AIR SEPERATION

TECHNOLOGIES USED IN
CEMENT INDUSTRY
AIR SEPARATION TECHNOLOGIES USED IN
CEMENT INDUSTRY
GENERAL
- DEFINITION OF AIR SEPARATION FORCES INVOLVED

SEPARATOR TYPES USED IN CEMENT INDUSTRY

* STATIC SEPARATORS
- CONE TYPE SEPARATORS
- V-TYPE SEPARATORS
* DYNAMIC SEPARATORS
- FIRST GENERATION SEPARATORS
- SECOND GENERATION SEPARATORS
- THIRD GENERATION ( HIGH EFFICIENCY ) SEPARATORS

A TOOL TO EVALUATE SEPARATOR PERFORMANCE TROMP CURVE

RELATIONS BETWEEN OPERATING VARIABLES AND PERFORMANCE CRITERIA OF SEPARATORS

QUALITY ASPECT OF CEMENT IN RELATION TO SEPARATION

LATEST DEVELOPMENTS IN AIR SEPARATION TECHNOLOGIES

DISCUSSIONS
 SEPARATION

Separation is a method to differentiate particles according to their size

exploiting the fact that different particles can obtain different velocities when
moving in a fluid under a certain force.

Air separation is the method of separating dry particulate materials into two
distinct size fractions, one above and the other below a defined cut-point
which normally range from 1 micron to 300 micron. It has a widespread use
in many industries such as cement, coal, ceramic, pulp and paper, fertiliser
and pharmaceutics.

The most important application of air separators is to reduce overgrinding in

a mill by separating the mill output into coarse and fine fractions, so that
fines can be removed as soon as they are produced and the coarse returned
for further grinding. It can be used also to produce products to meet higher
requirements by having for instance a more suitable particle size
distribution. In many applications it is used to enhance the operation of
some other process.

No single design of air separator is capable of satisfying the diverse range of

requirements of the many process which air separation can be applied. In
this relation a number of different types of separators have been developed
to meet special industrial requirements.
FORCES ACTING ON PARTICLES

First Generation Second Generation Third Generation

D BLADE
C D
R
R ROD
G

C
R D I
(?)
(Impact)
I
C
G
Low Energy
(displacement of material)

High Energy
G
(uplift of material)
Intermediate Energy
(uplift of material)
Forces acting;

Gravitation: G m.g. m: particle mass

D c.a. .
u v 2 g: acceleration due to gravity
: particle-air density difference
Drag Force: 2 c: drag coefficient
a: projected particle area

where c f d p u v u: air velocity

v: particle velocity
: air viscosity
2
mv f: function
Centrifugal Force: C
r dp: particle diameter
dr: rod diameter

dp 1
Impact Force (efficiency of capture): E 1
d r dp
1
d r

 STATIC SEPARATORS
VANE TYPE SEPARATORS
Principle: Static separators have no moving
parts and separation is executed by chances in air
velocity and direction. As seen in figure 1, the air
stream carrying particles is converted from a
directional flow through the outer cone into a
rotating flow by guide vanes. The particles are
subject to centrifugal force, the coarse particles
move to the outer wall of the inner cone and spiral
down it to enter the reject stream and the fine
particles move into an upward spiral in the center
of the cone and are carried away. The effect of
separation depends on the air volume, the feed
rate and the adjustment of the vane angles. As air
volume increases i.e.increase in air
velocity,centrifugal force increases and separation
becomes more efficient. The product size can
roughly be adjusted by changing the angle of the
vanes. When closing the vanes, finer particles will
be selected and the product becomes finer. The
limit to the closing of the vanes is the level of
pressure drop one can tolerate in the separator.

Static separators are mostly used in mill

ventilation circuits. The particles that are being
transported can be too coarse to be added to the
finished product. These separators can remove the
coarser fraction that goes back to the mill for
regrinding, while the finer fraction is added to the
finished product.
 V-SEPARATOR
Principle: This separator was developed to be
used in combination with high pressure grinding rolls.
The cake produced by the grinding rolls required
deagglomeration before separation into the coarse and
fine particles. The V-Separator was designed to do both
duties.

