Air separator

BALL MILL - Operating Principle

IMPACT
ATTRITION
Two Piece Rocker Arm
P
Permits
it E
Easy
Roller Swing-out

Rocker Arm
Upper Part
R k A
Rocker Arm
Fork
 Open
p Circuit cement mill
Dust filter

Fan

Dust return Motor

Water Spray
Feed

Gearbox
Feeder Mill Tube
Discharge system To storage
Closed Circuit cement mill Separator
Mill product
Fan Dust filter elevator

Rejects airslide Fi
Fines
Dust return

Feed
To storage

Feeder Mill Tube

Water
S
Spray Discharge Airslide
 Bag Filter Bag Filter

Static Sep
O-SEPA

p.
FRESH FEED

MILL
 Air Separators
p
• All dry powder separators use air to separate
coarse and fine particles ,
• There are different designs for separators.
• Qfeed / Qair (Qf /Qa) is an important principle
for all separators,
• Qf / Qa is the ratio of separator feed to the
total internal airflow used.
• The ratio is expressed in kg of feed per m³ of
air.
• On high efficiency separators the design
value is about 2.0-2.5 kg/m³

7
 Air separators
• It has
h no grinding
i di ffunction
ti but
b t increases
i th
the mills
ill
efficiency
• Optimizes
O ti i th recuperation
the ti off fines
fi
• Determines the maximum particle size of the
finished product
• It decreases the retention time in the mill reducing
coating and excessive temperatures
• It plays an essential role in the functioning of the
grinding shop
 Separators
Evaluating the performance of a separator?
• The tromp curve
It is a curve showing the probability for a particle
of size x to go into the rejects,
– Bypass
yp : the minimum p probability
y for the fines
to be sent back to the mill,
– Acuity limit : is the limit beyond which the separator
cannot see a difference between particle size size,
– Imperfection: it varies like the inverse of the slope,
the lower the imperfection, the better the separation.

9
 The Tromp curve
(on logarithmic paper)
Example Tromp Curve (Sturtevant)

100

99
obability, P(x)

93

69
50 Bypass
yp = 56%
Pro

30

6 Acuity
y Limit = 25 µ
µm

1 1 100 1000
0 0
Particle Size,
Size µm,
µm (x)

10
 The Tromp curve
Example Tromp Curve (Sturtevant, O’SEPA)
100

99
P(x)

93
obability, P

69
50
Pro

30 B
Bypass = 56% / 8%

6
A it Li
Acuity Limit
it = 25 µm / 11µm
11
0
1 10 100 1000
Particle Size,, µm,
µ , (x)
( )

11
 100

n%
Interpretations

of Rejection
Poor
Mechanical
Shape
100 50

Probability o
Rejection %

Indicates
agglomeration Good
(grinding aid Mechanical
problem)
bability of R

P
Sh
Shape
50 0
1 10 45 100
Particle size , μm (log scale)
100
Prob

Rejection %
0 Overfed
1 10 45 100 Probability of R
Particle size , μm (log scale) 50
Normal

0
1 10 45 100
Particle size , μm (log scale)

12
 Attention
• Before optimizing the process,
process it is necessary to
check separators and fans for proper
mechanical conditions
– no inleakage or false air flow (Bangladesh)
– no excessive wear
– no material short cuts
– proper
p p seals
– well adjusted pendulum valves ( false air )
– air flow measurement with corresponding results
compared to designed volumes Qf / Qa
– properly working automated control of fresh air inlet valves

13
separating action can be done by means of the three separator criteria:
Th circulating
The i l i lload d is
i the
h percentage off coarse return in i relation
l i to fines.
fi
The separator efficiency is applied to a determined grain size.
Tromp-curve shows for each grain size of the separator feed to which
portion the particles of this size are in the fine fraction or in the coarse
fraction.

