Properties of Cenosphere Available in India

Cenospheres are the sphere of inert hollow silicate. Cenospheres primarily utilized to abridge the weight of types of cements, Rubbers, Plastics, Resins, etc. utilized all-encompassing as filler lubricants in oil drilling procedure under eminent heat and eminent stress conditions down the hole. Also utilized as oil well cementing, mud putty and similar applications.

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Cenospheres were earlier utilized in the United States as an extender for plastic compounds, as they are well matched with thermoplastics, Phenolic resins, Latex, Epoxies, Polyesters, and urethanes. The compatibility of Cenospheres with particular types of cements and adhesives coating and composites have been well identified.

PROVIDING THE ADVANTAGES OF

  • reducing weight,
  • less shrinkage and warping
  • Reduces water absorption.
  • increased filler loadings,
  • better flow characteristics,

WHAT WE CATER

We cater complete project profiling of Cenospheres infusion and Processing Plant and Fly Ash dressing plant along with process technology.

PROJECT SPECIALTIES

Generally Cenosphere in India are being gathered from the ash ponds owing to its irrepressibility characteristics. These are skimmed out, washed, dried and sifted out as per customer’s specification for marketing. Due to immense requirement in international market for quality material, costs have gone up to a great extent whereas reach of collection from ash ponds still remains very limited without much reach for quality authority.

Well-nigh, all the ash ponds are now under control of local mafia who; for raw Cenosphere in India, charge high price without vouching any quality whatsoever. Besides quality discrepancies, collection from ash ponds remains stingy – leading to practice of mixing ash with Cenospheres without principle or scrupulous. WHEREAS in our developed process technology, one does not need to depend on collection from ash ponds at all and can extract Cenospheres right from the dry fly ash of thermal power plants. The process is a part of nanotechnology and a mergence of dry and wet process. By virtue of total control on the processes, one stands to extract reproducible quantity and quality of Cenospheres. The process generates zero outflowing and is therefore entirely non-polluting and ecofriendly.

We are a team of techno-research people having our roots in the India consecrated to the development of Cenospheres extraction and fly ash beneficiation.

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Are you Searching a Reliable Cenosphere Supplier in India

Cenospheres is one kind of light weight material with more function for petroleum field. Its main compositions include SiO2 and Al2O3, and whose color is light gray or white. Extracted from pulverized fuel ash from coal-fired power stations hollow alumina-silicate Cenospheres or microspheres are versatile lightweight filler with applications in a variety of industrial and commercial products.

Cenospheres-in-India

Cenospheres In India are filler used to replace minerals and resins where the benefits may be as diverse as weight reduction, improved thermal insulation, reduced shrinkage, improved fire resistance or simply easier application.

 Cenospheres range from 5-500 microns. A variety of standard grades is available with very accurate particle size top cuts and distribution ranges. Cenospheres in India are widely used in oil drilling cementing.

Various high value added products developed using Cenosphere as raw materials are found to be economically viable as discussed here.

The use of carbon derived from Cenosphere as an adsorbent for waste water treatment and its use as filler for rubber industry has been established.

The use of Cenosphere for the manufacture of high wear resistant tiles appears to be viable as a substitute for high alumina ceramics for various abrasion and wear resistant applications.

The use of Cenosphere in India alloys is about to be a commercial reality following its success on the pilot scale. The characterization of mechanical and tribological properties of ash alloys developed show that if possesses superior abrasion resistance, hardness, compressive proof strength, and elastic modulus compared to matrix aluminum alloys without any ash.

Coal ash mineral wool is produced abroad based on well-developed reliable technology. The quality of coal ash wool manufactured is comparable to the properties of conventional mineral wool at much lower prices.

A Cenosphere composite wood substitute developed in India using 25-35% Cenosphere is considered to be low cost and better alternative to ordinary wood. It has advantages over cellulose products, plywood and fiber board for all domestic and household applications.

Floater based light refractory materials developed are found to save 50% more energy compared to traditional refractory in furnace linings.