As seen in the Figure , the feed is directed down through

baffles to meet the rising air flow. The weak compacts
are broken as they collide with the baffles and the fine
and coarse particles are liberated. The coarse particles
can not be carried by the air flow and slide down to go
back to the grinding rolls. The fine particles are entrained
in the air and swept upwards through a further set of
baffles. The V-Separator fines normally have Blaine
surfaces around 1800 cm2/g, and this pre-classified
material goes into a high efficiency separator closed
circuited with a ball mill.

The separation size is adjusted by changing the air flow

rate. Like the static cone separator it is inexpensive; has
a low energy consumption and is reasonably efficient at
coarse sizes even with high solid to air ratios up to 4
kg/m3.
 DYNAMIC SEPARATORS

Air separation became important in the latter part of 19th century when tube mills were
developed to produce large volumes of portland cement which had become a
significant building material. The grinding process highlighted the need for efficient
separation of fine particles from mill discharge and static separators proved to be
inadequate. Askham air separator was patented for this duty by Mumford and Moodie in
1985 which was the basis of the first generation of dynamic separators.

Common characteristics of dynamic air separators are ;

- internal rotors that are also feed distribution plates,
- airflows generated by internal or external fans,
- collision plates that assist rejection of coarse particles ,

First generation dynamic separators and their evolution during 120 years into second
and third generation separators that improve rejection of coarse particles and minimise
by-pass will now be discussed.
FIRST GENERATION DYNAMIC SEPARATORS

Dynamic separators started with the Askham air separator in 1885. These type of separators
became known as the first generation separators. The Sturtevant Whirlwind separator
shown in the following Figure was a popular first generation separator which consists of a
funnel-shaped casing, within which is a second funnel with an annular space between the
two. The separation is affected by a current of air which is produced by a fan revolving in
the upper part of the casing. The material is fed on to a spinning distribution plate and
dispersed into an air stream created by a circulating fan. The spinning plate imparts a
centrifugal force to throw particles in the separation zone. Large particles drop out in the
inner cone and leave the apparatus. The current induced by the fan passes upwards and
outwards between the fan blades carrying with it the finer particles which are thrown into
the outer casing. The air carrying fines returns to the fan inlet via return air vanes because
of change in air direction and velocity, and the fines is discharged through the fines chute.

A problem with the first generation of air separators is that no external air is added and the
circulating air becomes very hot ( >120 degrees C ). This has an adverse effect on the
gypsum in finished cement so that these units are more appropriate on mills grinding raw
materials than clinker.

..........
 The main advantages of the first generation classifiers were reasonable
classification of very fine products on an industrial scale which had not previously
been possible and relatively low capital cost.

The main problems were

- fine particles were not removed from the recycling air effectively and they
accumulated in the coarse product leading to a high recycle of finished product to
the mill,
- the circulating air became very hot (>120 degrees C). This was unsuitable for cement
clinker circuits in which the gypsum could be affected and first generation units
have been preferred for circuits grinding raw materials for processing in the kiln,
- the sizing distribution and surface area of the fine product were difficult to change
although this problem was reduced when the auxiliary fan with the separate variable
speed drive was used,
- the distribution of feed on the disk and dispersion in the air were uneven and this
exacerbated the problem of high recycle.

For nearly 80 years classifiers of this type were used in cement plants and many are
still used today. The demand for cement increased rapidly in the 1950s and there
was also a continuing need to improve cement quality, which meant closer control
of size distribution. The deficiencies of the first generation air classifier had to be
corrected and attemps to do this resulted in the design of the second generation of
dynamic classifiers.
STERTEWANT FIRST GENERATION DYNAMIC
SEPARATOR
 SECOND GENERATION DYNAMIC
SEPARATORS

First generation separators suffered from high by-pass and difficulty in changing the particle size
distribution and surface area of the fine product and in the 1950s these problems were outweighing
the advantage of relatively low cost. One solution was to remove the fines from the circulating air and
this led to a second generation separator becoming available in 1960 whose main features were
- an external fan to circulate the air which replaced the internal fan,
- several external planetary cyclones which replaced the fines cone,
- independent control of separator speed and air circulation.