. To get the basic figures for these calculations a separator test must be
carried as follows :
Recording of separator data
(e.g. adjustment of separator, mechanical condition etc.)
• -Sieve analysis of the samples
• -Measuring
Measuring of quantity (either feed,
feed coarse fraction or fine fraction)
Evaluation of test
i.e. calculation of circulating load, efficiency and Tromp-values is carried out
b means off th
by the sieve
i analysis
l i and d th
the quantity
tit
. The results can then be compared with ideal values or other grinding
installations of the same type and if necessary the separator can be
adjusted accordingly.
 Air Separators
• Static separators
• Dynamic separators
– First
Fi t generation
ti
• single shaft
• d bl shaft
double h ft
– Second generation
• with external dust separation in cyclones or
dust collectors
– Third
Thi d generation
ti
• high efficiency separators
15
 Static Separators:
Principle cyclonic action
Fines
Adjusta
bl
ble
Fresh air vanes
• feed is air swept, bleed valve

• cyclonic action controlled by guide

vanes
vanes, Thimble

Inner
• high internal velocity important for Cone

good efficiency, Outer

Cone
Rejects
• NCC Exmp.

Feed (mill sweep)

 Static separators: Principle
Fine particles + air

Adjustable vanes

Selection by
centrifugation

Pre selection zone

for the elimination of
coarse particles
ti l
Rejects

Rejects Feed d
Particles
and Air

17
 Static separators
T be
To b used
d

• In air swept ball mills

– mainly
i l coall and
d raw mix
i
• In mill ventilation circuits
– to pre select fine particles directly sent to the
finished product

18
 Static separators
O
Operation
ti

The effect of the separation depends on

– the air volume ( Mill fan)
fan).
– the feed rate
– the adjustment of the vanes

19
 Dynamic Separators:
Principle
p First Generation
• Particle
classification byy
air flow using:
Drag force

– Centrifugal force Centrifugal forceA

– Drag
D fforce l
Gravity
– Gravity force

Material cloud

20
 Dynamic
y Separators
p
First Generation, single shaft
Material Feed
Parameters •
– for a circulating load:
100 - 300 %
– Then
• Bypass:
30-60%
• Imperfection:
> 0,45
• Acuity
A i lilimit:
i >
20 μm
Rejects

21 Fines
 Dynamic
y Separators
p -
First Generation, single shaft
Center feed

Motor shaft Selector blades

Fan blades
Diaphragm’s
command
Selector blades

Distribution table

Entrance for A
recirculation air Air flow

Rejects’ cone Fines’ cone

22
 Conventional Main fan
air
i separator
Auxiliary blades

Feed

Distribution plate

Rejects Finished Product

 Dynamic Separator
First Generation
Generation, single shaft
Mechanical considerations
• Tightness of feeding system , cone, selection
table
• Wear and adjustment of selector blades
–pprofile of selector blades,, p
position
– distance between blades and diaphragm
• Wear of fan blades
• Diaphragm condition

24
 Dynamic Separators -
First Generation,
Generation single shaft
Main applications
• raw material
• coarse products
• the p
production in a sequence
q of
cements with very different fineness is
very limited by the way the fineness is
controlled
25
 Dynamic
D namic Separators -
First Generation
Generation, single shaft
• Main parameters while operating
– diaphragm (adj
(adjustable
stable flap)
– adapt the circulating load through the feed rate or the
elevator power
• Separator adjustments
– work with the diaphragm as open as possible
– increase the separator speed to increase the air flow
provided kW are available
– increase the number of blades (selector or main fan)
– clean the return air vanes

26
 Dynamic Separators -
First Generation, single shaft
• Separator modifications
– to improve the flow of air
• open the return air vanes to improve the circulation of the air
• reinforce or replace the internal fan with external cyclones,
filters and fans
– to improve the material dispersion
• install a 3 table distribution system or change size of
distribution table
– to improve the separation
• install a basket type separation wheel

27
 Dynamic Separators -
First Generation, Double shaft

Fixed speed for Variable speed for

main fan separator wheel

Feed

Rejects
j Fines

28
 Dynamic Separators -
First Generation, Double shaft
• This type of separator works similarly to a
single
g shaft separator
p
• The added advantage of a double shaft
separator is that the speed of the selector
blades can be adjusted independently of
the main fan

29
 Dynamic Separators -
First Generation, Double shaft
• Separator adjustments
– increase the speed of the main fan
– adjust the size of the selector blades or
i t ll a cage ttype selector
install l t
– increase the dispersion
p area by y
distributing the feed on several plates
– look after the recirculation zone and
clean it, to facilitate the air flow

