Cenosphere - Hollow Ceramic Microspheres

A hollow microscopic ball made up of some minor ceramic elements with the smooth silica-aluminum is Cenosphere. Its derivation has been done from the extreme fire of coal-fired power plants and now it is being used to improvise the qualities of manufactured products in India.

In India, Cenospheres are made of iron, alumina & silica by Petra Buildcare Products. In thermal power plants, burning coal produces fly ash which has ceramic particles largely made of alumina and silica.

The size range of cenospheres varies from 1 to 500 microns with 3000+ psi average compressive strength. In low-density concrete, Cenosphere can be used as fillers; It can also be used in plastics and composite materials such as kayaks, surfboards, bowling balls and for automotive components it can be used in floor tiles, fire bricks, and other industrial materials.

Cenospheres are Hollow ceramic microspheres that are a by-product of coal burning power plants. When pulverized coal is burned at power plants fly ash is produced. Cenospheres are the lighter particles that are contained within the fly ash.

Most cenospheres are "harvested" or scooped up from ash ponds. Ash ponds are the final resting place for fly ash when wet disposal is carried out. Some cenospheres are also collected at the power plants themselves. The wet microspheres are than dried, processed to specifications, and packaged to meet customer requirements.

Not all cenospheres are alike. In fact, they can be quite different. The properties of cenospheres depend on the consistency of the coal used and the operating parameters of the power plant. As long as these two factors remain constant, the cenospheres will be quite consistent.

Hollow Glass Microspheres, Cenosphere


Chemical Properties of Cenosphere

  • Sillica : 55% - 65%
  • Aluminia : 25% - 35%
  • Iron Oxide : 1% - 5%
  • Titania : 0.5% - 1.5%

Petra Buildcare Products is actively engaged in offering well-processed Cenosphere to the clients. We procure the Cenosphere from reliable vendors who use cutting edge technology for its processing. Our Cenosphere is free from unwanted impurities and therefore assure unmatched quality. The Cenosphere offered by us, is moisture free and thus appreciated by clients. Owing to such efforts, we have become prominent Cenosphere Exporter and Supplier.

Cenospheres Benefits

The spherical shape of Cenospheres improves flowability in most applications and provides a more even distribution of the filler material.

This cenosphere is highly used in oil drilling, paints, fillers industries etc. Our products are used in oil field cementing to decrease the slurry density.Like sphered products, the properties of these are same. Therefore, this is also known as Glass Beads, Hollow Ceramic Sphere or Microspheres owing to the unique combination of spherical shape, low specific gravity, controlled size, high compression.

Cenospheres primarily used to reduce the weight of Plastics, Rubbers, Resins, cements and extensively as filler lubricants in oil drilling operations under high heat and high stress conditions down the hole. Also used as oil well cementing, mud putty and similar applications.

Cenospheres were first used in the United states as an extender for plastic compounds , as they are compatible with plastisols thermoplastics, Latex.

How Cenosphere is Produced?

The process of burning coal in thermal power plants produces fly ash containing ceramic particles made largely of alumina and silica in India. They are produced at temperatures of 1,500 to 1,750 °C (2,730 to 3,180 °F) through complicated chemical and physical transformation. Their chemical composition and structure varies considerably depending on the composition of coal that generated them.

The ceramic particles in fly ash have three types of structures. The first type of particles are solid and are called precipitator. The second type of particles are hollow and are called cenospheres. The third type of particles are called plerospheres, which are hollow particles of large diameter filled with smaller size precipitator and cenospheres manufacture in India.

Cenosphere Manufacturing:

Over the last 30 years, cenospheres and its definition have been completely changed. In the 1990s it was largely limited to the carbonaceous sphere. Oxygen-Deficient combustion is a reason of carbonaceous sphere which occurs because of liquid fuel droplet that has been cooled below 392 °F (200 °C) before consumption. An indication of fuel cenosphere combustion taken place using the open burning of heavy liquid fuels and fuel droplets such as a thermoplastic material or asphalt which causes bubbling as they get burned and the impact of the bursting of the bubbles has created airborne droplets of fuel.In environmental microscopy this is the basic definition that is used, to differentiate between high-temperature fly ash which is the result of efficient combustion of fuels with inorganic contaminants and inefficient combustion of liquid fuels. The color of fuel cenospheres will always be black.

As defined above the refractory cenosphere is synonymous with glass microspheres or microballons and excludes the traditional definition of fuel cenospheres. Instead of microballoons, name cenosphere has been widespread and became an additional definition of it. Petra Buildcare Products manufactures different types of cenosphere in India with various aspects.

Cenosphere in Syntactic Foams

Cenosphere are often used to produce syntactic foams. Cenosphere are used as fillers by these specialised solids. These benefit in various ways like it reduces cost, adds up the strength, thermal protection and more.
Syntactic materials resists the effect of hydrostatic pressure and long term exposure and hence they are ideal for oceaneering projects.

Cenosphere - Global Demand Analysis

Cenosphere is free flowing and hollow ceramic sphere in coal fire thermal power plant during burning of the coal at high temperature. It is being used in various industries including oil & gas, building, plastics, automotive and more.

New application areas of cenosphere are always being researched upon.
There are few factors that contributes chiefly to the increase demand of the cenosphere in industrial sector. As its role is to improve the durability and increase the strength of products along with allowing weight reduction and being cost effective. These factors enhances its application and demand as it interests governments, business and industrialist.

Cenosphere market is anticipated to grow strong for its increasing applications in different industries. New thermal power plants is one of the factor driving the increasing demand. It has been analysed that the growth of this segment is forecasted to its high demand in countries like Europe, North America, and Asia Pacific like India, China and Singapore. Due to rise in the production activities in Middle East countries and also increase in exploration of hale gas in North America, it is expected that the demand of cenosphere will increase over the years.

Industrial Uses

Ceramics : Refractories, Insulating Materials, Castables, Tile, Aluminum Cement, Coatings, Fire Bricks.

Plastics : Bmc, Injection Molding, Extruding, Smc, Pvc Flooring, Low Density Polyethylene, High Density Polyethylene, Polypropylene, Film

Nylon construction : Mortars, Grouts, Stucco, Specialty Cements, Acoustical Panels, Roofing Materials, Coatings, Shotcrete

Gunitere creation : Marine Craft, Flotation Devices, Surf Boards, Kayaks, Golf Equipment, Bowling Balls, Footwear

Lawn & Garden Decorautomotive : Composites, Tires, Engine Parts, Brake Pads, Body Fillers, Trim Molding, Plastics, Undercoatings, Sound Proofing Materials.

Energy & Technology : Oil Well Cements, Drilling Muds, Explosives, Industrial Coatings, Grinding Materials, Aerospace Coatings & Composites.

Cenosphere Applications

  • Oil Well and Geo Thermal Cementing
  • Thermal Insulation
  • Paints
  • Light Weight Concrete
  • Pace Craft
  • Insulation potting of Electrical Transformers and Coils
  • Foundry and Refractory.

Our Mission

To become a leader in processing and marketing of cenosphere in the world in most
      cost effective way.  

Mr.Ashish Raninga, Petra Buildcare Products

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