The air containing the fines went from classifier to the cyclone where the solids were removed through
the apex, and then to the fan which recycled it back to the separator. The separation is based on the
same principle as the first generation separators. The main advantages of the second generation
separators were better removal of fines, sharper separation, lower by-pass and continious control of
the fineness. The main disadvantage was their large size. The problems were incomplete dispersion
of the feed and removal of the fines from the recycling air which was still incomplete, and a rather
erratic cut size. For some years after they came on the market they were preferred to the first
generation units when new circuits were being installed but they had a relatively short life because of
their size and they were replaced by the third generation separators.
SECOND GENERATION SEPARATOR
SECOND GENERATION SEPARATOR
 SECOND GENERATION DYNAMIC
SEPARATORS
Operation principle: Same principle as in first generation separators

Main Features: - an external fan to circulate the air which replaced the internal fan
- several external planetary cyclones which replaced the fines cone
- independent control of the separator speed and air circulation

Advantages: - more efficient separation of fines in cyclones, higher efficiency

- independent adjustment of separator speed and air circulation gives a larger
regulation range and better efficiency with fine separation because of more
circulating air
- adjustment of fineness without stopping the separator
- material cooling by adjustment of fresh air inlet damper

Disadvantages: - incomplete dispersion of feed

- a rather erratic cut size
THIRD GENERATION DYNAMIC SEPARATORS
By the 1970s a new dynamic separator, third generation type, was being designed with the objectives
of decreasing by-pass, and giving a better precision of separation and decreasing cut size. The O-
SEPA separator installed in a plant in 1979 was the first of the third generation of air separators. Some
improvements were

- the air entered the classifier horizontally and had a uniform velocity across the flow,
- the distribution plate was at the top of the air flow and the feed fell as a completely dispersed curtain
of particles,
- particles passed through a rotating cage before entering the fine stream, and the collision of the
particles with the bars of the cage assisted in rejecting the coarser particles from the flowing air,
- the product size could be adjusted on-line by changing the rotor speed,
- the dust laden air from the mill was used as classifying air without impairing the classification
efficiency because the air left the separator and the fines were removed before it was recycled.

In operation the air passes through the stationary guide vanes and the feed material is dispersed in
the annular gap between these and the rotor. After passing through the vanes the air moves in a
horizontal vortex. The air carries the fine material tangentially across the face of the rotor that is
turning in the same direction as the vortex. The coarse particles are separated by a combination of
gravity, centrifugal and impact forces and fall into the collecting cone at the base. The fine particles
are conveyed to a dust collector. The sharp classification and low by-pass reduced the circulating load
in tube mill-separator circuits and allowed an increase in feed rate by 20-40%. The specific energy
consumption was reduced by 15-35%.
 PRINCIPLE OF OPERATION
Material is first dispersed on the distribution table and falls down into the gap between
the cage and the guide vanes forming a thin curtain of material. After passing through
the vanes the air moves in a horizontal vortex. The air carries the fine material
tangentially across the face of the rotor that is turning in the same direction as the
vortex. The coarse particles are separated by a combination of gravity, centrifugal and
impact forces and fall into the collecting cone at the base. The fine particles are
conveyed to a dust collector. The sharp classification and low by-pass reduced the
circulating load in tube mill-separator circuits and allowed an increase in feed rate by
20-40%. The specific energy consumption was reduced by 15-35%. Large air flows are
very important for good efficiency. Qf/Qa ratio of such separators is around 2 kg/m3 up
to 2,5 kg/m3, provided the fines are always lower than 1 kg/m3.
THIRD GENERATION DYNAMIC SEPARATOR
 FINENESS CONTROL IN HES

Fineness Control: The fineness of the product can be controlled in three ways.

- by varying the volume (velocity) of the air flowing through the separator. As the volume is increased
the product becomes coarser.

- by changing the speed of cage rotor. As the speed is increased fineness increases.

- by changing the annular setting of the guide vanes. A setting towards the redial position will give a
coarser product, whilst finer product will be obtained by going to as near tangential setting as
required.