30
 Separator adjustments
and their effects
SEPARATOR Resulting Change of Variable

Change of Parameter Fines Fineness

By pass
output
MAIN FAN
More Blades or longer blades

Fewer Blades or smaller blades

Higher Speed

SELECTOR BLADES
More Blades *

F
Fewer Blades
Bl d *

Higher Speed if double shaft

* Main
Factor
31
 Separator adjustments
and their effects
SEPARATOR Resulting Change of Variable

Change of Parameter Fines Fineness

By pass
output

MAIN FAN
More Blades or longer blades

Fewer Blades or smaller blades

Higher Speed

SELECTOR BLADES

More Blades * *

F
Fewer Blades*
Bl d * *

Higher Speed if double shaft

* Main Factor

32
 Separator adjustments
and their effects
SEPARATOR Resulting Change of Variable

Change of Parameter By pass Fines

Fineness
output

DIAPHRAGM *
% Opening

SEPARATOR FEED RATE

FINENESS of the
SEPARATOR FEED

* Main Factor

33
 Separator adjustments
and their effects
SEPARATOR Resulting Change of Variable

Change of Parameter By pass Fines

Fineness
output

DIAPHRAGM * *
% Opening

SEPARATOR FEED RATE An optimum has

to be found

FINENESS of the
SEPARATOR FEED
* Main Factor

34
 Dynamic Separators -
Second Generation
Feed
• Parameters
– for a circulating
load: 100 - 300 %
then: Exhaust
– bypass: 10-35 %
– imperfection: 0.30
0.30-
0.40 Fresh air
– acuityy limit: 15-20
µm
Fines
Rejects
35
 Dynamic Separators -
Second Generation
Fresh air
Feed
Exhaust

Cyclone

Di t ib ti ttable
Distribution bl

Recycling fan
Fines

Return air vanes

= air flow
Rejects

36
 Dynamic Separators -
Second Generation
• Main
M i operating
ti parameters
t
–fresh air inlet damper control
–speed of the selector plates

Remark: the air flow is in most cases adjusted to the

maximum (5-10
(5 10 m/s in the free cross section)

37
 Dynamic Separators -
Second Generation
• Separator
S t modifications
difi ti
– installation of high efficiency cyclones to
minimize the dust in separator air
– replacing
ep ac g tthee sepa
separation
at o wheelee with
t a
basket type rotor

38
 Dynamic Separators -
Third Generation Fines

• Parameters Material Feed

For : Secondary
Air
– circulating load:
100 - 300 %
then:
– bypass: Primary
Air
– 5-10 %
– imperfection:
– < 0.30
– acuity limit:
– < 15 µµm Rejects
j

39
 Dynamic Separators -
Third Generation
O’SEPA Details Feed Classification Zone

Feed
Cage rotation

Primary
Air Uniform
Inlet Flow distribution

Loovers guide vanes

40
 Dynamic Separators -
Third Generation
• Separator adjustments
– louver adjustment
• Main operating parameters
– cage speed
– adjustment of the circulating load
– the temperature of the air at the inlet or at the outlet
can be adjusted for cooling or drying purposes

Note: air volume should be adjusted

j to maximum
&Blaine control through cage speed

41
 Dynamic Separators -
Third Generation
• Separator modifications
– in order to improve ...
• distance between rotor and louvers,
• optimization
i i i off airi di
distribution
ib i iin the
h
separation zone modifying spiral casing.

42
 Separator adjustments
and their effects

Resulting Change of Variable

Change of Parameter By pass Fines Fineness

Output

ROTOR SPEED

AIR FLOW

43
 Separator adjustments
and their effects

Resulting Change of Variable

Change of Parameter By pass Fines Fineness

Output

ROTOR SPEED

AIR FLOW

44
Summary
• T
Typical
i l performances
f in
i case off circulating
i l ti lload
d
from 100 % to 300 %
1st generation 2nd generation 3rd generation

Bypass (%) 30-60 10-35 5-10

Acuity limit (µm) > 20 15-20 < 15
Imperfection
p > 0,45
, 0,30-0,40
, , < 0,30
,

The quality of separation requires sufficient

ventilation
45