3 -503.07e

Focus on efficiencyKHD Separators

www.khdhumboldt.com

The SEPMASTERHigh-performance separators have a long tradition at KHD Humboldt Wedag.Our SEPMASTER provides excellent selectivity and fits into small space. Inaddition to installation in new mill circuits, the SEPMASTER is particularlywell suited for increasing the productivity of mills already in operation. Theinnovative rotor cage system enables the grinding of premium product qualities.The investment cost incurred by a change of separators is quickly recovered.Through its compact dimensions and low operating and maintenance cost theSEPMASTER significantly increases grinding plant efficiency.

Depending on size and application, the SEPMASTER separator is available in variousversions and with specifically tailored protection against wear and tear.

Rotor stabilityThe rotor shaft is supported at both ends. This concept avoidsvibration and ensures a smooth and safe running machine, evenwhen producing very fine products.

Why is the drive on the bottom?For maintenance work on the separator, gearbox, motor and electriccables do not need to be moved. The drive is positioned away fromthe heat and easily accessible.

The bearings are outside.The support bearings are located outside the separator housing and canbe easily installed or removed, whilst the cage wheel remains in normalposition.

Resistance to wear and tear = lower costs.

Easily replaceable parts made of high quality materials suchas cast basalt, ceramics, chromium carbide or chilled ironguarantee long life.

Fits comfortably into small spaces.The SEPMASTER is the perfect replacement for oldseparators. Compared to older generation sepa-rators, the SEPMASTER cage wheel separator isnot only more efficient but also significantlysmaller and lighter.

FeedFines

CoarseDrive

Rotating

SKS-Z

4

3

2

1

4

3

2

1

fine products suchas high qualitycement or filler.As a result ofthe excellentselectivity,grits returnedto the mill inthe grindingcircuit are wellcleaned of fine mate-rial. Because of this,more fresh material can be fedto the mill. The “Tromp“ selectivitycurve is used to assess the selecti-vity performance of separators.The KHD SEPMASTER achieves topmarks, as can be seen in the graph.

Setting the cutpoint:Fineness of the finished product isquickly and accurately set by thecage speed.

Consistent qualityVariation in fineness and massflow of the feed material have littleeffect on the fineness of the finishedproduct. The quality of the product

remains constant.

Readily re-producibleseparatorresultsThe desired

material fine-ness can be

quickly reproduced,a great advantage when

switching to a different product.

Efficiency of separationPrecise separation was previouslyonly possible on a laboratoryscale, but can now be achievedin large plants because of theSEPMASTER's high performance.Upgraded plants show savings ingrinding energy of 10 to 20% onaverage and production increases

of 10 to 25% for cement raw mealand normal cement. Significantlyhigher production increases of morethan 50% have been achievedin the manufacture of extremely

SEPMASTERProcess and optionsFine material and coarse material are sepa-rated at the periphery of the rotor cage in avortex predetermined by air deflectors and therotation of the cage. The airstream, which is fedhorizontally, will drag the fine particles against thecentrifugal force to the inside of the cage wheel andfrom there to the fine material discharge. The coarsegrains are pushed away from the separatorwheel by the centrifugal force and dropinto the coarse material discharge.

10 100 200

1.0

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0.0 Grain size, µm

Degreeof

sepa

ration

1

Typical SEPMASTER selectivity curve according to Tromp.

Feed

Coarse

Fines

Replaceable cage bars makeeasy maintenance.

coarse separation t/h

150190240280350410480560640770880980

fine separation t/h

2303003704405506407508801,0001,2001,3701,530

SKS -Z and SKS - LRotor cage diameter (mm)

1,7502,0002,2502,5002,7503,0003,2503,5003,7504,0004,3004,600

SKS -MSeparator Size

4005507008501,0001,1501,3501,550

fine separation t/h

49152434436384

Feed material Feed materialcoarse separation t/h

71525395772104141

SEPMASTER SKS -V:For combination with the KHD V-SEPARATOR.

