Separating and Classifiers

Grinding with ball mill systems
Separating
Separating
HGRS
Tikaria_Mill Workshop
SEPT-07
Separating process
FR
Air
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Separation in 3rd Generation Separator

Basic function:
Feed
Material enters the separator at

Centrifugal Forces
the top.
Air stream is generated by
external fan.
Material falls down between rotor
Air Guide vanes Air
and guide vanes. Fines are sucked in. Coarse particles are accelerated by rotor and stopped by guide vanes, where they slip down and leave the casing at the bottom.
Fine material exits with airflow at
Turning cage rotor
the lower/upper part of the casing

Returns
Source: Chr. Pfeiffer QDK Separator
Air with fines
Product fineness is adjustable by
the rotational speed of rotor.

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What is the separating efficiency dependent on?

Material:
fineness
- Feed (A) - Fines (F) - Return (R)
Tromp curve
Amount of feed Feed distribution Air:
V
F
Volume (V [m3/h]) Distribution The fineness relationship mill filter / separator fines
R
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Possible causes that limit the separating efficiency

The typical situations for 3rd generation separators are:
Uneven airflow and/or feed distribution to the rotor Reduced separating airflow due to:

Separator fan damper (or speed) not at maximum Fan nominal too low Limited rotor speed due to mechanical problems or insufficient nominal capacity of the motor and/or gear box
Contamination of the fines by coarse product Separator fines much finer than final product
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Tromp curve key parameter

Tromp value [%] 100
Separator fines
Separator return
Bypass
HGRS Tikaria_Mill Workshop
[mm]
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Tromp curve key parameter

Tromp value [%] 100 Coarse in fines
Separator fines
Separator return
Bypass
[mm]
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Amount of material
Circulating load:
A, F & R en [t/h] A=F+R Circulating load factor:

u= A F [-]
R
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Separator performance (1/2)

6.0 5.5 5.0
Circulating load factor u [-]
High
4.5 4.0
Normal
3.5 3.0 2.5 2.0 1.5 1.0 2'500
Low
3'000
3'500
4'000
4'500
5'000
5'500
6'000
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Cement fineness [cm2/g]

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Separator performance (2/2)

50 45 40
High potential
35
By pass [%]
30
Medium potential
25 20 15 10 5 0 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0
Low potential
Circulating load factor u [-]

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Air volume
Separator specific feed load Asl = A X 1000 [kg/m3] A
V
Asl < 2.5 [kg/m3] Separator specific fines load Fsl = F V Fsl < 0.7 [kg/m3] X 1000 [kg/m3]
R
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Air distribution
FR
Air
Lower air speed

Higher airspeed
Finer product Coarser product

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Uneven airflow distribution

Uneven airflow distribution can
be identified from (1/2): Observation of the ducting configuration:

- General arrangement - Relative position inlet / outlet air ducts
Uneven wear of paintings or steel along the guide vanes height Uneven wear of paintings or steel along the rotor blades height Low separator efficiency despite low material specific loads
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How to determine the airflow profile

Uneven airflow distribution can
be identified and evaluated from (2/2):
Airspeed mapping at the inlet of the separator volute Static pressure profile in each duct ( ) Fineness comparison of the fines at each cyclone (mass balance for each cyclone)
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Solutions for even airflow profile

Even airflow distribution with
air guide plates

The positioning and length of
the air guide plates should be done considering the air flow distribution in the ducting (start from where the air is already evenly distributed)
Too short Good Laminar and even flow across whole duct section
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Feed distribution
< 50 [mm]
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Symptoms of uneven material distribution

Uneven wear of paintings or
steel of the impact ring

Uneven pressure loss and
fineness of the fines in a cyclone air separator

Separator efficiency is low in
spite of low material specific loads

Configuration of airslides from
separator discharge to the separator feed point(s)
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Solutions evaluation
Even as much as possible
material load to all separator feeding points:
Adjust / install splitters Install mixing boxes Change airslides configuration
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The fineness relationship mill filter / separator fines
MF F
If F finer than C check:

