4.

0 AIR SEPARATORS
4.1 Introduction
Separators are utilized in a closed circuit grinding system for the purpose
of separating (classifying) the fine and coarse particles of the feed. The fine
particles are passed through the separator to become finished product while the
coarse particles are returned to the mill as rejects for further grinding. All dry
grinding applications in the cement industry use what is referred to as air
separators or classifiers
Figure 4.1

Evolution from a Dropout box and Cyclone

The simplest form of a separator is a dropout box. By slowing the gas
velocity down the coarse particles will settle out. Dropout boxes are frequently
used to separate dust from gases. Since the velocities must be extremely slow to
cause superfines to drop out, they in fact can be used as a classifier. Exshaw
FM2 successfully uses this idea to make the mill sweep dust fine enough for

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finish cement. However the box is extremely large to accomplish this. As a rule
of thumb for cement mills, the air velocity around the discharge trunnion and
hood must be less than 4 m/s. In Exshaw's dropout box they strive for about 2
m/s.
A more sophisticated approach is the cyclone, shown in figure 4.1. The
outward spin forces the coarse particles out of the gas stream. Cyclones are
intended to separate dust from gases - they are very poor size classifiers.
WARNING: do not confuse cyclone efficiency with selection (recovery)
efficiency. Cyclone efficiency refers to the effectiveness of dust removal from gas
stream - not how good of a classifier it is. As a classifier we need inefficient
cyclones. The performance of the cyclone is very dependent on the internal gas
velocity. Higher speeds means more coarse particles are captured. Control by
just velocity alone is poor.

4.2 Types of Air Separators

Beyond dropout boxes and cyclones we've become very ingenious is

separation technology. There are basically 4 types:

Static Grit Separators

These permit the separation of large particles from the material being
transported in the mill air sweep. These are common on vertical roller mills, air
swept coal mills. One of the largest units in service can found on Alpena's raw
grind circuits.

First Generation Separators

These are separators with internal cyclones, e.g. Sturtevant and Raymond.
They have been in use for decades. Most plants in Lafarge Corporation are
equipped with these.

Second Generation Separators

These are separators with external cyclones, e.g. Wedag-Zub and O&K,
(mainly in Europe). As a general rule their efficiency in terms of bypass,
fractional separation, and grinding is superior to the first generation separators.
Some first generation separators can reach the same performance levels with

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modifications. To date, none are in service with Lafarge Corporation. Therefore

this class is not discussed in the Mill Grinding Reference.

High Efficiency Separators of the Third Generation

Introduced in the mid-eighties, these are characterized by external
ventilation, and by the presence of a squirrel-cage (rotor cage), which allows an
improved fractional separation over other separator types. Upgrades and new
installations will one of these units installed as the type of choice.

4.2.1 Static (Grit) Separator

Principle of operation
Figure 4.2.1a

Fine s

Adjustable vanes
Fresh air
bleed valve

Thimble

Inner
Cone

Outer
Cone

Rejects

Feed (mill sweep)

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During the process of grinding in the mill, an external fan drafts fine and
coarse particles from inside the mill through the mill discharge. In process
terms, the material is swept from the mill.
The method of particle separation in a static separator is a very basic
process - not unlike a cyclone. The dust laden air swept from the ball mill flows
upward into the bottom of the separator cone. As the air (gas) rises, it flows
between the inner and outer cone until it reaches the inlet vanes. There, it flows
through the vanes, imparting a circular motion, into the upper section of the
inner cone. Due to the much larger areas of the inner cone, the velocity decays
and the coarse particles (grits) fall by gravity to the bottom of the inner cone; out
the reject spout back to the grind circuit. In addition, the circular motion of the
air (gas) improves the separation of coarse and fines by centrifuge. The air (gas)
with the fine particles continues up through the thimble out of the separator to
elsewhere in the process.
Static Grit separators are commonly employed on semi air swept finish
mills and on air swept coal mills. Some large raw grinding vertical roller mills
use them. Alpena's roll press raw grinding circuit uses them as well.