Products like ceramic fibers, foam insulation products, continuous casting mold powders, decorative glass are other potential technologies are under development. The full viability implications of the can be assessed after they are tried on pilot scale level.

Cenospheres are now being successfully used as fillers in plastic like nylon and polypropylene. Size classified coal ash can successfully substitute various other fillers like aluminum hydrate, calcium carbonate, kaolin, mica, and tale and ground silica. Their applications have been well established in wall board, joint compounds, carpet backings, vinyl flooring, plastics and industrial coatings, etc.

Refuse fire abatement using Cenosphere injections has proved to be a safe and effective technique. Control of the process using temperature criteria has been shown to be reliable. On projects where steep slopes are burning or access to the burning area is difficult, Cenosphere injection has been the most economical and at times the only effective method of fire abatement.

Here is Reliable Cenosphere Supplier from India

First I’ll let you know that what Cenosphere is?? Cenospheres are hollow, light gray, thin-walled ceramic (alumino-silciate) microspheres which are very strong, non-flammable, chemically inert and temperature resistant up to more than 12000c. They are very easy to handle, have high insulation characteristics and due to their inert properties, they remain unaffected by solvents, water, acids, and alkalis. Owing to all these positive sides, Cenospheres have been vastly employed in various industries. The rising call for Cenosphere from end-user industries such as automotive, oil gas will positively wallop the market for Cenospheres.

Cenosphere suppliers

The global Cenospheres market has been analyzed with respect to different parameters such as demand, supply, end-users and Cenosphere suppliers. Cenospheres have wide usage in tires, refractory materials, insulating materials, roofing materials and engine parts, composites/FRP etc.

Cenosphere performance:

  • It can improve rheology, reduce the viscosity, and reduce the weight of the article.
  • high filling capacity, reducing the using amount of binders
  • chemical stable
  • fire resistance, can be used as fireproofing paints
  • Heat preservation, thermal resistance, and sound resistance.

Generally, Cenospheres are being garnered from the ponds of ash owing to its buoyancy characteristics. These are skimmed out, washed, dried and sieved as per client’s specification for marketing. Due to huge demand in the international market for the quality product, prices have gone up to a great extent whereas the scope of collection from ash ponds still remains very limited without much scope for quality assurance.

Cenosphere Suppliers  Pride their selves on the products and services they deliver, bringing people, materials, and energy together in constructive ways. They act as a conduit, building and growing supply chains between the power station sources and the end users of ash based products in the construction and manufacturing industries

Cenosphere Supplier’s team includes some of the most experienced ash service professionals in the industry and they all share a passion for delivering an unrivaled service. Their combined experience keeps Power Minerals at the forefront of the industry. They proffer consummate project profiling of Cenospheres Extraction and Processing Plant and Fly Ash beneficiation plant along with process technology.

Cenosphere Suppliers India – For a Variety of Uses

Cenospheres are natural occurring particles which are produced during the burning process at the coal-fired power plants as a by-product. These are lightweight, inert, and hollow sphere particles that comprise largely of silica and alumina and are filled with inert air or gases as they are classically produced as a by-product of coal combustion. Considering their size they consist of high compressive strength and thus, the Cenosphere suppliers India hoard the fly ash particles for using it as structural lightweight filler. Cenosphere holds some of the chemical and physical properties that are mentioned below. Have a look.

Chemical properties:

  • Silica: 48%-75%
  • Alumina: 26%-45%
  • Iron: 1.5%-4.0%

Physical properties:

  • Bulk density: 0.20-.025 grams per cubic centimeter (g/cc)
  • Particle size: 75-400 microns
  • Specific gravity: <0.4 g/cc
  • Softening point: 1040-degrees C
  • Compressive strength: ~90% survival @ 2500psi
  • Color: white to dark gray

Now, that you have gone through the chemical and physical properties, let’s understand that for what variety of uses the demand for Cenosphere Suppliers India is on rise.