Send MF to the separator feed Cut finer at the static separator (if any) Reduce mill ventilation Consider a static separator (or cyclone)
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Separator operating point (1/2)

100 95 90
Iso - fineness line
Rotor speed [%] of nominal
85 80 75 70 65 60 55 50 45 40 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
3500 [cm2/g]
Air [%] of nominal

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Separator operating point (2/2)

100 95 90
Bypass 3 Bypass 2
Rotor speed [%] of nominal
85 80 75 70 65 60 55 50 45 40 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
By pass 1
Bypass 1 > Bypass 2 > Bypass 3
CONCLUSION is to operate the fan at 100%
Air [%] of nominal

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Grinding with Ball Mill Systems
Separators
What is separating?
Splitting a given material by particle diameter Balls with 2, 4 and 10 mm diameter
> 3 mm
Separation by cutpoint of 3mm (e.g. by sieving)

Problem: Efficiency of separation is never perfect
< 3 mm
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Separation efficiency
The efficiency of a separation device (e.g. mill
separator) is a measure of the proportion of unseparated material following the separation process. It indicates how much fines is in the coarse fraction remaining and how much coarse is in the fines.
The efficiency is very much dependent on the separator.
Modern cage rotor separators show a far better efficiency than older static and dynamic separators.
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Basic working principles Separators

Particles are accelerated by a vortex or a
rotating device into the direction of the separator wall (Fz).

The big particles hit the wall (in older
separators) or the guide vanes (in 3rd gen. Separators) and slip down because they are too heavy for transport by the air stream.
The small and light particles are carried
out by the separator air (FL) stream supplied by an internal (older separators) or an external fan. The centrifugal force is smaller than the impulse of the air flow.
Changes of airflow or distributor (rotor)
speed (consequence higher centrifugal forces) lead to different product fineness.

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Main Separators used in Cement works

Type Static separators and cyclones Main features No moving parts / fineness adjustment via mechanical modification
Dynamic separators 1st Generation
Counter blades, distributor plate and internal fan/Fineness control by mechanical adjustment or counter blade speed change
Features as 1st Gen. / but external fans and cyclones Cage rotor instead of counter blades and distributor plate (variable speed drive) / external fan / fineness control by rotor speed change
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Dynamic separators 2nd Generation Dynamic separators 3rd Generation
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Static separators and cyclones

Cyclone
fines
immersion tube
Basic function:
Material enters the cyclone
in the air stream at the top.

feed
A vortex is generated. A fine vortex with opposite

cylindrical part
turning direction is generated at the bottom and carries the fine material back to the top.
Coarse material goes to the
view from top
conical part
walls because of centrifugal forces, slips down and leaves at the bottom.
Fine material exits at top via
the immersion tube.

tailings
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Static separators and cyclones
Cyclones of a cement mill separator
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Static separator and cyclones

fines
Grit separator
immersion tube adjusting device
Basic function:
Material enters the
adjustable blades
separator in air stream at the bottom.

A vortex is generated in the
top of the grit cone by the blades.

housing cone tailings cone
walls because of centrifugal forces, slips down and leaves at the bottom.
Fine material exits at the
rad.pos.
top via the immersion tube.

Product fineness is
tailings
adjustable by changing the blade position.

feed
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Grit separator
Adjusting device blades
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Basic function:
KHD V-separator Air + Fines

Air
Material enters the
separator from the top

Coarse material slips down
from plate to plate and leaves at the bottom.

Fine material leaves the
separator at top together with the air.
Plates
Returns
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12 6
Basic function:
5 9 16 10 8 1 7 4 11
Material enters the
separator at the top.

3 15 2
Sturtevant
13 14 1 fines chamber 2 3 4 5 6 7 8
tailings cone air vane inside drum fineness control valve rod gear reducer main shaft and distributing hub distributing plate
walls because of centrifugal forces generated by the distributor plate and counter blades, slips down at the grit cone wall and leaves at the bottom (13).
Fine material exits at the
bottom of the casing (14).

