Investigation on the Correlation between Mechanical Strength, Grain Size, and Density of Fly Ash Microspheres in the Context of Refining Process

Abstract

Fly ash microspheres, also called cenospheres, have many valuable properties that allow them to be widely used. Some of its most important properties are its mechanical and thermal strength as well as its chemical stability. These features constitute an important commercial parameter. Refining processes aim to select the highest quality product from raw materials that meets the expectations of recipients. Generally, preparing a final product involves selecting the appropriate sequence and parameters of the grain separation process. However, the key to the optimal selection of these parameters is knowledge of the specificity of the processed raw material. Microspheres are materials that are created spontaneously, uncontrolled, and without the possibility of intentionally influencing their properties. Therefore, due to the potential directions of microsphere use, it is justified to study the relationship between density, grain size, and mechanical strength. Understanding these relationships in microspheres from various sources is particularly important at the stage of planning refining processes. This paper presents the results of research on microspheres from two different sources. The tested raw materials (microspheres) are subjected to densiometric and grain analysis. Also, mechanical strength was determined for the separated density fractions and grain classes. The test results did not show significant correlations between the tested features of the microspheres. In the case of both raw materials, the highest density was observed in the smallest grain classes, and the highest mechanical strength was determined for microspheres with grain sizes in the range of 75–100 µm. For this grain size range, the value of mechanical strength is 26 for raw Material 1 and 38 for raw Material 2. The shares of this grain fraction in the microsphere stream are 11.2% and 16%, respectively. An important difference that may significantly affect the efficiency of the refining process is the method of distribution of the primary falling parts, which affects the mechanical strength of the tested raw materials.