  • Lightweight aggregate –Considering the lightweight aggregate, cenospheres can be used for replacing some normal-weight sand particles because they have a density of 0.7 which is lower than water, i.e., 1.0, whereas quartz sand particles have a density of 2.65 on an approx. Moreover, there is a prime advantage of cenosphere particles over the other lightweight aggregates and it is that they are generally invisible when mixed in the concrete even if it is refined.
  • Workability enhancer – As a matter of fact, cenosphere particles comparatively have small spherical particles and thus, they are treated as microscopic ball demeanors when mixed in a concrete. Blending the cenosphere particles with the normal weight concrete mix will result in the improved workability because of the ball bearing effect.
  • Bulk filler – Since the Cenosphere Suppliers India deliver extremely fine coal fly ash particles, they are ideal for use in cement grout slurry as cenosphere increases the volume of grout without the need of adding more cement to the mixture and also the aggregate gradation reduces shrinkage.

Rising Demand of Cenosphere exporter for Different Composites

A cenosphere is a lightweight and hollow particle that contains a large amount of silica and alumina and inert gases. The particles are produced as a by-product at thermal coal power plant. The color of these fly ash particles varies from white to dark gray and their specific gravity ranges in between of 0.4 to 0.8 g/cm3 which makes the particles extremely lightweight that are suitable to use as fillers. Due to its physical and chemical properties, the particles are appropriate to use in a variety of products including insulation, sports equipment, automobile bodies, paints, marine craft bodies, and fire and heat protection devices. And as it offers great advantages like increased filled loadings, reducing weight, less shrinkage, better flow characteristics, and reduced water absorption, the demand of cenosphere exporter has extremely increased within the last few years.  An appropriate set of matrix and such fillers at specific weight fractions can lead to a preferred combination of properties in syntactic foam. However, available carbon and iron contents are responsible for the quantity of the ash produced.

Composites of cenosphere:

Alulite – This is a saturated matrix complex of calcined alumina and cenosphere. It contains the inflexibility of high alumina tiles; however, it has improved thermal power for shock resistive property and is relatively light in nature. Thus, a compound strength of the composite can be increased by adding cenosphere contents to it.

Ashref – The cenosphere exporter supply the fly ash particles based refractories that are lightweight and have great thermal shock properties. Despite their relatively low cool pounding quality, they are warmed up again and again at 1100o c and cooled to 25o c without infuriating their structural integrity.

Keralite – These cenosphere-based rigid headed composites consist of an arrangement of hollow spheres and are blended at their purpose of contact. The cenosphere exporter India has stated that producing creative aptitude has been urbanized to make Keralite. However, it is extremely tough to produce such a product because of low shear resistance of the fly ash particles produced at a thermal power plant.

Demand of Cenosphere exporter in Various Industries

A cenosphere is an inert, lightweight, and hollow sphere that is largely made up of silica and alumina filled with air and inert gas, which is usually produced at thermal power plants as a byproduct of coal combustion. Generally, the color of the cenosphere ranges from gray to almost white with a density of about 0.4-0.8 g/cm3 (0.014-0.029 lb/cu in) which contributes as a great buoyancy. As a result, cenosphere is exclusively considered as a free flowing powder that is comprised of hard-shelled, tiny, and hollow spheres collected from coal ash. Because of these qualities, the demand for the cenosphere exporter has immensely increased as the byproduct consist of higher particle strength, lower value of thermal conductivity, ultra-low density, and impermeability that is suitable for its usage in various industries. The particles are 75% lighter compared to other different minerals which are used as fillers in clay, talc, and calcium carbonate and 30%, furthermore, lighter than general pitches. The great finished outcome of cenosphere is immeasurable like tiles of space boats, flying machine coatings and oil well bonds.

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However, several techniques have been evolved over the last 50 years to mend the metal values from the coal ash. Different studies have focused on the extraction of alumina, carbon, magnetite, cenosphere, and several other metal values. The elements present in coal ash, aluminum, and iron have been tested by the cenosphere exporter to ensure the quality of the particles. Regaining of element components from coal ash has been proficient for its use in the both physical and chemical processes.

