In the powder processing industry, the classifier, as core equipment for precise particle size separation, directly affects the final product quality and production operation costs. High energy consumption, unstable operation, and low classification efficiency of traditional classifiers have long been key pain points plaguing enterprises. JACAN Powder Equipment, with its deep technical accumulation in powder equipment optimization and energy-saving renovation, has successfully completed an energy-saving transformation project for the classifier system of a large non-metallic mineral processing enterprise in East China, achieving a 20% reduction in the unit energy consumption of the classifier while improving classification accuracy by 5%. This case has become a typical model for energy-saving and efficiency-improving transformation in the powder processing industry, fully demonstrating JACAN’s professional strength in customized renovation of powder equipment.
1. Project Background: High Energy Consumption of Traditional Classifiers Restricts Enterprise Development
The cooperating enterprise is a key enterprise engaged in calcium carbonate (ground calcium carbonate) deep processing in East China, with an annual output of more than 300,000 tons of ultra-fine calcium carbonate powder. Before the renovation, the enterprise used a set of traditional air classifier put into operation in 2018. With the expansion of production scale and the upgrading of product quality requirements, the problems of the equipment gradually emerged:
- High energy consumption: The unit energy consumption per ton of finished powder reached 85 kWh, which was 15-20% higher than the industry average level, resulting in an annual increase of nearly 2 million yuan in energy costs for the enterprise;
- Unstable classification accuracy: The D97 particle size deviation of the finished powder was ±3μm, failing to meet the precision requirements of high-end customers, and the unqualified rate of finished products was as high as 8%;
- High maintenance cost: The impeller and guide vane of the classifier were seriously worn, requiring replacement every 3 months, and the annual maintenance cost exceeded 500,000 yuan;
- Poor system matching: The mismatch between the classifier and the previous grinding equipment led to low overall operation efficiency of the production line and frequent shutdowns for adjustment.
Faced with the dual pressure of rising energy costs and product quality upgrading, the enterprise urgently needed a professional energy-saving renovation plan to reduce energy consumption while improving classification efficiency and stability. After comparing multiple equipment manufacturers, the enterprise finally chose JACANPowder Equipment based on its rich experience in classifier renovation and mature energy-saving technology solutions.
2. JACAN Customized Renovation Plan: Precision Optimization to Achieve Energy Saving and Efficiency Improvement
After on-site investigation, data collection and system simulation analysis of the enterprise’s production line, JACAN’s technical team targeted the pain points of the traditional classifier and formulated a full-system customized energy-saving renovation plan, focusing on four core aspects of optimization:
2.1 Aerodynamic Structure Optimization
Abandoning the traditional impeller structure, JACAN adopted a new type of airfoil guide vane and high-efficiency impeller designed by CFD fluid simulation. The optimized air flow field reduces the internal wind resistance of the classifier by 35%, makes the air flow distribution more uniform, and reduces the energy loss caused by turbulent flow. At the same time, the gap between the impeller and the casing is optimized to 0.5mm, eliminating the short-circuit flow of air flow and improving the utilization rate of kinetic energy by 20%.
2.2 Intelligent Control System Upgrade
Replace the original manual control system with JACAN’s independently developed intelligent control system, which realizes real-time monitoring and automatic adjustment of key parameters such as classifier speed, air volume, and feeding amount:
- Real-time collection of particle size data through the online particle size analyzer, and automatic adjustment of the impeller speed to ensure the D97 particle size deviation is controlled within ±1μm;
- Adopt frequency conversion speed regulation technology for the main motor and fan, realize stepless speed regulation according to production load, and avoid energy waste caused by “high load operation at low output”;
- Build a data monitoring platform to record energy consumption data, operation status and failure information in real time, and provide data support for subsequent production optimization.
2.3 Wear-Resistant Material Upgrade
Replace the original ordinary steel components with JACAN’s proprietary wear-resistant ceramic composite material for the impeller, guide vane and other key wear parts of the classifier. The wear resistance of the components is increased by 3 times, the service life is extended to 12 months, and the annual maintenance cost is reduced by more than 70%.
2.4 Whole Production Line Matching Adjustment
Optimize the connection parameters between the classifier and the previous jet mill, adjust the feeding speed and air pressure parameters, realize the seamless matching of the grinding-classification system, reduce the idle running time of the equipment by 15%, and improve the overall operation efficiency of the production line by 18%.
3. Renovation Effect: 20% Reduction in Energy Consumption, Multiple Indicators Exceed Expectations
The renovation project was completed and put into operation in 30 days. After a 3-month stable operation period, the data shows that all indicators have exceeded the enterprise’s expectations:
- Energy consumption reduction: The unit energy consumption per ton of finished powder is reduced from 85 kWh to 68 kWh, a decrease of 20%, saving more than 1.6 million yuan in annual energy costs for the enterprise;
- Improvement of classification accuracy: The D97 particle size deviation is controlled within ±1μm, the unqualified rate of finished products is reduced from 8% to 1.5%, and the qualification rate of high-end customer orders is 100%;
- Reduction of maintenance costs: The service life of wear parts is extended to 12 months, and the annual maintenance cost is reduced from 500,000 yuan to 120,000 yuan, a decrease of 76%;
- Improvement of production efficiency: The daily output of the production line is increased from 850 tons to 980 tons, an increase of 15.3%, and the annual output is increased by more than 40,000 tons;
- Environmental protection upgrade: The optimized air flow field reduces dust emission by 12%, meeting the latest national environmental protection standards.
The person in charge of the enterprise said: “JACAN’s energy-saving renovation plan not only solved the long-term high energy consumption problem of our classifier, but also improved product quality and production efficiency. The investment in renovation was recovered in only 8 months, which brought substantial benefits to the enterprise.”
4. JACAN’s Advantages in Classifier Energy-Saving Renovation
As a professional powder equipment R&D and manufacturing enterprise with more than 15 years of experience, JACANPowder Equipment has formed a set of mature solutions for classifier energy-saving renovation, with three core advantages:
- Customized scheme: According to the actual production conditions, equipment type and product requirements of different enterprises, formulate exclusive renovation schemes to avoid “one-size-fits-all” renovation;
- Short renovation cycle: Relying on standardized construction processes and prefabricated spare parts, the renovation cycle is controlled within 30-45 days, minimizing the impact on enterprise production;
- Long-term after-sales guarantee: Provide 1-year free maintenance and lifelong technical support after renovation, and regularly track and optimize equipment operation parameters to ensure long-term stable energy-saving effect.
5. Conclusion: Energy-Saving Renovation Becomes a New Engine for Enterprise Development
Under the background of national “dual carbon” goals and rising energy costs, energy-saving renovation of powder processing equipment has become an inevitable choice for enterprises to reduce costs and increase efficiency. The successful case of this classifier energy-saving renovation fully proves that JACANPowder Equipment can help enterprises achieve a win-win situation of “energy saving, efficiency improvement and quality upgrading” through professional technical means.
Up to now, JACAN has completed more than 200 sets of classifier energy-saving renovation projects for enterprises in non-metallic minerals, chemicals, lithium batteries and other industries, with an average energy consumption reduction of 15-25% for renovated equipment. In the future, JACAN will continue to focus on the R&D and innovation of energy-saving technologies for powder equipment, and provide more efficient and customized energy-saving renovation solutions for more enterprises, helping the powder processing industry move towards a green, low-carbon and high-efficiency development path.