Components
This separator does not compare in design to the conventional separator. Its
design compares to a cyclone with the exception that the internal vanes can be
adjusted.
a) Outer Cone
Can be described as the outer shell of the separator. The bottom of the cone
(inlet) receives unclassified material from the mill sweep. The outer may not
exist where static separators are built into a unit such as a vertical roller mill.
Poor outer cone designs have led to significant performance problems.
b) Inner Cone
Installed inside the outer cone. The bottom is piped outside the separator for
rejecting coarse (grit) particles from the separator.
c) Inlet Vanes
Located below the top of the separator, separates the inner and outer cone. The
vanes are adjustable and can be moved to increase or decrease the circular
motion of air as it enters the inner cone. Typically they are mechanically linked
and are adjusted using a single hand wheel.

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 Air Separators

d) Thimble
Placed through the separator top (center). Fines and (exit gas) leaves the
separator through this duct. Thimble height can be adjusted to pick fines from
the air flow inside the separator. However, the thimble is set up at installation
and not moved as a regular procedure.
e) Bleed-in Air Valves
This is a modification idea that originated in Demopolis. Small manual valves
are mounted in front of each vane. Bleeding air in accomplishes two things.
First it reduces mill sweep such that super fines are preferred. Second the air
velocity inside the inner cone is kept high for best separator efficiency.
Demopolis only bleeds air in when making TIII or high blaine products.

Control
a) Fineness Control
The product fineness can be changed by changing the volume of air swept from
the mill or the separator vanes are adjusted. Keep in mind that either change
will have effect on the separator efficiency.

• Air Volume
An increase in volume of air swept from the mill results in a higher percentage
of coarse material going through the separator to the collector - which lowers
product blaine. If the sweep also increases the internal velocities then bypass
also falls. Large fans are needed to make these units effective.

• Vane Adjustment
Each static separator vane adjustment area is marked for direction of movement.
A coarser adjustment (less spin) will result in the removal of fines to the collector
with a higher percentage of coarse particles - which lowers product blaine.

Figure 4.2.1b

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Older Design Newer Design

Co arse
particles loses
velocity and
drops out, only KHD and FCB are
to be re- two suppliers who
entrained at the made this
inlet wh ere the modification to
velocity is much capture the coarse
higher. The particles as rejects.
resu lting cloud Thus efficiency
blocks flow. improves on the
unit.

Inspection requirements
The main advantage is that it has no moving components or power source.
Basic inspection requirement is a visual inspection of the separator and related
intake and exhaust piping for leaks. Depending on the material abrasiveness the
vanes and the inner cone should be checked for replacement at least every 4 to 6
years.

Outer Cone Design Problems

All static separators with double cones have this particular problem, shown on
the left side of figure 4.2.1b. Inlet gas velocities have to be high enough to keep
all particles in suspension. As it enters the separator, the cross sectional area
increases because it goes from a round duct to an annulus that's increasing in
diameter. This causes the velocity to drop and the coarse particles to fall out.
Unfortunately these particles fall down into the inlet - only to be re-entrained. A
circulating load is created and this blocks flow, (sometimes referred to as a dust

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 Air Separators

cloud), drastically reducing the separator performance. The same phenomena

has been known to occur in kiln riser ducts where there's an expansion in duct
area going up. This blockage can be detected by extremely high differential
pressures across the separator or the inlet duct (especially if its a straight duct).
This problem has occurred on Demopolis' Fuller and KHD (1984) static
separators on FM 1 & 2, and on Alpena's Polysius static separators on FG 20 & 21
(1991). To cure this problem, both plants replaced the inlet ducts with dropout
boxes. By dropping out the coarse particles, alleviated the internal circulating
load.
Recently suppliers, (KHD and FCB) have modified the design to take
advantage of this characteristic and improve efficiency. This is shown on the
right side of figure 4.2.1b