For recovering the major constituents of coal ash, a chemical processed test is been formulated and scaled-up in four general categories, that is:

  1. Hydrothermal leaching
  2. Sinter-leach
  3. Gas solid reaction
  4. Direct reduction

Therefore, the cenosphere exporter exports the fly ash particles to multiple industries for various purposes:

  • Foam insulation
  • Coal ash mineral wool
  • Fly ash fire bricks
  • Decorative glass
  • Filler application
  • Light weight refractories
  • Fire abatement application

Rising Demand of Cenosphere Suppliers India

Cenospheres are hollow, low-density, spherical, and free-flowing aluminosilicate microspheres that are produced as a by-product of coal ignition at the coal-fired power plants. It is a rich-in-ceramic industrial waste formed at the time of coal combustion in the thermal power plants. Inside the each sphere there is a near vacuum that produces good properties of thermal and acoustic insulation making a product ideal for automotive acoustic insulation applications where the mass is a major factor to be considered. These spheres are used globally in several automotive application including tyres, brake linings, friction linings, dashboard, and clutch facings. The broad range of usage has increased the demand of cenosphere suppliers India in the industry.

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According to the global market report, cenospheres are providing emerging opportunities along with the future effects of major drivers and challenges that support the managers to make cost-effective decisions in favor of the business. The market report measures the major opportunities for the cenosphere suppliers India in the marker and underlines the factors that are responsible for the growth of the industry. The increasing demand from end-use industries including refractory, construction, paints and coatings, and oil and gas, which is expected to take the market to the next level in the near future.  However, restricted sources of raw material and deficiency of quality control across developing countries are key factors that may restrain the growth of the industry.

The Gray Cenospheres segment is estimated to experience the highest growth in the upcoming years because of its wide uses across the industrial segment. The demand will increase also because the gray cenosphere is produced more frequently as compared to the white cenosphere in fly ash. The demand for gray cenosphere suppliers India is rising because they deliver quality material which contains a low content of alumina and is high in silica and iron content that is used in a number of applications such as plastics, concretes, coatings, resins, bricks, and rubbers

Cenosphere Exporter Delivers Best Quality Hollow Spheres

Lightweight, inert, hollow sphere cenosphere particles are produced from the silica and alumina that is filled with air or inert gasses. The particles are basically produced as a byproduct of coal combustion at the thermal power plants and then are delivered to the cenosphere exporter to distribute the product to the places where it is demanded. The cenosphere particles are rigid, lightweight, waterproof, and insulative that makes them a demanding byproduct. The cenosphere has color varying from gray to white and consists density that is about 0.4-0.8 g/cm3, i.e. 0.014 to 0.029 lb./cu giving them a great buoyancy. Cenospheres are broadly used as filler for metals and polymers to make them a lightweight compound material along with high strength when compared to another kind of foam materials. For conductive coatings, fabrics, and tiles silver-coated cenospheres are widely used.

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Cenosphere exporter has been using these hollow sphere particles to improve the properties of finished consumer products. At first, the particles were introduced as an extender for plastic composites to make them compatible with thermoplastics, plastisols, latex, polyesters, phenolic resins, epoxies, and urethanes. Synthetic foams that are produced from cenosphere have been verified with great mechanical properties as compared to those components that are produced with fabricated microspheres. Cenosphere exporter has quickly identified the compatibility of cenosphere particles with the cement and other building material that are used as coating and composites. Since the uses of cenospheres have been identified, the lightweight, hollow particles are widely used for manufacturing insulations, sports equipment, marine craft bodies, automobile bodies, heat and fire protection devices, and paints.

Different market sectors in which the cenospheres are used:

  • Ceramics – castables, refractories, fire bricks, tile, aluminum cement, coatings, insulating materials
  • Plastics – SMC, BMC, extruding, molding, injection, PVC flooring, low and high density polythene, nylon, film, polypropylene
  • Constructions – mortars, grouts, specialty cement, roofing materials, coatings, acoustical panels, stucco, shotcrete, gunite
  • Recreation – floatation devices, marine craft, surf boards, bowling balls, golf equipment, kayaks, footwear, lawn and garden décor
  • Automobiles – tires, composites, engine parts, trim molding, brake pads, body fillers, sound proofing material, plastics
  • Energy & technology – drilling muds, oil well cements, grinding materials, industrial coatings, aerospace coatings and composites, propeller blades, explosives.

