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Separating
Separating
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HGRS Tikaria_Mill Workshop SEPT-07
Separating process
FR Air
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HGRS Tikaria_Mill Workshop SEPT-07
Separation in 3rd Generation Separator
Basic function:
Material enters the separator at
Feed
Centrifugal Forces the top.
Air stream is generated by
external fan.
Material falls down between rotor
and guide vanes. Fines are
sucked in. Coarse particles are
Air accelerated by rotor and stopped
Guide vanes by guide vanes, where they slip
Air
down and leave the casing at the
bottom.
Turning cage rotor
Fine material exits with airflow at
the lower/upper part of the casing
Air: V
F
Volume (V [m3/h])
Distribution
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HGRS Tikaria_Mill Workshop SEPT-07
Possible causes that limit the separating efficiency
The typical situations for 3rd generation separators are:
Uneven airflow and/or feed distribution to the rotor
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HGRS Tikaria_Mill Workshop SEPT-07
Tromp curve key parameter
Tromp value [%]
100
Probability for a particle
to be in the return
Separator fines
Separator
return
The BYPASS is one of
the best indicator of the
separator efficiency
Bypass [m]
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HGRS Tikaria_Mill Workshop SEPT-07
Tromp curve key parameter
Tromp value [%] Coarse in fines
100
Agglomeration
Separator fines
Separator
return
Bypass [m]
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HGRS Tikaria_Mill Workshop SEPT-07
Amount of material
Circulating load:
A, F & R en [t/h]
A=F+R A
Circulating load factor:
A
u= [-]
F
V
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HGRS Tikaria_Mill Workshop SEPT-07
Separator performance (1/2)
6.0
5.5
High
5.0
4.5
Circulating load factor u [-]
4.0
Normal
3.5
3.0
2.5
2.0
Low
1.5
1.0
2'500 3'000 3'500 4'000 4'500 5'000 5'500 6'000
Cement fineness [cm2/g]
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HGRS Tikaria_Mill Workshop SEPT-07
Separator performance (2/2)
50
45
40
High potential
35
30
By pass [%]
Medium potential
25
20
15
10
5
Low potential
0
1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0
Circulating load factor u [-]
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HGRS Tikaria_Mill Workshop SEPT-07
Air volume
Separator specific feed load
A
Asl = X 1’000 [kg/m3]
V A
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HGRS Tikaria_Mill Workshop SEPT-07
Air distribution
FR Air
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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HGRS Tikaria_Mill Workshop SEPT-07
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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HGRS Tikaria_Mill Workshop SEPT-07
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
< 50 [mm]
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HGRS Tikaria_Mill Workshop SEPT-07
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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HGRS Tikaria_Mill Workshop SEPT-07
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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HGRS Tikaria_Mill Workshop SEPT-07
The fineness relationship mill filter / separator fines
MF
F
C
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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HGRS Tikaria_Mill Workshop SEPT-07
Separator operating point (1/2)
100
95
Iso - fineness line
90
85
Rotor speed [%] of nominal
80
3’500 [cm2/g]
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
95 Bypass 3
90
Bypass 2
85
Rotor speed [%] of nominal
By pass 1
80
75
70
55
50
CONCLUSION is to operate the fan at 100%
45
40
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
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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HGRS Tikaria_Mill Workshop SEPT-07
Separation efficiency
The efficiency of a separation device (e.g. mill
separator) is a measure of the proportion of un-
separated material following the separation process. It
indicates how much fines is in the coarse fraction
remaining and how much coarse is in the fines.
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HGRS Tikaria_Mill Workshop SEPT-07
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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HGRS Tikaria_Mill Workshop SEPT-07
Main Separators used in Cement works
Type Main features
Static separators and cyclones 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
Dynamic separators 2nd Generation Features as 1st Gen. / but external fans
and cyclones
Dynamic separators 3rd Generation Cage rotor instead of counter blades
and distributor plate (variable speed drive) / external fan / fineness
control by rotor speed change
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HGRS Tikaria_Mill Workshop SEPT-07
Static separators and cyclones
Cyclone Basic function:
fines
Material enters the cyclone
immersion tube
in the air stream at the top.
A vortex is generated.
feed
Cyclones of a
cement mill
separator
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HGRS Tikaria_Mill Workshop SEPT-07
Static separator and cyclones
fines Grit separator Basic function:
immersion tube
Material enters the
adjustable blades adjusting device separator in air stream at
the bottom.
A vortex is generated in the
top of the grit cone by the
blades.
Coarse material goes to the
housing cone walls because of centrifugal
tailings cone
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 33
HGRS Tikaria_Mill Workshop SEPT-07
Static separator and cyclones
Grit separator
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HGRS Tikaria_Mill Workshop SEPT-07
Static separator and cyclones
Basic function:
KHD V-separator
Material enters the
separator from the top
Air + Fines Coarse material slips down
from plate to plate and
Air
leaves at the bottom.
Fine material leaves the
separator at top together
with the air.
Plates
Returns 35
HGRS Tikaria_Mill Workshop SEPT-07
Dynamic separators 1st Generation
12 6
Basic function:
5
11 Material enters the
9
16
separator at the top.
