AIR SEPARATORS
Training Diploma in Cement Manufacturing Engineering
Air Separators
• Function of air separators
• Different technologies
( 3 Generations)
• Efficiency, TROMP curve
• Circulating load
Function of air separators
Adding a separator places the mill into a loop the principle of which is:
§ All particles leaving the mill are sent to the separator.
§ The separator sorts fines and sends the “rejects” to the mill for further size
reduction. In this loop, coarse particles can pass several times through the mill until
they have the required size, but as soon as they reach the right fineness, they are
taken out of the circuit.
Separator air flow system
Rejects Fines to Silo
Separator Ground
material
Feed
Mill fan
Gas flow Gas flow
Dedusting
Different technologies
1) Static separator Fines
• Can be installed with high gas flow mills. They Fresh air Thimble
use the cyclone effect for separation. Ground valves
Vanes
material enters from the bottom, dragged by
the mill air flow.
• Adjustable vanes create a vortex effect which
centrifuges the material. This mostly concerns Inner Cone
biggest particles, which fall along the inner
cone.
• Fines are swept through the thimble out of the Outer Cone
separator.
• On this separator it is possible to adjust the
vane orientation: the lees open, the higher the Rejects
fineness.
Feed (Mill sweep)
Different technologies
2) Dynamic separator – First Generation
• This separator is usually referred as to the
“STURTEVANT” type
The material is fed onto a rotating distribution plate which
spreads it and throws it outward.
Ventilation blades create an internal recirculating air flow.
Separation is carried out by the combination of three forces on the
particles:
• Centrifugal force due to the selector blades
• Drag force of the air sweep generated by
the ventilation (or fan) blades carrying the
particles toward the top of the separator.
• The particle weight
Fines are blown to the outer cone
Coarse material falls into the inner
cone and sent back to the mill
Different technologies
2) Dynamic separator – First Generation
• Depending on the particles size the three
forces have different relative influence.
• Fines are dragged up to the top of the
separator by the ascending air flow and then
to the outer cone.
• Coarse particles, rejected by gravity, fall into
the inner (reject) cone.
• The air flow is re-circulated to the selection
area via the return vanes.
• It is also possible to inject into the system cold
or hot gases to cool or dry the material.
Different technologies
2) Dynamic separator – First Generation
Let us study in details what is happening.
a) Case of a 500 µm particle
• The particle falls on the distribution plate which
throws it into the gas flow.
• The particle is now under the influence of 3 forces
q Its own weight
q The centrifugal force
q The air drag
For biggest particles, the weight is the most important force
hence the particle falls directly into the reject cone.
Different technologies
2) Dynamic separator – First Generation
Let us study in details what is happening.
b) Case of a 50 µm particle
• The particle falls on the distribution table which
throws it into the gas flow.
• The air drag which is greater than the weight, lifts
the particle to the level of the selector blades.
• The blade imparts an additional centrifugal force to
the particle.
• As the weight remains relatively great with respect to
the air drag, the particle cannot reach the diaphragm
and is pushed against the wall.
The particle falls along the walls of the rejects cone
Different technologies
2) Dynamic separator – First Generation
Let us study in details what is happening.
c) Case of a 20 µm particle
• The particle falls on the distribution table which
throws it into the gas flow
• The air drag is now relatively greater and lifts the
particle up to the level of selector blades
• The blade increases the centrifugal force but as the
drag is much greater than the weight, the particle
reaches the diaphragm and passes into the fine cone.
The descending airflow in the outer cone returns to the
separation zone by air vanes.
But super fine material will pass with the airflow back to
separator zone creating a small re-circulating load within the
separator.
Different technologies
2) Dynamic separator – First Generation
Effect of diaphragm adjustment:
when the diaphragm is closed, coarse particles hit the diaphragm and cannot
reach the top of the separator.
a) The diaphragm is closed b) The diaphragm is opened
Different technologies
2) Dynamic separator – First Generation
Here ar the main parts of this separator
Different technologies
2) Dynamic separator – First Generation
vDouble shaft separators
Ø To improve efficiency, separator with
different drives for the distribution plate
and ventilation blades have been
developed.