It is readily seen that the product fineness control is much easier with the HES than the other types. By
playing with the first two variables it can be made without stopping of the grinding circuit and from
the control room.
 USE OF HES
The use of HES become widespread as these units offer several combined advantages which can be given as;

mill system production increase of 20-40% for existing ball mills or a propertional reduction in the size of
new mills producing ordinary cement.

specific power reduction of 15 to 35% in the grinding department.

lower cement temperature, which minimises or eliminates mill internal coating and the tendency for false
or pack set in the cement.

simple separator rotor speed control of product fineness making it no longer necessary to stop the mill to
make separator adjustments when changing the product fineness. The amount of fringe cement is much
less.

smaller relative separator size and ability to accept dusty process air which reduces the amount of
auxiliary equipment and power consumption, thereby classifying all cement through one machine for more
uniform physical properties.

ability to have better control of cement strength, and to enhance characteristics such as coarse particle
residue. Variations of these characteristics are minimised resulting in higher confidence in cement quality.

ability to make special cement products that were previously very difficult, such as coarse oil well and fine
masonry blends.

the investment payback period is sufficiently low for cement manufacture

 A TOOL TO EVALUATE SEPARATOR
PERFORMANCE - TROMP CURVE
There are various methods of defining the separation efficiency. However it has long been realised that the best and
most common method is to use the Tromp Curve which is a graph showing the proportion of feed fractions which will
pass into the tailings and go back to the mill on the ordinatehaving a linear scale, and the mean size of the fractions
on the abscissa having logarithmic scale.

Table x gives the data taken from an actual plant. Weight percentage of three different streams are given for each size
fractions concerned. For each individual particle size of the separator feed the curve indicates the weight percentage
which goes into the finished product and into the rejects. With experience and a good data base one can analyze a
tromp curve and deduce valuable information about the separator and the circuit from the curve characteristics
which are:

Cut point: The cut point d50 corresponds to 50% of the feed passing to the coarse stream. It is therefore the size
which has equal probability of passing to either coarse or fine streams.

Sharpness: The sharpness of separation is defined as d75/d25, where d75 and d25 denote the sizes with Tromp
values of 75% and 25%. For an ideal separation this would be 1.

Imperfection: The imperfection of separation is usually defined as I=[ d75-d25 ] / 2d50. The lower the imperfection the
better the separation.

By-Pass: The percentage of the lowest point on the tromp curve is referred as the by-pass. It indicates a portion of
each size fraction which bypasses the classifying action. Expressed in an other way, it is part of the feed which
passes to the coarse stream without being classified. Experience has shown that the by-pass parameter variea with
classifier feed rate , and hence it is difficult to describe a single Tromp curve which is representative of the classifier.

Fish Hook: It is the portion of fines returning back into rejects. In certain separators, mainly in those having rotating
vanes, the fine particle stream from a primary classification is met by a circulating air stream containing still finer
particles which recoat the separated particles causing them to behave as coarse particles. This secondary action
leads to a fish-hook pattern of Tromp curve. A similar effect can be seen in separators in which there is incomplete
feed dispersion at the separator entry, or even within the classification zone, whereby aggregates of fine particles
may be classified as coarse particles and thus report to the coarse stream. If during the size analysis, these
aggregates are dispersed, the analysis give more fines than the separator did.
 MADDE DENKLNN HESAPLANMASI
F=U+O
F . f = U . u + O . o

F : Separatr beslemesi tonaj O, o

U: Separatr iri rn tonaj
O: Separatr ince rn tonaj
F, f
f, u, o : Srasyla separatr beslemesi, irileri ve incelerinin
ilgili boyut fraksiyonundaki % miktarlardir.

