Aerograder Air Classifier
Efficient material separation with the Aerograder Air Classifier: optimising material recovery for sustainable, high-quality processing.
The CFlo Aerograder is a dry air classifier that separates fine and coarse materials by size, density and shape, using no process water at all. It needs no cyclones, baghouses or external fans, runs as one of the most energy-efficient systems in its class and includes integrated dust suppression, making it ideal for water-scarce sites and dedusting.
Dry classification for water-scarce sites
The Aerograder is an advanced air classification system designed to separate fine and coarse materials efficiently with minimal water usage. It is the reliable choice where water availability is limited and operational cost matters, and it excels at dedusting: reducing dust and fine particles from feed materials so the final product is clean, well graded and meets high quality standards. Because the system operates without process water, it opens up sites that wet washing simply cannot serve.
Key features
- Efficient separation of both fine and coarse materials using advanced air classification
- Minimal water usage, ideal for water-scarce sites
- No auxiliary equipment: no cyclones, baghouses or external fans, significantly reducing complexity, capital and operating costs
- Low energy consumption, one of the most energy-efficient systems in its class
- Eco-friendly dust suppression built in, controlling particulate emissions for environmental compliance
- Super modular design that adapts easily to the specific needs of any project
How the Aerograder works
The Aerograder uses dry air classification to separate particles based on size, density and shape, giving high-precision sorting for industries where quality control and consistent grading are essential. Four parameters give Super smart control over the cut: - Number of selector blades: controls particle rejection; fewer blades allow more fines to be removed, more blades remove fewer - Feed rate to air ratio: controls particle saturation; lower feed rates remove more fines, higher rates remove less - Number of fan blades: controls drag force in the classification zone - Rejector speed: controls centrifugal force and particle rejection, with fan speed setting air velocity through the classifier
Versatile applications across industries
- Construction and infrastructure: producing graded sand and aggregates from crushed rock fines for road construction, concrete production and other infrastructure projects
- Mining and minerals: efficiently classifying materials such as silica and other minerals
- Dedusting: stripping dust and ultra-fines from feed material so products meet tight gradation limits
Proven in the field
On the water-scarce Samruddhi Mahamarg Expressway, Afcons Infrastructure used a 60–70 TPH Aerograder to produce consistent, high-quality graded manufactured sand without water. "The technology not only helped us save valuable water resources but also delivered consistent, high-quality graded manufactured sand," says Mihir Mishra, General Manager, Afcons Infrastructure Limited. In Abu Dhabi, four Aerograder C100 units running at a combined 260 TPH cut minus 200 mesh fines to 0.94%, delivering a 91.6% yield of locally sourced frac sand from desert dunes.
Frequently asked questions
Does the Aerograder use any water?
No. The Aerograder separates particles with air rather than water, using size, density and shape to make the cut. That makes it the practical option for water-scarce sites: Afcons produced graded manufactured sand on the Samruddhi Mahamarg Expressway without drawing on scarce local water, while integrated dust suppression keeps the dry process clean.
What materials can an air classifier process?
The Aerograder produces graded sand and aggregates from crushed rock fines for roads and concrete, classifies silica and other minerals for the mining industry, and handles dedusting duties wherever dust and ultra-fines must be stripped from a feed. It suits any operation where consistent grading and quality control are essential.
How precise is the separation?
Precise enough for frac sand. In Abu Dhabi, four Aerograder C100 units reduced minus 200 mesh fines to 0.94% while delivering a 91.6% yield from local dune sand. Operators tune the cut with four controls: selector blades, feed rate to air ratio, fan blades and rejector speed.
What does the Aerograder cost to run?
Less than comparable systems, for two reasons. It needs no auxiliary equipment: no cyclones, baghouses or external fans, which cuts both capital and operating cost and reduces complexity. And it draws low power, making it one of the most energy-efficient classification systems in its class, with zero water procurement or treatment cost.
When should I choose an Aerograder over a wet washing plant?
Choose air classification when water is scarce or expensive, when your feed mainly needs dust and fines removed rather than clay scrubbed off, or when you want the simplest possible flowsheet. Where feeds carry heavy clay or surface contamination, a wet plant such as the CFlo Combo remains the right tool; many operations use both.
What capacity can the Aerograder deliver?
A single unit produced 60–70 TPH of graded manufactured sand for Afcons on the Samruddhi Mahamarg project, and units combine for larger duties: Abu Dhabi's frac sand operation runs four Aerograder C100s at 260 TPH combined. The Super modular design means capacity scales by adding units, not redesigning the plant.
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