Cenosphere from India Has Various Usages

Cenospheres are sometimes also called as microspheres that are widely used in a variety of materials from plastics and caulking to paints and finishes. Although, they are sometimes also used in concrete. Cenosphere from India consists a range of uses in concrete countertops including:

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  • A lightweight aggregate – cenospheres can be treated as a substitute of the normal-weight sand that is used in concrete. They have a density that is less than water (approx. 0.7 vs water’s 1.0); quartz sand particles typically have a density of about 2.65 which means that 1 pound of cenospheres takes up the similar absolute volume as about 3.8 lbs of sand.
  • A workability enhancer and extra-fine aggregate – Cenospheres are known for their very small spherical particles. As such they act just like minute ball bearings in a concrete mix. By adding cenospheres to a conventional weight concrete mix will increase workability because of its ball bearing effect and since they are also structural aggregate, they expand concrete density and strengthen it by providing a better packing. Furthermore, the added fines mend the trowelability and finishability. Usually dosages of 1% to 5% by weight of aggregate are added to a concrete mix to improve the workability.
  • A bulk filler and shrinkage reducer in cement grouts – Meanwhile Cenosphere from India have very fine particles and are generally light in color; they are perfect for the use in cement grout slurry. By adding the bulk from the cenospheres, it not only increases the volume of grout without adding more cement, but also the fine aggregate gradation of the particles supports to reduce the shrinkage. In spite of everything, cement grout is still a kind of concrete, so the same rules apply.  Finally, the spherical shape marks packing pinholes at ease and more effective because of the polishing action delivered by the particles. And the spherical shapes are further likely to “roll” into small holes better than pointed or angular crushed particles. Typical cenosphere measured quantity is approximately around 10% to 30% by weight of cement.

A Brief about Cenospheres

Coal fly ash is a compound blend of anthropogenic materials formed during the combustion of pulverized coal in coal-fired power plants. They carry environmental concerns that lead to air and water pollution. The efforts have been done for reducing the production of coal fly. Cenospheres are light, low density, thin-walled hollow ceramic microsphere with distinctive properties. Conventional cenosphere production procedures involve the separation of cenospheres from coal fly ash. Fine fractions of non-magnetic cenospheres comprise 2.6–3.5 wt % Fe2O3 and embrace globules with an even smooth surface and shells with different degrees of absorbency. The aluminum absorption rise leads to an increase in the mullite phase content and a decrease in the average sphere diameter, shell thickness and porosity, glass-crystalline, and the crystalline quartz content.

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The advantages of Cenospheres:

  • Lightweight
  • Spherical shape
  • Inert
  • Free flowing
  • High-melting point
  • Insulating
  • Electrical properties
  • Low oil absorption
  • Good packaging factors
  • Versatile filler with applications in an extensive range of products for both commercial and industrial use.

However, in each case, Fillite is used for its unique properties, such as strength, low density, and chemical resistance. Fillite can be used for the applications in Cement, Latex emulsions, Polyurethane, PVC, Epoxy Resins, and Unsaturated Polyester Resins.

Properties of Cenospheres:

  • Cenospheres are made up of silica, iron, and alumina.
  • They have a size ranging from 1 to 500 microns with a usual compressive strength of 3000+ psi.
  • Colors range from white to dark gray.
  • They are chemically inert & are reclaimable and labeled as environmentally sound.
  • They are formed during the molten state of ash and attain spherical shape to have minimum surface tension.

The residue from coal after combustion has been a challenge for Indian power sector, which is dominated by coal. Presently the country produces approximately 160 million tons of fly ash, of which merely 80 million tones is being utilized. Improvements in the durability and strength of manufacturers’ end products and a reduction in product weight enhance marketing strategies are required.  Manufacturers are dedicated in producing quality chemical and physical product on a consistent basis is critical for the end use customer.