9 10 11 12 13 14
fan cone counterblades main fan blades feed spout and intake cone tailings outlet fines outlet
Product fineness is
15 air inlet 16 air outlet
adjusted by counter blade position and rods (5) (No counter blade speed adjustment is possible!)
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Dynamic separators 1st Generation (Sturtevant) Internal Fan
Counter blades
External adjustment of fineness control valve rods

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Polysius Turbopol
Air vanes Grit cone
Distributor plate
Counter blades
Internal Fan
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Dynamic separators 1st Generation (Example: Pfeiffer Heyd)

Basic function:
8

9
the top.
Air stream is generated by internal
10 7 5 4 1 6 3
fan (9).
Coarse material goes to the walls
Airflow
2
because of centrifugal forces, generated by the distributor plate and counter blades, slips down at the grit cone wall and leaves at the bottom (11).
Fine material is sucked into the
11 1 fines chamber 2 3 4 5 6
tailings cone air vane separation chamber distributor + counterblades distributor plate
12 7 8 9 10 11 12
fines chamber counter blades fan shaft fan blades feed spout tailings outlet fines outlet
outside chamber (1) and exits at the bottom of the casing (12).
Product fineness is adjustable
usually by rotational speed of the plate and counter blades (6+7). 39

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Separator Type Heyd
Variable speed drive for counter blades and distributor plate
Fan Motor
Fan Counter blades Feed spout
Distributor plate
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Dynamic Separators of 2nd Generation

8 7 6 1 separation chamber 2 3 4 5 6 11 1 14 4 15 3 13 7 8 9 10 11 12
tailings cone air vanes distributor plate counterblades feed spout gearbox motor fines outlet tailings outlet cyclones air duct to fan
5 11
9 2
13 fan 14 dust collecting

pipe to filter
15 return air duct
Polysius Cyclopol
10
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Dynamic Separators of 2nd Generation (Wedag)
to filter
Air flow direction
fresh air
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Basic function:
Material enters the separator at the top. Air stream is generated by the external fan and
is recirculated.
Coarse material is separated by fan suction into
the main casing and leaves at the bottom via a pendulum flap.
Fine material exits at the top of the casing by
airflow and enters the cyclone via gas duct. The material separated by the cyclones leaves at the bottom and goes into air slides. A part of the recirculated air together with the fine dust from the cyclones goes to a filter.
Product fineness is adjustable usually by
rotational speed of the plate and counter blades.

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Counter blades
Distributor plate
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Separators of 3rd Generation

Basic function:
Feed Centrifugal Forces
the top.
external fan.
Material falls down between rotor
Air
Guide vanes Turning cage rotor Air
and guide vanes. Fines are sucked in. Coarse particles are accelerated by rotor and stopped by guide vanes, where they slip down and leave the casing at the bottom.
Fine material exits with airflow at
the lower/upper part of the casing

Returns Air with fines
the rotational speed of rotor.

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Main parts cage rotor separator

Cage rotor
Bars
Guide vanes (in bad shape)
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11
Example: Polysius Sepol

10 5 5 3
6 7
1 guide vanes 2 rotor blades 3 distributor plate 4 rotor shaft 5 feed spouts 6 sealing
7 air + fines outlet 8 tailings outlet 9 air inlet 10 gear box 11 motor
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Drive
Basic function:
Example: FLS O-Sepa

Air outlet + fines Feed Sealing
the top.
Airstream is generated by
external fan.
Material falls down between the
Prim. air
Sec. air Distributor Guide vanes Rotor Coarses
Tert. air
Fines
Coarses
rotor and guide vanes. Fines are sucked in. Coarse particles are accelerated by the rotor and stopped by guide vanes, where they slip down and leave the casing with the tailings outlet.
Fine material exits with the
Centrifugal force
airflow at the upper part of the casing .

Air force Prim.air Gravity force
the rotational speed of the rotor.

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Example: O&K cross-flow separator
feed spout gearbox motor
Basic function:
the top.
distributor plate
Airstream is generated by an
air inlet air guide vanes
external fan.
rotor blades separating zone
rotor and guide vanes. Fines are sucked in. Coarse particles are accelerated by the rotor and stopped by the guide vanes, where they slip down and leave the casing via the tailings outlet.
Fine material exits with the
fines coarses
air + fines outlet
airflow at the lower part of the casing .