4.2.2 Sturtevant Separators

Operation (see Figure 4.2.2a)
• Material goes down the feed spout to the intake cone and to the lower
distributing plate hub.
• By centrifugal action (rotation) the particles are thrown outward through
the ports of the hub and onto the lower distributing plate.
• Particles are dispersed from the plate into the separating zone. A curtain or
umbrella of material is formed outside the lower distributing plate.
• Forces acting on the particles are ascending air, gravity, and centrifugal
action.
• Coarse particles settle by gravity to the tailings or rejects chamber.
• Finer particles are acted upon by the upward air flow created by the main
circulating fan and lifted to the selective zone where final selection takes
place.
• The selector blades impart additional centrifugal force. Heavier particles
are thrown outward underneath the drum cover to the rejects cone. The
finer, lighter particles are drawn through the path of the selector blades to
the finished product area.
• More selector blades or fewer main fan blades will result in a finer product.
• Control valves (or diaphragm) are located between selector blades and
main fan blades, and move in or out to vary the size of the opening
between the two - fine tuning the upward draft to control fineness.

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• Return air vanes (between the fines cone and the inside drum cone) allows
fines to settle, while returning air to the separating zone.
• Drying in the separator can also be achieved through balanced hot air
inlet(s) and outlet(s) to a dust collector and fan.
• Cooling in the separator can also be achieved drawing in cold air.

Ce nt r if uga l For c e

Figure 4.2.2a: Material Flow Pattern inside a Sturtevant

Parts of a Sturtevant Separator are shown in figure 4.2.2c.

Sturtevant Separator Adjustment (see table & figure 4.2.2b)

The possible operating adjustments that can be made on a separator are, in order
of decreasing priority:
• Diaphragm if there is one
• Number of fan or selector blades
• Main fan diameter
or by means of the feed flow rate in terms of the output and fineness.

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The general rules under all circumstances are:

SEPARATOR ARROW DIAGRAM Direction Change of Variable

Bypass or Fines Blaine or

Direction Change of Adjustment
Rejects TPH 325Mesh

MAIN FAN
More Blades (or larger Diameter)

Fewer Blades (or smaller Diameter)

Higher Speed (sheave change)

SELECTOR BLADES
More Blades
*

Fewer Blades *

Higher Speed (for separate drives)

DIAPHRAGM or VALVES *
% Opening

SEPARATOR FEED RATE Varies with Mill

(or mill circulating load) Circuit Type

SEPARATOR FEED
Varies with Mill
PRODUCT FINENESS
Circuit Type

* MAIN FACTOR
In the case of a separator with a diaphragm, as a general rule, it should be adjusted for
the different modes of operation (selector fan, main fan) in such a manner that, during
normal operation, the diaphragm will be near its maximum opening.

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Figure 4.2.2b: Diaphragm Operation

Main Fan Blades

Fe ed Cone

Inside Drum Cover

Inside Drum

Outside Drum

Valve Shafts Pushed In

Diap hra gm Plates Fully Closed

Diap hra gm Plates Fully Open

Valve Shafts Pulled Out

Separator Diaphragm
Shown above, the diaphragm has many names depending on the plant -
diaphragm, valves, plates, selector (valves), etc. Understanding what they do is
easier when you look at it in plan view. The main fan is a centrifugal fan on its
side. The diaphragm then is just an iris type opening. Pushing the valves in
closes them restricting fan flow. The reduced up draft causes less of the coarser
particles to be drawn up and hence blaine and 325 mesh rises. However
separator bypass will increase too. The diaphragm allows the operator to make
small adjustments while running.