Ø It is thus possible to adjust separately the
air flow and the separation process.
Usually, fan speed is fixed and the actuator is the selections
blades plate speed.
On this separator the possible adjustments are:
q Number of selector blade (coarse adjustment)
Ø Increasing the number of blades will increase the centrifugal effect
and send more material to reject. The impact is a higher fineness.
Ø Increasing the total blade area will have the same result: higher
fineness.
Different technologies
2) Dynamic separator – First Generation
Different technologies
2) Dynamic separator – First Generation
Summary of adjustments
Different technologies
2) Dynamic separator – Second Generation
This type of separator is usually refer to as the
“WEDAG” type.
The principles of operation remain the same as first
generation separators.
• An external fan is used to create
The main the re-circulating air flow
difference are: • Fines are collected in the
external cyclone group
• The air return circuit has several
return air vanes
• An air inlet damper can be used
for material cooling or drying.
Different technologies
3) Dynamic separator – Third Generation or High Efficiency Separator
This type of separator was first developed by Onoda. Filter
Its was called “OSEPA”, and now is sold by Fuller.
As per the second generation, an external fan s used
to create the circulating air flow.
Fines
Ø Feed enters the inlet chute at top of separator
Ø Material falls onto the dispersion plate at top of
rotating cage Primary
air inlet
Secondary
air inlet
Ø Drawn by the air flow, fines pass through the rotating
cage and are lifted to the dust collector.
Ø Coarse fraction of feed material is discharged by Rejects
gravity into the rejects cone (reject hopper)
Different technologies
3) Dynamic separator – Third Generation or High Efficiency Separator
Dispersion
plate
Rotating
cage or
rotor
Different technologies
3) Dynamic separator – Third Generation or High Efficiency Separator
Let us see in details how it works
Air seal
Ø Fresh feed enters inlet chutes (2 or 4) at the top of the
separator. The feed is well balanced between inlet chutes Buffer plate
assuring an even distribution around the rotor. Material
feed is directed onto the dispersion plate at top
Ø Material is thrown outwards by centrifugal force against
buffer plate and falls into the annular gap between the
spinning rotor and the inlet guide vanes.
The finest fraction of feed material is accelerated
In this equipment, the particles also receive three forces: into the horizontal gas flow as it enters the
§ The horizontal force due to air drag.
separation zone then is carried through the rotating
§ The centrifugal force is created by rotation of the
cage cage and exits with the air stream through the
§ And their weight. outlet duct.
The coarser the material, the greater the impact of the
centrifugal force.
Inlet guide
vanes
Different technologies
3) Dynamic separator – Third Generation or High Efficiency Separator
Let us see in details how it works
Air seal
With this system, while in the separation zone, the
material is continually classified by horizontal air Buffer plate
flow, speed of rotating cage & gravity.
At any point in this zone, remaining materials can
become finished product if fine enough to be
entrained or “dragged” into airflow passing through
the rotating cage.
Inlet guide
vanes
Different technologies
3) Dynamic separator – Third Generation or High Efficiency Separator
Let us see in details how it works
Air seal
With this system, while in the separation zone, the
material is continually classified by horizontal air Buffer plate
flow, speed of rotating cage & gravity.
At any point in this zone, remaining materials can
become finished product if fine enough to be
entrained or “dragged” into airflow passing through
the rotating cage.
Finally, the coarse fraction of feed material is
discharged into the rejects hopper and evacuated
through a tipping valve located at the bottom of Inlet guide
rejects cone and returned to the mill for further size vanes
reduction.
Different technologies
3) Dynamic separator – Third Generation or High Efficiency Separator
The increased efficiency of 3rd generation separators is due to an increased residence time
and an even distribution of material and air in the separation zones.
Fineness is controlled by:
Ø The rotor or cage speed
Ø The independent air flow
Feed 1
Feed 2
§ Increasing the cage speed increases the centrifugal
Buffer plate
force applied to material pasing through separation
zone.