Product fineness is adjustable
tailings outlet
shaft
by the rotational speed of the rotor. 49

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Separators of 3rd Generation (FLS SEPAX)
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Separators of 3rd Generation (FLS SEPAX)

Basic function of the compact version:
Material enters the separator at the bottom with the air stream. The air
stream is generated by an external fan.

Material enters the rotor in the air stream via guide vanes. Fines are
sucked in. Coarse particles are accelerated by the rotor and stopped by guide vanes, where they slip down and leave the casing on the side.
Fine material exits with the airflow at the top of the casing .
Product fineness is adjustable by the rotational speed of the rotor.
Additional functions roller press version:

Roller Press slabs enter desagglomerator under the compact separator
where they are crushed

Fines go up in the air stream to the separator
Coarses fall down and pass through the grit separator, where additional
fines are separated und go up in the air stream. Rejects go back to the press
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Separators of 3rd Generation (Polysius Sepol SM)

Basic function:
Rotor drive
Fines with air
the bottom with the air stream (e.g. air swept mill)
Air stream is generated by an
external fan.
Rotor Guide vanes
Material enters the rotor in the air
Inspection doors Returns
stream via guide vanes. Fines are sucked in. Coarse particles are accelerated by the rotor and stopped by guide vanes, where they slip down and leave the casing at the bottom.
Fine material exits with the airflow
at the top of the casing .

Airflow with material from mill HGRS Tikaria_Mill Workshop
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Separators of 3rd Generation (KHD Sepmaster)

Sepmaster SKS-D (for RP* circuits)
feed material feed material
Sepmaster SKS-LS (for ASM**)
desagglomerator rotor impact ring air and fine product
air+fines
air+fines
coarse fraction 2
coarse fraction 1 feed material+air coarse product
* Roller Press
** Air Swept Mill 53

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Sepmaster SKS
5 1 2 4 7 6 3 2 3 4 5 6 7 8 9 1 9
guide vanes rotor blades distributor plate rotor shaft feed spout sealing air + fines outlet tailings outlet air inlet
10 gear box 11 motor
11
10 8
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Basic function:
Material enters the separator at the top. Air stream is generated by external fan. Material falls down between the rotor and guide vanes. Fines are
sucked into the rotor. Coarse particles are accelerated by the rotor and stopped by guide vanes, where they slip down and leave the casing at the bottom.
Fine material exits the separator with the airflow at the top of the casing
.
Product fineness is adjustable by the rotational speed of the rotor. Special features SKS-D: Additionally equipped with slab
desagglomerator at the top (use in roller press circuits)

Special features SKS-LS: Used for air swept mills. Function is very
similar to Polysius Sepol SM.

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Separators of 3rd Generation (Pfeiffer QDK)

Basic function:
Rotor drive
the top.
external fan.
Air inlet
rotor and guide vanes. Fines are sucked in. Coarse particles are accelerated by the rotor and stopped by guide vanes, where they slip down and leave the casing at the bottom.
Air +Fines Fine material exits with the airflow

at the lower part of the casing .
Rotor Returns
HGRS

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Separators of 3rd Generation (vertical roller mill ; Loesche)

Feed
Basic function:
Separator drive
the bottom with the air stream. external fan.
Air Air Cage rotor

Material enters the rotor in the air
Guide vanes
Returns flow
Conical casing Grit cone
stream via guide vanes. Fines are sucked in. Coarse particles are accelerated by the rotor and stopped by guide vanes, where they slip down, leave the grit cone at the bottom and fall back on to the grinding table. at the top of the casing .
Fine material exits with the airflow

The product fineness is adjustable
Airflow with material from grinding table HGRS Tikaria_Mill Workshop
by rotational speed of the rotor.57

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Separators of 3rd Generation (Vertical roller mill)

Reject cone
Cage rotor
Guide vane system

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Separators of 3rd Generation (coal grinding) in VRM

Basic function:
Coal from the grinding table enters the
separator at the bottom with the air stream. (Used in vertical roller mills)
Air stream is generated by external fan. Material enters the rotor in the air
stream via guide vanes. Fines are sucked in. Coarse particles are accelerated by the rotor and stopped by guide vanes, where they slip down and leave the casing at the bottom.
Fine material exits with the airflow at the
top of the casing .