Cooling, Drying and Venting

These units are vented to a dust collector. By connecting the air intakes to
a furnace allows one to dry materials. Many plants put fresh feed to the
separator first - to "flash" dry the material. By bringing fresh air only cools the
rejects flow and helps cool the mill circuit. Over venting is possible. As a rule of
thumb the dust from the separator must as fine or finer than the finish product.
Otherwise it's over-vented. (See also figure 4.2.2d)

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 Air Separators

Figure 4.2.2c: Parts of a Sturtevant

12

17 18

21
11
24 13
9
19

5
10 15
23
22 7

20
16 14 8
6
4

3
1

1. Fines Chamber 9. Inside Drum Cover 17. Intake Cone

2. Tailings Cone 10. Inside Drum Cover Liner 18. Intake Cone Line
3. Ring Liner 11. Valve & Valve Rod 19. Fan Cone
4. Air Vane 12. Gear Reducer 20. Packing Ring
5. Outside Casing 13. Main Shaft 21. Upper Dist. Plate
6. Outside Casing Liner 14. Distributing Hub 22. Upper Dist. Plate Liner
7. Inside Drum 15. Dist. Hub Liner 23. Selector Blade
8. Inside Drum Liner 16. Lower Dist. Plate 24. Main Fan Blade

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Figure 4.2.2d: Air (Gas) Flow Paths

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Performance Troubleshooting
The following items should be checked regularly:
• Clearance between the top of the selector blades and the underside of the
drum cover should be 1/4 to 3/8 inch.
• Selector blades should pass a minimum of 2 inches under the drum cover
(overlap) - not the edge of the diaphragm.
• Check for holes between the fines chamber and the tailings cone (use a
good light). Also check the intake cone and the seal.
• Check for leaks on the inside drum cover, with the valves pushed in all
the way and out all the way.
• Check for wear on selector blades, upper and lower distribution plates
(especially holes), valves, air vanes and all liners.
• Make sure that the positioning of selector blades is properly balanced.
• Check that the position of all valves is synchronized in all positions or
opened by the same amount.
• A separator functions better with long selector blades rather than short.
This implies that for long blades, fewer are required for the same fineness. The
possible fineness range by means of diaphragm adjustment then, is always less.

General Rules:
1) Maximize the number of fan blades then the number selector blades that
gives you the largest diaphragm opening.
2) Increasing the main fan diameter or the shaft speed will dramatically
increase motor power drawn exponentially. Watch your motor power carefully.
See also sections on Qf/Qa and Modification Ideas.

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Sturtevant Modifications
A: Selector Blade Wear and Blade Shapes
Dr um Cov e r Adj us t a ble Dia phr a gm Pla t e ( Va lv e ) S e le c t or
Bla de

Flow P a t t e r n
Line s Ac r os s t he
Bla de

Out s ide
Cone

Highe s t We a r Uppe r
Ins ide Cone Zone Dis t r ibut ion
Ta ble
Flow
Dir e c t ion

Out line f or Hoc ke y S t ic k Bla de

Out line f or Tr a pe z oid Bla de

Notes:
1) The flow pattern along a selector blade is shown above, where most of the material is
concentrated at the blade edge nearest the upper distribution table. Material travels straight up,
but curves away as it begins to travel outward. This pattern is sometimes etched into the blade
steel, or appears as build-up, or can be replicated using a blade that has been spray painted.
2) The general rules for selector blades is as follows:
a) Increasing the number of blades increases the % passing 325 mesh.
b) Increasing the blade total area increases the product blaine.
Caution: in both cases it appears to be a non-linear relationship. There's insufficient
data to say exactly how they relate.
3) Keeping these general rules in mind, St. Constant developed the Trapezoid blade and Demopolis
developed the Hockey Stick blade. In each case, each plant has trimmed the excess steel (the
latter more extremely) in order to maximize the number of blades for a better 325, but at the
same time keeping the blaine about the same. To get the right shape a lot of experimenting is
required.