§ It makes it more through the rotor to finished
product
§ Result is a finer finished product. Reject hopper Inlet guide
§ Decreasing the cage speed has the opposite effect Tipping valve
vanes
Different technologies
3) Dynamic separator – Third Generation or High Efficiency Separator
An increase in airflow will increase the force of horizontal flow or
“Drag” making it possible to entrain coarser particles through the rotor.
Ø Results is a coarser finished product
Ø Decreasing the airflow will have the opposite effect
In fact this possibility is not used as a control mean Feed 1
Feed 2
in third generation separators. Buffer plate
When optimized the air flow is not adjustable in order
not to unbalance the complete system.
Reject hopper Inlet guide
vanes
Tipping valve
Different technologies
3) Dynamic separator – Third Generation or High Efficiency Separator
We have been studying the FULER OSEPA separator.
Here is an other type of high efficiency separator developed by POLYSIUS (SEPOL). The
principle is identical but here the fines are directed downward.
Different technologies
3) Dynamic separator – Third Generation or High Efficiency Separator
In conclusion the advantages of the latest generation are:
ü Simple design
ü Smaller equipment
ü Easier operation due to the different controls for separation and air flow
ü High efficiency, better separation due to the long size of separation zone
ü Higher production as nearly all fine material is immediately extracted from the
circuit, without overloading the mill
ü Energy savings
Efficiency of separator
The question is: how to evaluate the efficiency of a separator?
in theory a perfect separator should send back to the mill all particles bigger than a given
size (for example 50 µ𝑚) and send to the finish product all material smaller than 50 µ𝑚 (if
we use the same example).
It is possible to describe this perfect “screen” by following red curve:
Efficiency of separator
The question is: how to evaluate the efficiency of a separator?
in theory a perfect separator should send back to the mill all particles bigger than a given
size (for example 50 µ𝑚) and send to the finish product all material smaller than 50 µ𝑚 (if
we use the same example).
It is possible to describe this perfect “screen” by following red curve:
This curve is the probability for
a particle to be sent to the mill.
In this example, this curve
means that 0% of particles
smaller than 50 µm are rejected
or, on the contrary, 100% of
particles bigger than 50 µm are
rejected to the mill.
Efficiency of separator
This curve is called the Efficiency Curve or Tromp curve.
Now, what is the efficiency of a real separator?
The curve for a “STURTEVANT” separator is:
Efficiency of separator
This shows that in reality the size classification is far from perfect:
Ø Fine material is also reject to the mill: respectively below 25 µm or 10 µm. This limit is expressed by the
probability of rejection in % is called the “bypass” (respectively 50 and 10%).
Ø Coarse particles between 10 and 50 µm, in a third generation separator, can be sent to the finish product silo.
Ø Below a given size (respectively 25 µm or 10 µm), the separator cannot distinguish the size of the particles
and sends to rejects some ultra fine material.
Ø The second generation equipment is between the two other families.
Efficiency of separator
In other words, to evaluate the quality of separators just have a look at the curve:
1. The more the curve is “vertical” the more the separation is good, the more the separator is
efficient.
2. The lower the by-pass level the less fines are returned to the mill.
Circulating load
To estimate the ratio of material which is rejected by the separator with respect to the mill
feed we use the “Circulating load” (CL):
Fines F
!
It is expressed in %. CL =
" Rejects R
Separator
Separator feed
Feed B
For mill producing a 3300 – 3800 SSB cement, the average circulating loads are:
Ø In a first generation separator: 200 to 300 %
Ø In a second generation separator: 100 to 200 %
Ø In HES, lower than: 100 to 200 %
Circulating load
To estimate the ratio of material which is rejected by the separator with respect to the mill
feed we use the “Circulating load” (CL):
Fines F
!
It is expressed in %. CL =
" Rejects R
Separator
R = 60 t/h Separator feed Solution:
Mill feed = 30 t/h
FeedB Circulating load = 200 %
B = 30 t/h 90 t/h
So, (30 x 200)/100 = 60 t/h
Question: A 30 t/h mill is operating is steady conditions with a 200% circulating load. reject by separator
How many tonnes per hour of material are circulating in the mill tube?