SEPMASTER SKS -Z:The hundredfold proven separator for separating in the range from 20 to 250µm cut point.

SEPMASTER SKS - L:For use on air-swept systems. Highly suitable for “In-Process-Drying”.

SEPMASTER SKS -M:For extremely fine products.

Important effect on downstreamperformanceExcellent product quality isachieved by accurate controlof oversize material. For rawmeal, low levels of super finematerial allows for good burnand flow characteristics.

Fine material – without "OSP's"(oversized particles)The rotor seal, which is purgedwith fresh air, ensures fine pro-ducts without oversized particlesand higher protection againstwear. Quick-Lime producers inparticular enjoy the "OSP" freeoperation performance of theSEPMASTER.

SEPMASTER SKS -V:The feed material is fines from the V-SEPARATOR.

FeedFines

CoarseCoarse 1

Coarse 2Secondary air

SKS - L SKS -M

6

5

4

3

2

1

1

1

65

4

3

2 2

2

The SEPMASTER family

Open-circuit mill (blue)and closed-circuit mill (blue and red)

Fresh materialFinished materialCoarse materialWaste gas4

3

2

1

2

2

Although tube mills have higher energy consumptionthan more modern grinding systems, they do offera number of benefits which justify their use:• High availability• Perfect cement characteristics• Simple adjustment• Easy maintenance• Extreme resistance to abrasion

Our classicFor grinding cement or granulated slag, tube mills are inoperation either as „open-circuit mill“ or as „closed-circuitmill“ with the SEPMASTER high performance separator.These mills have a length to diameter ratio of morethan 3.0 and are supplied with one or two grin-ding chambers.

Optimum solutions for each grinding processGrinding with the tube mill

1

3

4 4

Grinding and drying, all in oneA short tube mill with or without drying

chamber (depending on feed material moi-sture) is used for drying and

grinding of cement rawmaterial. The air-swept

mill is advantageouswhen the moisture level

is high, whereas theclosed-circuit mill is mostly

used for low moisture and highfineness levels. Air-swept mills are

generally used for grinding coal.

Team work is top!The TANDEM grindingplant is a KHD Humboldt Wedag develop-ment. An impact hammer mill (PHM) isconnected in series with a tube mill. Thesolution offers excellent drying performan-ce and handles feed sizes of up to 120mm. Highly abrasive raw material can befed directly to the tube mill.

When the going gets hardThe center discharge mill is used for materialwhich is very difficult to grind. It has twogrinding chambers, both of which canbe fed with fresh material and grits.The SEPMASTER SKS - L, which is fedby a gas stream from below andvia a bucket-elevator fromabove, is the separator ofchoice for this mill.

PHM impact dryer

Center discharge mill

TANDEM grinding plant: Pneumatic transfer of groundmaterial from PHM and tube mill to the separator

Airswept grinding plant(blue) and TANDEMgrinding plant (blue and red)

Fresh materialFinished materialCoarse materialHot gasWaste gasReturn gas6

5

4

3

2

1

5

4 4

33

21

6

6

5

44

3

2

1

Shape giving nameThe V - SeparatorThe V -SEPARATOR in operationOriginally developed to separate finematerial from a roller press circuit, theV-SEPARATOR has, however, alsoproved its value in tough applicationswith large mass flows and abrasivematerial of wide size range and highlevels of feed moisture.

How does it work?Material is fed from above to the built-in step grate. From here, the fine ma-terial is carried upwards with the airthrough the separating channels, thecoarse material falls down over thestep grate and is discharged at thebottom of the housing. The ratio ofmaterial load to separating air can beup to three times higher than with anairstream separator.

Virtually unlimited useThe required product fineness is achie-ved by adjusting the air speed in theseparating channels. Cut pointrange is fromapprox. 80µmto 1.5mm.

Limiting wearand tearAll internalparts are fixedand havestraight andlevel surfaces, asdoes the housing.This ensures simple buteffective protection againstwear, eliminating the need for main-tenance work for many years.