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 Air Separators

Sturtevant Modifications
B: Controlling Selector Bypass or Gap Reverse Flow
Adj us t a ble Dia phr a gm P la t e ( Va lv e )
Ga p Re v e r s e Flow
Dr um Cov e r

We a r Ring
S e le c t or Bla de
Bla de De f le c t or

Flow
Dir e c t ion

Ins ide Cone ( Re j e c t s ) Uppe r Dis t . Ta ble

Notes:
1) A minimum clearance of 1/4" must be maintained between the top the blade and the underside
of the inside drum cover. As well a 2" overlap should be maintained between the inside
diameter of the drum cover (valves fully retracted) and the outside diameter of the mounted
selector blades.
2) Due to the high pressure that exists just beyond the selector blades and the low pressure around
the center of the main fan, air will try to flow in the reverse direction through the gap between
the blade and drum cover. The wider the gap the more reverse air flow. This reverse air flow
will drag coarse particles along, contaminating the finish product.
3) To improve performance despite tight clearances there are two modification ideas to try:
a) A 1/4" X 1" flat bar can be welded on the top edge and on the side facing the direction
of travel as shown above, (the correct length requires experimenting). The flatbar or lip
prevents coarse particles from leaving the top edge and getting re-entrained with the
reverse air flow. This idea was first developed in Demopolis and tried successfully in
Woodstock.
b) A wear ring can be welded to the underside of the inside drum cover all of the way
around. This blocks the reverse air flow and thus prevents any re-entrainment. This
idea was developed by St. Constant.
c) Exshaw found that one works just as well as the other. Trying both did not improve on
the first.

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Sturtevant Modifications
C: Ideas from Sturtevant
Dr um Cov e r Adj us t a ble Dia phr a gm Pla t e ( Va lv e ) S e le c t or
Bla de

Flow P a t t e r n
Line s Ac r os s t he
Bla de
Ve r t ic a l Inne r
De f le c t or Ring

S uppor t
Br a c ke t

Ta ble Ex t e ns ion Uppe r

Ins ide Cone Dis t r ibut ion
Ta ble

Flow
Air a nd m a t e r ia l m a y w e a r
Dir e c t ion
of f dr um c ov e r e dge ,
a llow ing m a t e r ia l t o lif t
t he dia phr a gm pla t e .

Dia phr a gm P la t e ( v a lv e pla t e )

Ins ide Dr um c ov e r

Air a nd Ma t e r ia l Flow

Notes:
1) On many Sturtevants, operators have found that the upper table diameter is too small giving less than
satisfactory performance. One idea from Sturtevant is to install a 6" table extension, shown above which does
help improve the 325 mesh on fines product. WATCH that no gap exists between the table and new
extension.
2) Another idea from Sturtevant is to install a deflector ring in behind the blade all of the way around the upper
table, as shown above. The idea works in that it does improve mesh and blaine performance, but it is not
recommended in that it appears to increase separator bypass as well. In addition, material builds up in behind
which adds a lot of extra weight to the table.

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 Sturtevant Modifications
D: Other Upper Table Modifications
View of Uppe r Sturtevant Assembly
Fresh Air Vent
Intake
Cone

Fa n Blade

Selector Turnbuckle
Blade

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Inner Cone
Upper Lower
Table Table Outer Cone

Notes:
1) Often the upper distribution table warps or sags with time, thus creating an irregular clearance between blades and the inside
drum cover. To help correct this one can install reinforcing struts with turnbuckles (one per fan blade arm, 12 total). Since the upper
table is normally a bolted assembly, these can be loosened, allowing the struts to be adjusted, then retightened with the proper
clearance. In addition the struts add extra mechanical strengh to the assembly, minimizing future problems.