10
8 7 4
Coarse material goes to the
1 walls because of centrifugal
forces generated by the
3
distributor plate and
15
2
counter blades, slips down
at the grit cone wall and
leaves at the bottom (13).
Sturtevant
Fine material exits at the
13
bottom of the casing (14).
14
Counter blades
External
adjustment of
fineness control
valve rods
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HGRS Tikaria_Mill Workshop SEPT-07
Dynamic separators 1st Generation
Polysius Turbopol
Air vanes Grit cone Distributor plate
Counter blades
Internal Fan
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HGRS Tikaria_Mill Workshop SEPT-07
Dynamic separators 1st Generation (Example: Pfeiffer Heyd)
Basic function:
8
Material enters the separator at
9 the top.
10
Fan Motor
Fan
Counter blades
Feed spout
Distributor plate
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HGRS Tikaria_Mill Workshop SEPT-07
Dynamic Separators of 2nd Generation
8 7
1 separation chamber
2 tailings cone
6 3 air vanes
4 distributor plate
5 counterblades
5
6 feed spout
11 11 7 gearbox
1 8 motor
14 9 fines outlet
4
10 tailings outlet
15 13 11 cyclones
3 12 air duct to fan
13 fan
14 dust collecting
9 9 pipe to filter
15 return air duct
2
Polysius Cyclopol
10 41
HGRS Tikaria_Mill Workshop SEPT-07
Dynamic Separators of 2nd Generation (Wedag)
to filter
fresh air
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HGRS Tikaria_Mill Workshop SEPT-07
Dynamic Separators of 2nd Generation
Basic function:
Material enters the separator at the top.
Counter blades
Distributor plate
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HGRS Tikaria_Mill Workshop SEPT-07
Separators of 3rd Generation
Basic function:
Feed Material enters the separator at
Centrifugal Forces
the top.
Air stream is generated by
external fan.
Material falls down between rotor
and guide vanes. Fines are
sucked in. Coarse particles are
Air
accelerated by rotor and stopped
Guide vanes Air by guide vanes, where they slip
down and leave the casing at the
Turning cage rotor
bottom.
Fine material exits with airflow at
the lower/upper part of the casing
Cage rotor
Bars
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HGRS Tikaria_Mill Workshop SEPT-07
Separators of 3rd Generation
11
5 3
1 2
4
9
6
7
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HGRS Tikaria_Mill Workshop SEPT-07
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 .
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 51
HGRS Tikaria_Mill Workshop SEPT-07
Separators of 3rd Generation (Polysius Sepol SM)
Basic function:
Rotor drive Material enters the separator at
the bottom with the air stream
(e.g. air swept mill)
Fines with air
Air stream is generated by an
external fan.
Material enters the rotor in the air
Rotor
stream via guide vanes. Fines are
Guide vanes sucked in. Coarse particles are
accelerated by the rotor and
stopped by guide vanes, where
they slip down and leave the
Inspection doors casing at the bottom.
Fine material exits with the airflow
Returns
at the top of the casing .
Product fineness is adjustable by
Airflow with material from mill the rotational speed of the rotor. 52
HGRS Tikaria_Mill Workshop SEPT-07
Separators of 3rd Generation (KHD Sepmaster)
Sepmaster SKS-D (for RP* circuits) Sepmaster SKS-LS (for ASM**)
feed material feed material
desagglomerator
rotor air+fines air+fines
impact ring
air and fine
product
coarse fraction 2
coarse fraction 1
feed material+air
1 guide vanes
2 rotor blades
3 distributor plate
4
4 rotor shaft
7 6 3
5 feed spout
2
6 sealing
11 10
8 54
HGRS Tikaria_Mill Workshop SEPT-07
Separators of 3rd Generation (KHD Sepmaster)
Basic function:
Material enters the separator at the top.
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.
Reject cone
Cage rotor
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HGRS Tikaria_Mill Workshop SEPT-07
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.
1 Fresh-Air
high cooling is
Product
required
1 Feed bins
2 Mill with water injection
3 Separator with filter
4 Mill dedusting filter 60
HGRS Tikaria_Mill Workshop SEPT-07
Separator arrangements in grinding circuits
Standard Arrangement 1st Generation Separator
4a 4
1
3
Product
2
1 Feed bins
2 Mill with water injection
3 Separator with filter
4 Mill dedusting filter
4a Grit separator
5 Optional cement cooler 61
HGRS Tikaria_Mill Workshop SEPT-07
Separator arrangements in grinding circuits
Product
1 Feed bins
2 Mill with water injection
3 Separator with cyclone and dedusting filter
4 Mill dedusting filter 62
HGRS Tikaria_Mill Workshop SEPT-07
Potential Problems
Wear /
Clogging
Wear
Wear
Wear
Wear
Wear
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HGRS Tikaria_Mill Workshop SEPT-07
Potential Problems
Wear
Wear
Breakouts
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HGRS Tikaria_Mill Workshop SEPT-07
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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HGRS Tikaria_Mill Workshop SEPT-07
Reduced separation efficiency 1st and 2nd generation dynamic separators
Reduced number of
counter blades