U=FO
F . f = (F O) . u + O . o

F . f = F . u O. u + O . o

F . f F . u = O . o O. u

F.( f u) = O . (o u) U, u

O fi ui

F oi ui
MADDE DENKLNN K TEMEL AAMASI

I. Ham verileri kullanarak O/Fnin en iyi tahmini deerinin hesaplanmas

O (o i u i )(f i u i )

F (o i u i ) 2

II. Belirlenen O/F deerini kullanarak analiz deerlerinin dzeltilmesi

O
u i O oi
^
f f i fi 1
2 F F
^
o o ^ ^ ^
2
f , o ve u dzeltilmi analiz deerleridir.
^
u u
2
 Separatr Ham Verileri
Besleme Separatr irisi Separatr incesi
Tonaj (ton/saat) 530
Tane Boyu (m)
0.177 0.00 0.00 0.00
0.125 5.68 7.78 0.04
0.088 12.19 16.52 0.47
0.063 19.90 26.15 2.98
0.044 19.47 29.10 9.64
0.031 12.38 11.18 15.64
0.022 8.30 4.68 18.11
0.016 4.48 1.78 11.98
-0.016 17.60 2.81 41.14
Toplam 100.00 100.00 100.00
 Herhangi tane boyu iin rnek hesaplama (O/F: 1066.37/3006.54=0.3547 0.3547530=187.98)
Tane Boyu (m) oi-ui fi-ui (oi-ui)( fi-ui) (oi-ui)2 i
5.68-(1-0.3547) 7.78-
0.125 0.04-7.78=-7.74 5.68-7.78=-2.1 (-7.74) (-2.1)=16.25 (-7.74)2=59.91
0.35470.04=0.645
12.19-(1-0.3547)
0.088 0.47-16.52=-16.05 12.19-16.52=-4.33 (-16.05) (-4.33)=69.50 (-16.05)2=257.60
16.52-0.35470.47
19.90-(1-0.3547)
0.063 2.98-26.15=-23.17 19.90-26.15=-6.25 (-23.17) (-6.25)=144.81 (-23.17)2=536.85
26.15-0.35472.98
2
Tane Boyu (m) oi-ui fi-ui (oi-ui) ( fi-ui) (oi-ui) i
0.177 0 0 0 0 0
0.125 -7.74 -2.1 16.25 59.91 0.645
0.088 -16.05 -4.33 69.50 257.60 1.363
0.063 -23.17 -6.25 144.81 536.85 1.968
0.044 -19.46 -9.63 187.40 378.69 -2.728
0.031 4.46 1.2 5.35 19.89 -0.382
0.022 13.43 3.62 48.62 180.36 -1.143
0.016 10.2 2.7 27.54 104.04 -0.918
-0.016 38.33 14.79 566.90 1469.19 1.195
=1066.37 =3006.54
 HAM VERLERLE DZELTLM VERLERN KARILATIRILMASI

100

90

80

70
birikimli % elekalt

60
Besleme
50 Sep.risi
Sep.ncesi
40

30

20

10

0
0.01 0.1 1
tane boyu (mm)
SEPARATR PERFORMANS ERSNN
OLUTURULMASI

Temel yaklam; beslemede herhangi bir boyut

aralnda bulunan tanelerin ne kadarnn hangi rne
gittiinin belirlenmesine dayanr.

ri rne Gre Partisyon ri rne Gre Partisyon

nce
(Ayrm) Katsays (Ayrm) Katsays
U.u i O.o i
Pi Pi
F.fi F.f i
Madde denklii yaplm verilerden hesaplanan separatr partisyon katsaylar

Besleme Sep.risi Sep.ncesi

ortalama
tane boyu % arlk % arlk % arlk tane boyu iri rne ince rne
(mm) (mm) giden % giden %
0.087 0.00 0.00 0.00
0.061 5.27 8.05 0.19 0.073 98.79 1.28
0.044 11.32 17.07 0.79 0.052 97.53 2.46
0.031 18.63 26.92 3.44 0.037 93.45 6.52
0.022 21.27 27.96 9.02 0.026 85.02 14.98
0.016 12.63 11.05 15.52 0.018 56.58 43.41
0.011 9.03 4.21 17.85 0.013 30.15 69.83
0.008 5.07 1.40 11.80 0.009 17.86 82.21
-0.008 16.78 3.34 41.39
tonaj (t/s): 371 239.946 131.054
DEAL VE GEREK SEPARATOR PERFORMANSLARININ
KARILATIRILMASI
 Besleme Separatr ri rn
Tonaj (t/s) 500 365.73