2) In cases where the mill circuit is producing a very high blaine product and all 60 selector blades are normally required, one is
left with just fan blade adjustments to make on the separator. Since there is normally only space for 12 blades, adjustments are often
too much or too little. By installing a fresh air vent, shown above, one can fine tune the main fan updraft by short circuiting it with
some fresh air. The "bleed" air vent should be located as close to the intake cone as possible. (Woodstock plant installed a 4" line
on a 16' diameter Sturtevant for 7700 blaine masonry cement.)
Air Separators
 Sturtevant Modifications View of Upper Sturtev ant Assembly
Volume 1

E: Demopolis Whizzer and Lower Table Modifications (Whizzer)

Fan Blade

Selector Blade

Support Ring

Whizzer Blad es (4 8)

De flector Plates

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Fines Flow Lines
Shortened Lower Table

Re je cts Dispersion Zo ne
Second Separation Zone First Separation Zone
Notes (modifications developed by RC Watts, Demopolis for a 20' diameter Sturtevant):
1) Reduce lower table diameter (7' to 5') to increase size of the dispersion cloud. This improves the separation of smaller
particles from the coarse particles. Note enlarging the table has the opposite effect.

2) Weld on 12 long whizzer blades (as in a Raymond Separator) with an extra support ring as shown. The support ring is used
to mount extra whizzer blades (48 total) and deflector plates or baffles (12 total, alternating long and short). The tip to tip diameter in
Demopolis' 20' diameter Sturtevant is 10'.

3) The whizzer blades takes advantage of the bigger cloud which in effect creates two separation zones. Note that installing whizzer
blades by themselves increased separator bypass. Deflectors and a smaller lower table marginally improves 325 and efficiency.
Both need to be installed to maximize performance.
 Sturtevant Modifications View of Upper Sturtevant Assembly
F: Montreal East Retrofit Showing Montrea l East Prototype Retrofit

Before Retrofit Afte r Retrofit

Fa n Blade

Modified Dia phragm

Cage Brace
Upper Table

216 Pin
Squirrel
Selector Blade Ca ge
Diap hra gm Plate

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Inside Drum Cover Lower Table Extended Grum Cover

Drum Cover Brace

Notes:
1) 18' Montreal East Sturtevant modified with a pin or rod cage. 64 selector blades were replaced with a cage
consisting of 216 vertical pins or rods. The inside drum cover was extended to overlap as shown, with a simple labrynith
seal at the top of the cage assembly. Diaphragm plates and control rods were modified to suit the smaller diameter
opening. As well the shaft rpm was increased 10% to take advantage of the drop in power that occurred.

2) Production increased by approximately 4-5%; % passing #325 mesh improved by 2%; and a better RR# (particle
size distribution) was achieved.

3) Study was done jointly by Lafarge and Sturtevant 1986-1988. Report available through CTS.
Air Separators
Volume 1

Sturtevant Modifications
G: Internal Airflow Considerations

Notes:
A) If the air intake duct is not being used for drying or cooling then according to
Demopolis experience, this duct (and other protrusions) should be cut flush
to the inner cone. The extended duct(s) into the inner cone disturbs the
cyclonic action and re-entraining coarse particles when it is no longer
necessary. Fluidizing the coarse particles at the bottom of the inner cone
serves only to increase the chance that they will flow out through the return
air vanes contaminating the finish product. Note that excessive reverse air
flow through the rejects duct will do the same thing. In the latter case it may
be necessary to install a flap valve of some sort.

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 Air Separators

B) Some effort has been spent testing different configurations on pilot scale
models. Unfortunately nothing conclusive came out of this. Clearly this is a
source of separator bypass (which is avoided in high efficiency cage rotor
type separators) - an inherent flaw in this design that we can do little about.
However recognize that as the table and fan turns, the air flow in both the
inner and outer cones will turn in the same direction. Thus it is important
that the return air vanes be oriented such that air flows from outer to inner
cone. This does increase bypass but that's better than having coarse particles
flowing from inner to outer cone which will happen if the these blades are
turned the wrong way.

C) In some instances, it is possible to over vent the separator. In such cases over
venting will pull coarse particles from the inner cone into the outer cone,
decreasing the fines product mesh and blaine. However this is difficult to
detect unless the dust collector is dedicated to just the separator. In this case
the dust collector fines should equal or better the separator fines.

