The customer is located in South Korea, specializing in high-purity filler materials for semiconductors and display panels. Their main products include spherical silica and ultrafine quartz powder.
At the end of 2024, after securing new project orders from Samsung and LG Display, the customer needed to upgrade their existing angular ultrafine quartz powder from D97 ≈ 12–15 μm to D97 < 5 μm. At the same time, the powder had to achieve SiO₂ purity ≥ 99.99% with absolutely no metal contamination.
Customer Pain Points
Extremely fine target particle size (D97 < 5 μm): Conventional jet mills caused coarse-powder backflow, resulting in low yield.
High material hardness (Mohs 7): Standard steel equipment wears quickly and easily introduces excessive iron contamination.
Lab-to-pilot scale transition: Required capacity is only 30–80 kg/h; the customer does not want to invest in a million-yuan large-scale line.
Limited factory space: Installation footprint must be less than 8 m².
Must pass KFDA and the semiconductor industry’s strictest metal ion testing standards.
Equipment Selection
After multiple onsite tests in Korea and remote sample-grinding trials, Epic Powder recommended:
MOQ serious Jet Mill (Full-Ceramic Premium Version)
Process Parameters & Performance Results
To ensure the ultrafine quartz powder could be successfully ground to D97 < 5 μm, key process parameters were fine-tuned and optimized repeatedly.
Key Parameter Settings (Example)
| Parameter | Setting Range | Purpose |
|---|---|---|
| Grinding Pressure | 0.8 MPa – 1.0 MPa | Provides maximum kinetic energy for effective breakage of high-hardness quartz. |
| Classifier Wheel Speed | Ultra-high speed (e.g., > 5000 RPM) | Achieves an ultrafine cut point below 5 μm. |
| Feed Rate | Precisely controlled (low) | Maintains optimal material concentration for efficient collision while preventing blockage. |
| Grinding Medium | Clean, dry compressed air | Ensures product purity with no contamination. |
Project Outcomes
| Indicator | Target Requirement | Actual Performance |
|---|---|---|
| Particle Size (D97) | < 5 μm | Stably maintained at 4.0–4.8 μm |
| Product Purity | Ultra-high purity | No mechanical impurities; meets stringent high-end application standards in Korea |
| Equipment Wear | Low wear | Ceramic lining significantly extends continuous operation life |