iri rne giden Ksa devre yapan ksm ayrldktan sonra

Elekstnde Elekstnde miktar (%)-
Tane Boyu Kalan lgili Boyun Kalan lgili Boyun gerek %12.5 ksa Besleme Separatr ri dzeltilmi
Aral(m) Miktar (%) Tonaj(t/s) Miktar (%) Tonaj(t/s) partisyon (%) devre (t/s) (t/s) rn(t/s) partisyon (%)
+900 32.8 164.0 44.8 163.8 99.9 20.5 143.5 143.3 99.9
-900+600 11.3 56.5 14.9 54.5 96.4 7.1 49.4 47.4 95.9
-600+480 10 50.0 12.6 46.1 92.2 6.3 43.8 39.8 91.0
-480+378 3.9 19.5 4.6 16.8 86.3 2.4 17.1 14.4 84.3
-378+318 5.7 28.5 6.2 22.7 79.6 3.6 24.9 19.1 76.6
-318+270 4.5 22.5 4.3 15.7 69.9 2.8 19.7 12.9 65.6
-270+228 7.1 35.5 5 18.3 51.5 4.4 31.1 13.8 44.6
-228+126 8.3 41.5 2.9 10.6 25.6 5.2 36.3 5.4 14.9
-126+84 3.9 19.5 0.8 2.9 15.0 2.4 17.1 0.5 2.9
-84+54 2.3 11.5 0.4 1.5 12.7 1.4 10.1 0.0 0.3
-54+42 1.6 8.0 0.3 1.1 13.7 1.0 7.0 0.1 1.4
-42+30 1.9 9.5 0.5 1.8 19.2 1.2 8.3 0.6 7.7
-30+18 2 10.0 0.7 2.6 25.6 1.3 8.8 1.3 15.0
-18+12 0.9 4.5 0.4 1.5 32.5 0.6 3.9 0.9 22.9
-12 3.8 19.0 1.6 5.9 30.8 2.4 16.6 3.5 20.9
TOPLAM 100 500 100 365.73
 Besleme Separatr ri rn
Tonaj (t/s) 500 365.73

iri rne giden Ksa devre yapan ksm ayrldktan sonra

Elekstnde Elekstnde miktar (%)-
Tane Boyu Kalan lgili Boyun Kalan lgili Boyun gerek %12.5 ksa Besleme Separatr ri dzeltilmi
Aral(m) Miktar (%) Tonaj(t/s) Miktar (%) Tonaj(t/s) partisyon (%) devre (t/s) (t/s) rn(t/s) partisyon (%)
-900+600 11.3 56.5 14.9 54.5 96.4 7.1 49.4 47.4 95.9
-600+480 10 50.0 12.6 46.1 92.2 6.3 43.8 39.8 91.0
-480+378 3.9 19.5 4.6 16.8 86.3 2.4 17.1 14.4 84.3

A B B/A C D=A-C E=B-C E/D

-900+600 0.113500 0.149365.73 54.5/56.5 0.12556.5 56.5-7.1 54.5-7.1 47.4/49.4

-600+480 0.100500 0.126365.73 46.1/50 0.12550 50-6.3 46.1-6.3 39.8/43.8
-480+378 0.039500 0.046365.73 16.8/19.5 0.12519.5 19.5-2.4 16.8-2.4 14.4/17.1
MOVIE CLIP-TROMP CURVE
GRADUAL EVOLUTION AND CORRESPONDING
IMPROVEMENT IN THE PERFORMANCE OF
AIR SEPARATORS SINCE 1885

Type Precision d50(microns) By-pass (%) RRB slope

Static 0.25 60+ 0.65-0.75

1st generation 0.30-0.40 20+ 50+ 0.80-0.85
2nd generation 0.50-0.55 15-20 15-35 0.85-0.90
3rd generation 0.60-0.70 10-15 5-15 0.95-1.20
LV-TECHNOLOGY
LV-TECHNOLOGY
 LV-TECHNOLOGY

