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What is separating?
Splitting a given material by particle diameter Balls with 2, 4 and 10 mm diameter
> 3 mm
< 3 mm
Separating Force
Gravity Centrifugal force Aerodynamic Drag Collision Force
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.
The efficiency is very much dependent on the separator. Modern cage rotor separators show a far better efficiency than older static and dynamic 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.
Tikaria_Mill Workshop
Tikaria_Mill Workshop
Cyclone Separator
fines
Basic function:
Material enters the cyclone in the air stream at the top.
immersion tube
A vortex is generated. A fine vortex with opposite turning direction is generated at the bottom and carries the fine material back to the top. Coarse material goes to the walls because of centrifugal forces, slips down and leaves at the bottom. Fine material exits at top via the immersion tube.
feed
cylindrical part
conical part
tailings
Static Separator
fines
immersion tube adjustable blades adjusting device
Basic function:
Material enters the 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 walls because of centrifugal forces, slips down and leaves at the bottom. Fine material exits at the top via the immersion tube. Product fineness is adjustable by changing the blade position.
rad.pos.
tailings
feed
Grit Separator
V Separator
Basic function:
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. Separation zone is the area between the plates and the series of baffles Fineness control by air velocity
Airflow
2
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 fan shaft fan blades feed spout tailings outlet fines outlet
counter blades
Product fineness is adjustable usually by rotational speed of the plate and counter blades (6+7).
Fan Motor
Distributor plate
5 11
9 2
Polysius Cyclopol
10
to filter
Air flow direction
fresh air
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.
Counter blades
Distributor plate
Operation philosophy
Swirling action induced in material stream The sweeping action of rotor blades creates an outward centrifugal force controlled by speed of rotor) and obstacle in path of material flow Direct impingement on blade imparts tangential velocity of blade to particle and throws them out of stream Coarse particles which are not able to remain airborne fall in the general direction of outer wall or drop out cone. Inefficiency occurs when particles rejected by the rotor are directed back to grinding table but re-entrained by gas stream Coarse particles can block the path of fine particles and cause overgriniding of fines and due to agglomeration of fines on coarse .
Air
Guide vanes Turning cage rotor Air
Returns
Bars
Operation of HES
http://www.sturtevantinc.com/air-classifiers.php The separator feed is directed into a rotating dispersion plate, located at top of cage rotor. The material starts a spiral movement due to spin of plate and high velocity swirl of air leaving the guide vanes. Material distributed between the guide vanes and the rotor and forms a thin cylindrical curtain in the annular gap classifying zone. Air carries the material around at the rotational speed of the rotor The radial drag force is trying to pull the material inside the rotor. The centrifugal force is tying to push the material towards the guide vanes. Gravity is pulling the material down.
Adjustment of Fineness
Independent adjustment of separating forces- centrifugal force and aerodynamic drag force which act in a plane perpendicular to gravity force Rotor speed Increasing speed increases centrifugal force. The centrifugal force is responsible for sorting out the coarser particles and is proportional to the cube of diameter Only ultrafine particles with high surface area (blaine value) will end up as product. Air flow Increasing air flow increases aerodynamic drag The air stream is able to carry larger particles through the separation zone than before and the fineness of final product will decrease. Since drag is proportional to square of diameter, larger particles are not affected much- hence blaine may not be disturbed, but % retained on 45 microns will increase.
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
Basic function:
Airstream is generated by external fan. Material falls down between the 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.
Prim. air
Tert. air
Fines
Coarses
Centrifugal force
Fine material exits with the airflow at the upper part of the casing .
Product fineness is adjustable by the rotational speed of the rotor.
Gravity force
Material enters the separator at the top. Airstream is generated by an external fan.
air guide vanes
fines coarses
Material falls down between the 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 airflow at the lower part of the casing . Product fineness is adjustable by the rotational speed of the rotor.
tailings outlet
shaft
Material enters the separator at the bottom with the air stream (e.g. air swept mill) Air stream is generated by an external fan.
Rotor
Material enters the rotor in the air stream via guide vanes. 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
air+fines
air+fines
coarse fraction 2
* Roller Press
11
10 8
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.
Tikaria_Mill Workshop
Air inlet
Material falls down between the 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.
Rotor Returns
Basic function: Material enters the separator at the bottom with the air stream.
Separator drive
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, leave the grit cone at the bottom and fall back on to the grinding table.
Returns flow
Fine material exits with the airflow at the top of the casing .
The product fineness is adjustable by rotational speed of the rotor.
Cage rotor
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
Contamination of the fines by coarse product Separator fines much finer than final product
Air distribution
FR
Air
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
Tikaria_Mill Workshop
Tikaria_Mill Workshop
Too short Good Laminar and even flow across whole duct section
Feed distribution
< 50 [mm]
Solutions evaluation
Even as much as possible material load to all separator feeding points: Adjust / install splitters Install mixing boxes Change airslides configuration