60 + 30 = 90 t/h circulating
ANSWER: 90 t/h in the mill
Circulating load
Let us take one last example to think a little bit! Fines F
Rejects R
Conclusion: F is equal to B and we can write Separator
when the mill is operating in stable R = 60 t/h Separator feed
condition:
𝑅 𝑅 Feed B
CL = = B = 30 t/h 90 t/h
𝐵 𝐹
Of course this relation does not apply during
transient phases for example when starting,
stopping the mill or when changing the
fineness.
Circulating load
Be careful! This expression of the circulating load:
𝑅 𝑅
CL = =
𝐵 𝐹
You may find other formulas in external documents using differently A, F, R
Circulating load
To calculate the CL we need to know R, B, or F
𝑅 𝑅
CL = =
𝐵 𝐹
1. B is known by weighing the mill feed
2. A is known thanks to the elevator power
Circulating load
To calculate the CL we need to know R, B, or F
𝑅 𝑅
CL = =
𝐵 𝐹
1. B is known by weighing the mill feed
2. A is known thanks to the elevator power
How can we calculate CL using A which does
not enter in the formula??? And, why are we
speaking of the elevator power? What is
elevator?
Let us see…
Circulating load
To lift the ground material from the mill to the separator we use an elevator
It is obvious that the power consumed by its motor depends on the quantity of material raised to the
separator.
The more material (the more Circulating Load) the more KW absorbed by the motor.
The necessary energy is proportional to the mass of material (A).
Knowing this energy, we can calculate A.
𝑅 𝑅
CL = =
𝐵 𝐹
Circulating load
To lift the ground material from the mill to the separator we use an elevator
It is obvious that the power consumed by its motor depends on the quantity of material raised to the
separator.
The more material (the more Circulating Load) the more KW absorbed by the motor.
The necessary energy is proportional to the mass of material (A).
Knowing this energy, we can calculate A.
Ok! But A does not gives us CL !
Have a look: A = F+R or R = A-F
𝑅 𝐴−𝐹 𝐴
THAT IS TO SAY: CL = = = -1
𝐹 𝐹 𝐹
Circulating load
How to manage this Circulating Load?
The Circulating load depends on:
Ø The required fineness of the finished product
Ø The mill adjustment in particular the ball charge (in case of ball mills)
Ø The separator efficiency.
For each grinding shop and for each product, there is an optimum level of the circulating load
established by tests.
Circulating load
Do you remember the CL average value for a HES?
q 200 to 300 %
q 100 to 200 %
q Lower than 100 to 200 %
EXCELLENT!
For a mill producing a 3300 - 3800 SSB cement, the average circulating loads are:
Ø In a first generation separator: 200 to 300 %
Ø In second generation separator: 100 to 200 %
Ø In a HES, lower than 100 to 200 %
Circulating load
Why is the circulating load lower in the case of a HES? Because:
q We usually associate bigger mills to HESs and by the way the feed is higher
q In a HES the separation is more efficient and fines are evacuated more rapidly
q In a first generation separator, the by-pass is high
q HESs are smaller equipment than first or second generation separators and they cannot
support high circulating loads.
EXCELLENT!
In HESs the efficiency is much higher than in other types of separators.
Fines are taken out of the circuit efficiently as soon as they appear.
They do not return to the mill and the flow of reject material is smaller and by the way the CL is
lower. Of course the size of equipment has nothing to do with the quality of separation.
To summarize
A separator is a piece of equipment that improves mill efficiency by eliminating fine particles as soon as they
are produced, avoiding over grinding and thus facilitating the work of the mill.
It produces products with a narrow distribution curve.
TROMP curve show the quality of grinding of a given mill.
𝑅 𝑅
The Circulating Load CL = = expresses the quality of material return to the mill for further size
𝐵 𝐹
reduction. It can be monitored by the energy absorbed by the elevator to lift material up to the separator.
This parameter is a key indicator for controlling the mill shop operation.
To control the fineness / production it is possible to modify the speed of the distribution plates and/or the air
flow depending on the type of the separator. But do not forget, for a given system already optimized.
Increasing the fineness means decreasing the production and vice versa!
Thanks to additional gas input it is also possible to dry or cool the material by injecting hot or cold gas flows.
End of the topic
THANK YOU VERY MUCH!