GUIDE
GUIDE
SEAL
SEALRING
RING
VANES
VANES

ROTOR
ROTOR
BLADES
BLADES

GRIT
GRIT CONE
CONE
LV TECHNOLOGY CLASSIFIER FOR
VERTICAL ROLLER MILL
 SEPARATOR IMPROVEMENTS AIM AT

Improving Performance

Optimizing airflow-reducing volume ( >600gm/m 3)

Reducing Internal Material Circulation

Reducing Pressure Drop

Reducing Fan Power

Increasing Grinding Efficiency

A TYPICAL LV MODIFICATION
 CLAIMED BENEFITS OF LV CLASSIFIER

Vertical Roller Mills:

10 - 30 % Increased production

fan
1.0 5.0 kWh/t Saving in power consumption of both mill and

Vibration level decreasing

Cement strength increases
TROMP AND EFFICIENCY CURVES OF A BALL
MILL-LV SEPARATOR SYSTEM
 RELATIONS BETWEEN OPERATING
VARIABLES AND PERFORMANCE CRITERIA
OF SEPARATORS

The fact that the separator runs in a circuit means that operating variables of the circuit may change.
These variables can be feed rate, feed fineness, rotor speed, air ventilation and so forth. In reviewing
separator performance some over-riding relations, which affect efficiency, must be known and if
possible would be expressed mathematically.One of these relations relates to the feed concentration,
i.e. Kg feed to separator/ m3 of separator air sweep =Qf/Qa ). It is claimed to tie up the combined effect
of circulating load, system output and fan speed as well as blade position and number and also
separator sweep on high efficiency separators. Its effect on by-pass of two separators is given below.

What the above graph shows is that as separator feed is increased by-pass also increases prowided
that the amount of separator internal airsweep remains the same. Increasing sweep through the
separator with more fan, more speed, more blades or larger diameter fan should reduce the by-pass.
Therefore reducing sweep through closing the diaphragm will reduce efficiency or increase by-pass. In
general high efficiency separator operators have the luxery of being able to adjust separator draft as
separator feed changes and adjust cage rotor speeds to control fineness.
fineness. It is seen from the graph that
for an HES the curve is flatter, which means that they can withstand bigger changes in Qf/Qa with a
much smaller effect on by-pass. It can be seen that the general rule is to strive for the largest amount
of internal air flow or the lowest Qf/Qa ratio that still meets product quality constrains.

Qf/Qa ratios suggested for different separators are roughly given below.

HES 2nd. Gen. 1st. Gen. Static Sep.

2.0-2.5 1.6 1.0 < 1.0
RELATION BETWEEN DUST LOAD AND BY-PASS
 TABLE OF SPECIFIC LOADING RATIOS

O-SEPA O-SEPA** S-D SEPOL SEPAX RANGE

SEPARATOR FEED
KG/AM3 OF AIRFLOW
1.39 2.25 2.23 1.7 1.8 1.5-2.25

SEPARATOR PROD.
KG/AM3 OF AIRFLOW
0.49 0.76 0.73 0.62 0.72 0.6-0.75

SEPARATOR FEED
T/H*M2 OF ROTOR 22.8 30.46 22.81 21.38 20.6 20-22
SURFACE AREA

SEPARATOR PROD.
T/H*M2 OF ROTOR 7.99 10.24 7.49 7.72 8.25 8.0-11
SURFACE AREA
POSSIBLE SEPARATOR ADJUSTMENTS AND THEIR EFFECTS

SEPARATOR Resulting Change

Fines
Type of Adjustment By pass Fineness
Output

MAIN FAN

More blades or larger diameter

Fewer blades or small diameter

Higher speed

SELECTOR BLADES

More blades

Fewer blades

Higher speed (if double shaft)

POSSIBLE SEPARATOR ADJUSTMENTS AND THEIR EFFECTS

DIAPHRAGM or VALVES
% opening

Varies with the mill

SEPARATOR FEED RATE circuit type

Varies with the mill

SEPARATOR FEED
circuit type
FINENESS

ROTOR SPEED *

AIR FLOW *

Applies only to 2nd and 3rd generations.