grains can be as coarse as 1,300 microns in poultry feed or as fine as 2 microns in paper coatings.

Milling the limestone to the correct particle size distribution is a test for GCC processing. But addressing this challenge successfully makes the difference between high and low-quality calcium carbonate materials.


<h2>Mastering impact, shear, and attrition to control particle size</h2>
Crushed limestone is turned to powder in a spectacular engineering phenomenon that occurs at a millimetric level. <a href="https://making.com/calcium-carbonate">Calcium carbonate particles</a> are broken down through impact, shear, and attrition.

Imagine you shank to a nanoparticle and were dropped into a limestone-grinding mill. It would feel like a galactic clash. The blades in the equipment break the rocks by the force of impact; the swirling particles shear off against each other; large particles attrite smaller ones flying at different velocities.

But devising this intricate process to produce homogenous grains of accurate dimensions takes expertise with the raw material. Control over the impact, shear, and attrition parameters allows you to produce the right particle size distribution that matches multiple applications.
<h2>Find the right fineness profile for the job</h2>
Calcium carbonate is ubiquitous in manufacturing but producing it at a suitable grade demands precision and flexibility from the milling technology. Grinding is not simply a race to the finest grain size – equipment has to adapt to the specific use. The requirements change not only by industry but by manufacturer too.

Wood coatings, for example, typically use calcium carbonate as a filler. But manufacturers employ GCC of different grain sizes in their formulas, depending on the product range. Polymers made primarily to enhance the aesthetic effect of wood use GCC with a particle size distribution of around 7 µm. Coating products designed for scratch resistance require finer grains of about 3 µm.

Ground calcium carbonate is a versatile material, but its effectiveness is determined by the precision of particle dimensions.  The power of GCC lies in its broad fineness spectrum, whether it is formulated into an antacid tablet, used to dye a silk shirt, or mixed to increase the adherence of wall paints.

Grinding calcium carbonate down to size

Mineral

The nearly 5,000 known minerals on earth share some characteristics to be classified as minerals – they are inorganic, solid, naturally occurring elements and have a particular chemical formula and an ordered internal geometric structure. However, minerals are not all the same. One way to divide them is based on their physical characteristics such as hardness, luster, color, and shape. For example, the diamonds we use to make jewelry are very hard minerals while talc is a soft mineral; gold is a shiny mineral while others are less so.

Minerals

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