The production process of microspheres involves several steps. Overview of the microsphere production process:

1. Fly Ash Collection:

Fly ash is collected as a byproduct from coal-fired power plants. This fine powder, composed of aluminosilicate materials, is rich in silica, alumina, and other oxides.

2. Separation and Grading:

The collected fly ash is processed to remove impurities and is then graded based on particle size. The desired particle size distribution is crucial for achieving consistent and predictable properties in the resulting microspheres.

3. Heat Treatment:

The graded fly ash is subjected to high temperatures in a combustion chamber or furnace. During this heat treatment process, the remaining carbon content in the fly ash combusts, creating a hollow interior within the particles. The temperature is carefully controlled to avoid sintering or collapsing of the microspheres.

4. Formation of Microspheres:

As the fly ash particles undergo heat treatment, they transform into spherical structures with thin, solid walls and hollow interiors. The process ensures that the resulting microspheres maintain their lightweight properties and specific size distribution.

5. Cooling and Collection:

After the heat treatment, the microspheres are allowed to cool. Once cooled, they are collected and separated from any remaining ash or impurities. The collected cenospheres are then ready for further processing or direct use in various applications.

6. Surface Modification (Optional):

Depending on the intended application, the surface of the microspheres may undergo additional treatment or modification. Surface modifications can enhance specific properties such as hydrophobicity, adhesion, or compatibility with certain materials.

7. Quality Control:

Throughout the production process, quality control measures are implemented to verify the physical and chemical properties, such as particle size distribution, density, compressive strength, and chemical composition. This ensures that the microspheres meet the required specifications for their intended applications.

8. Transportation:

After packaging and quality control measures, fly ash is loaded at the power plant in transport. It undergoes customs procedures before being dispatched to our customers. Various transportation methods, such as trucks and sea containers, are employed to ensure efficient and reliable delivery.

The resulting cenospheres can be used in a variety of applications, including as lightweight fillers in composites, insulating materials, and syntactic foams, among others. The controlled production process ensures that these microspheres exhibit consistent and predictable properties, making them valuable in diverse industries.

*Note:

Production methods may incorporate additional steps or variations to meet specific customers requirements and market demands.