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4.2.3 Raymond Separators

Operation (see also figures 4.2.3a & 4.2.3b)
• Material is introduced into the top of the separator and falls on the
distribution plate. The material is slung outward into an air stream, created
by the fan, and lifted to and through the separation blades.
• The double whizzers knock down the coarse particles where they are
collected and discharged from the inner cone back to the mill inlet for
regrinding.
• The finer particles are lifted through the whizzers passing by the selector
vanes and collected and discharged from the outer cone to a transport devise.
• The selector vanes determine how much air and material is directed through
the double whizzer blades. If all the material were to be directed through the
whizzer blades there would be too many returns. This means higher
production costs. If too little material is directed through the whizzer blades
there is not proper segregation and the proper amount passing a 325 mesh
screen is not achieved.
• The selector vanes can be adjusted and serve the same function as the
adjustment plates in a Sturtevant separator.
• Since the system is not of the air through type there is no need for a large
dust collector. The only air generated is from the transportation system (air
gravity conveyor) and thermal displacements.
• Water cooling jackets are fixed on the exterior of the outer cone in case the
finished product is excessively hot.

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 Air Separators

Figure 4.2.3a: Raymond Double Whizzer Separator

Material Flow and Air Sweep Through The Air Separator (schematic)

Raymond Double
Separator Feed (through hollow shaft)
Whizzer
Separator

Fan Blade

Damper

Deflector

Whizzer Blades

Lower Table

Guide Vanes

Fresh Air
Intake To Dust Collector

Internal Airflows

Rejects

Fines

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Figure 4.2.3b: Raymond Air Classifier

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 Air Separators

4.2.4 High Efficiency Separators

Principle of Operation
High efficiency separators (HES) are sometimes called CAGE ROTOR
separators. One of the most obvious differences between HES and the older
Sturtevant and Raymond separators is that the older machines had internal fans
while the HES has no fan and relies on an external fan to supply air for
separation and transport of material. Within Lafarge in North America there
two types of HES presently in service. O-SEPA's are built and sold by Fuller
under license from Onoda Cement in Japan. SEPOL's are built and sold by
Polysius. Note also that the major difference between the O-Sepa and the Sepol,
is that air is down-drafted in the Sepol where as it is up-drafted in the O'Sepa.
Operational installations are as follows:

O-SEPA: Bath FMA, FMB

Richmond FM1, FM2
Whitehall FM2

SEPOL: Alpena FM19, FM20, FM21

Classification Process (see figure 4.2.4a)

The only moving part within the separator is the cage rotor. The rotor is
driven by a variable speed motor controlled from the control room. Clean air
enters the volute housing and is forced to travel in a circular path by the shape of
the housing. The air encounters the inlet vanes which are arranges in a circle
completely around the cage rotor. The air next enters the classification zone
which is the space between the inlet vanes and the cage rotor vanes. The air now
enters the cage rotor through its vanes. The air then exits through the bottom of
the cage rotor in Sepol's; or through the top of the cage rotor in O-Sepa's; and
then out of the separator through the exit elbow. Unclassified material enters the
separator at the top and falls by gravity to the top of the cage rotor and lands on
the distribution table. Since the table is rotating, centrifugal force propels the
material outwards and off the rim of the distribution table where it impacts a
wear ring and begins to fall into the classification zone.
At this time, the material encounters the air entering through the inlet
vanes and begins to fall through the classification zone in a circular path induced
by the air currents. The larger, heavier particles tend to fall through the circular
air currents while the smaller lighter particles tend to flow with the air currents

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into the cage rotor and out of the classifier as finished product. Particles which
are marginal in size may enter the cage rotor vanes but may also be rejected if
their velocity is not great enough to pass between adjacent vanes without being
struck by a vane. One way to visualize this operation is to consider that there is
specific amount of time between the passing of one vane and the next vane. If a
particle can travel through the rotor vanes in less time than this passing time, it
can penetrate the cage and flow out of the separator. If the particle is traveling
too slowly, it will be struck by a vane and be rejected.
Figure 4.2.4a
OSEPA Details
Fe e d Cla s s if ic a t ion Zone