Product fineness is adjustable by the
rotational speed of the rotor.

Pfeiffer RTKM Separator for coal mills
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Separator arrangements in grinding circuits

Single Pass design
1
Fresh-Air
Mainly used where high cooling is required
3 Product
4 2
Feed bins
2
3 4
HGRS
Mill with water injection

Separator with filter Mill dedusting filter
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Standard Arrangement 1st Generation Separator
4a 1 3
Product 2
1 2
Feed bins Mill with water injection
3
4
4a
Separator with filter

Mill dedusting filter Grit separator Optional cement cooler
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5
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Cyclone Air Separator
1 3
Product
4 2
Feed bins
2
3 4
HGRS
Mill with water injection

Separator with cyclone and dedusting filter Mill dedusting filter
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Potential Problems
Wear / Clogging
Wear Sealing not tight
Wear Wear Blades too short

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Potential Problems
Wear,clogging uneven feed distribution
Wear
Wear
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Potential Problems
Wear Sealing not tight
Wear
Guide vanes not
correctly adjusted
Wear Breakouts
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Potential Problems / clogging

Cage rotor separator casing
partly clogged guide vane system
Material deposits due to insufficient airflow or airflow distribution
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Reduced separation efficiency 1st and 2nd generation dynamic separators
Gap between internal fan and separating chamber bigger than 5 [mm]
Reduced number of counter blades
Gap between counter blades and wall of separating chamber bigger than 10 [mm]
Possible consequence: Desired fineness can not be achieved anymore

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Separating and Classifiers

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Grinding with ball mill systems

Separation in 3rd Generation Separator

Material enters the separator at

Air Guide vanes Air

Turning cage rotor

the lower/upper part of the casing

Air with fines

Product fineness is adjustable by

the rotational speed of rotor.

What is the separating efficiency dependent on?

Amount of feed Feed distribution Air:

Possible causes that limit the separating efficiency

Tromp curve key parameter

Tromp curve key parameter

A, F & R en [t/h] A=F+R Circulating load factor:

Separator performance (1/2)

Cement fineness [cm2/g]

Separator performance (2/2)

Circulating load factor u [-]

Lower air speed

Finer product Coarser product

Uneven airflow distribution

be identified from (1/2): Observation of the ducting configuration:

How to determine the airflow profile

be identified and evaluated from (2/2):

Solutions for even airflow profile

air guide plates

Symptoms of uneven material distribution

steel of the impact ring

fineness of the fines in a cyclone air separator

spite of low material specific loads

separator discharge to the separator feed point(s)

material load to all separator feeding points:

Adjust / install splitters Install mixing boxes Change airslides configuration

The fineness relationship mill filter / separator fines

If F finer than C check:

Separator operating point (1/2)

Iso - fineness line

Rotor speed [%] of nominal

Air [%] of nominal

Separator operating point (2/2)

Rotor speed [%] of nominal

Bypass 1 > Bypass 2 > Bypass 3

CONCLUSION is to operate the fan at 100%

Air [%] of nominal

Grinding with Ball Mill Systems

Separation by cutpoint of 3mm (e.g. by sieving)

The efficiency is very much dependent on the separator.

Basic working principles Separators

rotating device into the direction of the separator wall (Fz).

speed (consequence higher centrifugal forces) lead to different product fineness.

Main Separators used in Cement works

Dynamic separators 1st Generation

Dynamic separators 2nd Generation Dynamic separators 3rd Generation

Static separators and cyclones

in the air stream at the top.

A vortex is generated. A fine vortex with opposite

view from top

the immersion tube.

Static separators and cyclones

Cyclones of a cement mill separator

Static separator and cyclones

separator in air stream at the bottom.

top of the grit cone by the blades.