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Separators- Types, applications and operation
Josef KochHTC – Operational Support (Comminution)Cement Production Intense TrainingLeimen, 16 th November 2011
Slide 2 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Agenda
� Working principle
� Static Separators
� Dynamic separators
Slide 3 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Working principle
� Definition of Separation
– Separation of material into a fine and a coarse fraction.
– Separation of solids from gas/liquid
– Ideally with a defined / predictable cut-size
– Not using Sieves / Filters (amount and fineness of material)
– Available forces to perform Separation:
� Gravity
� Air-Stream Drag Force
� Centrifugal Force
Slide 4 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Working principle
� Working principle
Wind
Gravity
Slide 5 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Working principle
� Conventional separators
Forces acting on the particles
– Aerodynamic forces
– Centrifugal forces
– Gravity
Slide 6 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Working principle
� High efficiency separators
Forces acting on the particles
– Aerodynamic forces
– Centrifugal forces
– Gravity
Slide 7 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Working principle
� High efficiency separators
Centrifugal force Centrifugal force FFZZ = m x (v= m x (vtt²²/R)/R)
Aerodynamic forceAerodynamic forceFFLL = = CdCd x A x x A x ρρaa x (x (∆∆vvrr²²/2)/2)
GravityGravityFFGG = m x g = m x g
m : particle massvt : tangential speedR : radiusCd : aerodynamic coefficient f(Re)ρa : air densityA : particle section∆vr : vr(air) - vr(particle)
Slide 8 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Working principle
� Centrifugal force and gravity force increase with m ass
– increase with d3 (cubic value of diameter)
� Drag force increases with cross section
– increases with d2 (square value of diameter)
� Increase of size impacts more on centrifugal and gr avity forces than on drag force
Slide 9 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Agenda
� Working principle
� Static Separators
� Dynamic separators
Slide 10 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Static Separators
� Cyclone
Slide 11 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Static Separators
� Cyclone - Working principle
-Separation of coarser Particles:
Centrifugal Force
-Separation of finer Particles:
Gravity + Centrifugal Force
-Up / Transport:
Air Drag Force by external Fan
Slide 12 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� Cyclone
36006,2πnV4
d∗∗∗
∗=&
Rule of thumb for dimensioning
d= nominal diameterV= total airflown= number of cyclones
Static Separators
Slide 13 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� Cyclone
1. Operation
- ∆p ≈ 10 – 15 mbar
- Dedust. Efficency ≈ 75 – 80 %- Adjustment to fineness:
� Gas flow
� Diameter immersion pipe� Depth of immersion pipe
2. Applications- Dryers
- Preheater Tower
- Dynamic separators (2nd & 3rd Gen.)
Static Separators
Slide 14 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� Grit separator
Static Separators
Slide 15 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Static Separators
� Grit separator - Working principle
-Separation of coarser Particles:
Centrifugal Force
-Separation of finer Particles:
Gravity + Centrifugal Force
-Up / Transport:
Air Drag Force by external Fan
Slide 16 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� Grit separator
V0127,0d &∗=
Rule of thumb for dimensioning
d= nominal diameterV= total airflown= number of cyclones
Static Separators
Slide 17 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� Grit separator
1. Operation
- ∆p ≈ 10 – 15 mbar
- Dedust. Efficency ≈ 75 – 80 %- Adjustment to fineness:
� Position of blades
� length immersion pipe
2. Applications
- Vertical Roller mills- Air swept mills
Static Separators
Slide 18 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� VS Separator
Static Separators
Slide 19 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Static Separators
� VS Separator - Working principle
-Separation of coarser Particles:
Gravity
-Separation of finer Particles:
Air drag force
-Up / Transport:
Air drag force
Slide 20 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� VS Separator
1. Rule of thumb for dimensioning
- Specific air load: 4 kg/m³
2. Operation� ∆p ≈ 10 – 15 mbar� Dedust. Efficency ≈ 75 – 80 %� Adjustment to fineness:
- Air velocity
3. Applications- Combi grinding plants- Finish grinding plants
Static Separators
Slide 21 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Agenda
� Working principle
� Static Separators
� Dynamic separators
Slide 22 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Dynamic Separators
� 1. Generation
Slide 23 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Dynamic Separators
� 1. Generation - Working principle
-Separation of coarser Particles:
Gravity
-Separation of finer Particles:
Air drag force
-Transport:
Air drag force & Gravity
Slide 24 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 1. Generation
1. Dimenisioning
- Varying with the suppliers
- Guide values (Cement fineness – spec. Load)� 2500 cm²/g – 2,2 – 3,6 t/h.m²
� 4500 cm²/g – 1,0 – 1,5 t/h.m²
2. Applications
- Fineness range: 3000 – 5000 cm²/g
- Grinding plants
Dynamic Separators
Slide 25 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 1. Generation
1. Adjustment of fineness during operating time
- Increased speed of counterblades
- Reduce air flow rate
2. Adjustment of fineness during stop
- Increased number of counterblades- Increased size of counterblades
- Reduced distance of counterblades
Dynamic Separators
Slide 26 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 1. Generation
1. distribution plate below selecting zone : part of material not selected.