Fe e d

Ca ge Rot a t ion

Inle t
P le num Unif or m
Flow Dis t ' n

Guide Va ne Dir e c t ion

Fineness control
Understanding of the previous described classification process leads to an
understanding of the manner in which the fineness is controlled. Two methods
are available for controlling the fineness:
A) By varying the volume of air flowing through the separator, the velocity of
the air entering the cage is also varied. As the volume and velocity is
increased, the PRODUCT becomes coarser. As the volume and velocity is
decreased, the PRODUCT becomes finer.
B) By varying the speed of the cage rotor, the blade passing time is varied. As
the rotor speed is increased, the PRODUCT becomes finer. As the rotor
speed is decreased, the PRODUCT becomes coarser.

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 Air Separators

(Table speed refers also to cage rotor speed.)

It is readily seen that product fineness control is much easier with the HES
than with the older types of separators. In addition, there are no selector blades
to change. All fineness control can be done from the control room.
The finer material that leaves the HES in the air stream is considered finished
product. This product is carried in the air stream and on to the dust collection
system. It is here that the dust laden air entering the collector is cleaned and the
finish product is collected and transported via air slides and air lock feeders to
the cement pump which pumps it to the storage silos.

ALPENA HES DESIGN DATA

FM 19 FM 20,21
Separator horsepower 200 500
Cage rotor diameter (m) 2.0 3.1
Fan HP 300 700
Draft rating (ACFM) 59,000 143,000
Rotor speed range (RPM) 47-280 31-190
Design feed rate (TPH) 165 514

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Volume 1

Figure 4.2.4b: Fuller O-SEPA

Fine s

Secondary Feed
Air

Primary Air

Rejects

Troubleshooting
High efficiency separators for the most part run trouble free. The
dispersion plate, impact plate, guide vanes and rotor cage need to be inspected
occasionally. Of particular importance are the intake duct. For best
performance, the gas flow velocity must be as uniform as possible over the entire
height of the cage. Damaged dampers and dust build-ups have caused skewed
intake flows, resulting in poor performance.
The cage seal is another source of problems. The seal between the cage
and the outlet duct must be in good shape to prevent coarse particles from
contaminating the finished product. Newer OSEPA's have a better seal design.
Research by ONODA suggests that the different sizes of separators may
not have been scaled up correctly. Cage height, gap width (between the cage
and guide vanes) and especially cage bars or blade spacing are important
factors. Apparently there is a critical optimum spacing width between cage
blades or bars. Too wide or too narrow results in poor 325 mesh values. The
spacing varies with unit size. Larger units appear to have spacing that's too
wide.
OSEPA vs SEPOL
We only have experience with these models in Lafarge Corporation. In
France, Five-Cail Babcock's (FCB) TSV high efficiency units have been installed
with very good success. Other models include FLS SEPAX and Sturtevant SD

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 Air Separators

Classifier. OSEPA's are characterized by a top discharge duct, twin feed chutes
and a bladed rotor cage. They also have both a primary and secondary air
intake ducts. The tertiary ducts have been eliminated from newer units.
SEPOL's are bottom discharge, with a single feed chute, single intake duct and
rotor cage with bars. To date there is no discernible difference in performance.
Figure 4.2.4c: High Efficiency Separator: O-SEPA Cross Section

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Volume 1

Moto r
Reducer
Reducer Support
Coupling
Drive Support

Shaft Assembly

Exit Du ct (To Du st
Collector & Fa n)
Feed

Air Seal

Buffer Plate

Dispe rsion Plate

Guide Vanes

Partition Plate

Swirl Blade

Secondary
Air Intake
Primary
Air Intake
Tertiary Air
Intake &
Dampe r

Hopper

Flap Gate

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 Air Separators

Figure 4.2.4d: High Efficiency Separator: Polysius SEPOL

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