The benefit to youThe V-SEPARATOR is an uncomplica-ted static separator without any mo-

ving parts. Since it carriesout a whole range of

process functions,it considerablyextends therange of ap-plications forhigh pressurecomminution.In additionto reduced in-vestment for

machinery, theV-SEPARATOR also

results in energy savings.With the rising cost of energy, this willbecome increasingly important.

The Allrounder.Despite its simple design, the V-SEPARATOR carries out a whole range of process-related tasks within thegrinding circuit:• Separating fine material fromfresh material

• Drying moisture from freshmaterial

• Cooling hot fresh material

• Deglomeration• Mixing fresh material and grits• Preventing formation of depositswhen grinding granulated slagby positioning the V-SEPARATOR

underneath the roller press.• Producing a finished material withcustom tailored grain size distribu-tion by combining V-SEPARATORand cage wheel separator.

V-SEPARATOR:gas and material flow

Computerized-Fluid-Dynamic (CFD) Simulation

FeedFinesCoarseAirSeparating channels5

4

3

2

1 4

5

2

3

1

m/sec

VSK ®e Separator(“e” = extended version)The VSK®e Separator will require significantly less mechanical conveyingcapacity. To accomplish this, the VSK® is split into two parts. The static“V” - part underneath the roller press and the dynamic “SK”- part above theroller press are connected by a riser duct (e), over which all fines from the“V“- part are lifted by air flow to the “VSK®“- part.

KHD Humboldt WedagGmbHColonia -Allee 351067 Cologne/GermanyPhone +49 2216504 0

ZAB Zementanlagenbau GmbH &Industrietechnik & Service GmbHBrauereistraße 1306847 Dessau/GermanyPhone +49 340 5029 0

Humboldt Wedag India Private Ltd.Espire CampusA - 41, Mohan Co - op Estate,Mathura RoadNew Delhi - 110044/ IndiaPhone +91114210 1100

KHD Humboldt (Shanghai)International Industries Ltd.Office Beijing Guo Ji Da Sha 25 -A19, Jiangou Menwai DajieBeijing/PR ChinaPhone +861065004101

Humboldt Wedag, Inc.400 Technology ParkwayNorcross GA 30092/USAPhone +1770 810 7315

OOO KHD Humboldt EngineeringMjasnizkaja ul., 24/7Office 108Moscow 10100/RussiaPhone +7 495 9233480

KHD Humboldt Wedag Rep.Iran Branch Office3rd Floor, No. 244Navak Building, Africa Avenue,Tehran 15186/ I.R. IranPhone +98 218888 9880

Humboldt Wedag SA (Pty) Ltd.36 Wankel Street, Jet ParkBoksburg, 1459/South AfricaPhone +27 11397 4660

VSK® features:• Five jobs in one unit:• Relieving the dynamic classifier of coarse material by pre-classifying.• Mixing feed and recycled material before entering the roller press.• Deglomeration of RP discharge by impact action of the cascade.• Drying/ cooling.• High efficiency classifying.

• Cut size between 25 and 150µm.• Effective wear protection.

The benefits of the VSK®e are:• Minimizing of bucket elevator capacity• Higher feed rates can be processed

• Reduction in building volume• Lower capital investment.

VSK ® SeparatorThe VSK® combines the sturdy designof the V-Separator with the highperformance of the SEPMASTER.The cage wheel is arranged as anadd-on module to the V. With theV and VSK® Separator, the needfor auxiliary equipment is greatlyreduced: no separate dryer, nodeglomerator. New ways of pro-cess design are now open to awide field of applications for newplant and upgrade alike. Wear isminimized, even when grinding

abrasive materials. These newsystems are not exclusively boundto the roller press, but can beapplied in grinding circuits with

tube mills and impact hammer mills.Tailor-made solutions by KHDHumboldt Wedag are available.

V + SK = VSK®