2. airflow : no control, inefficient fan.
3. Poor cycloning effect
4. selection zone :action not constant, very narrow.
5. fineness:narrow range of adjustment.
Dynamic Separators
Slide 27 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 2. Generation
Dynamic Separators
Slide 28 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Dynamic Separators
� 2. Generation - Working principle
-Separation of coarser Particles:
Gravity
-Separation of finer Particles:
Air drag force
-Transport:
Air drag force
Slide 29 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 2. Generation
1. Dimenisioning
- Varying with the suppliers
- Guide values (Cement fineness – spec. Load)� 3000 cm²/g – 8 t/h.m²
� 4000 cm²/g – 5 t/h.m²
� 5000 cm²/g – 4 t/h.m²
2. Applications
- Fineness range: 3000 – 5000 cm²/g- Grinding plants
Dynamic Separators
Slide 30 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 2. Generation
1. Adjustment of fineness during operating time- Increased speed of counterblades
- Reduce air flow rate
2. Main suppliers- Krupp Fördertechnik- KHD- Krupp Polysius
Dynamic Separators
Slide 31 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 2. Generation
Improvements1. external fan
2. several small cyclones
but1. no improvement in the selecting
zone
2. distribution plate still below
selecting zone
Dynamic Separators
Slide 32 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 3. Generation
Dynamic Separators
Slide 33 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Dynamic Separators
� 3. Generation - Working principle
-Separation of coarser Particles:
Gravity
-Separation of finer Particles:
Air drag force
-Transport:
Air drag force
Slide 34 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 3. Generation
1. Dimenisioning
- Varying with the suppliers
- Guide values (Cement fineness – spec. Load)� 3000 cm²/g - 10 t/h.m²
2. Applications- Fineness range: 3.000 – 6.000 cm²/g acc. Blaine
- Ball mill Grinding plants (raw, cement)
- Vertical roller mills- Roller Press grinding circuits
Dynamic Separators
Slide 35 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 3. Generation
1. Adjustment of fineness during operating time
- Increased speed of rotary cage- Reduce air flow rate
2. Main suppliers- KHD
- Krupp Polysius
- F.L. Smidth
Dynamic Separators
Slide 36 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 3. Generation
Dynamic Separators
Sepol (Polysius)
QKD (Christian Pfeiffer)
O-SEPA (Fuller)
Slide 37 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� 3. Generation
Dynamic Separators
Sepax (F.L. Smidth)
SD (Sturtevant)
Slide 38 - 16.11.2011Separators – Types, applications and operation – Josef Koch
� Vertical Mills
Dynamic Separators
LSKS (Loesche)
Sepol (Polysius)
SLS (GPAG)
Slide 39 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Agenda
� Working principle
� Static Separators
� Dynamic separators
Slide 40 - 16.11.2011Separators – Types, applications and operation – Josef Koch
Added bonus
� Effects of modifications in cage and airflow on a high efficiencySeparator
IncreaseAirflow
DecreaseAirflow
IncreaseCage Speed
DecreaseCage Speed
IncreaseAir and
Cage Speed
DecreaseAir and
Cage Speed
Blaine = =
%P 325
CL = =
Caution: These are just general rules of thumb. Actual reactioCaution: These are just general rules of thumb. Actual reactions may differ depending on the casens may differ depending on the case.
Slide 41 - 16.11.2011Separators – Types, applications and operation – Josef Koch
for better building…..
Thank You!