Cgo-Separators in The Cement Grinding Circuits

SEPARATORS IN THE CEMENT GRINDING CIRCUITS
1 Introduction:
Separators are widely used in the cement industry and particularly in the grinding circuits.
But what are separators?
Basically, separators separate fine particles from coarse particles.

The fine particles are generally collected as finished product while the coarse particles are sent back for
further grinding.
The trick is to make sure that the stream of coarse particles doesn’t contain any fine particles and, on the
other hand,
to make sure that the stream of fine particles doesn’t contain any coarse particles.
An efficient separator prevents overgrinding and as consequence a waste of energy.
There are mainly two types of separators: static separators and dynamic separators
The biggest difference is that static separators don't have moving parts and can be adjusted only with
mechanical modifications.
Static separators are divided in three sub-categories:
- Cyclones
- Static (or grit) separators
- V-separators
Dynamic separators are also divided in three sub-categories:
- Turbo separators (also called: first generation)
- Cyclone separators (also called: second generation)
- Cage type separators (also called: high efficiency separators and/or third generation)
Each type of separator will be developed in the following pages.

2 Static separators:
2.1 Cyclones
2.1.1 Introduction:
- In cement manufacturing industries, large-sized cyclone separators are used as main process equipments
significant numbers for handling high volumetric flow rates of dust-laden gases.
The cyclone is a simple mechanical device commonly used in the grinding circuits to remove relatively
-
large particles
from gas streams.
Cyclones are often used as precleaners to remove more than 80% of the particles greater than 20µm in
-
diameter.
Smaller particles that escape the cyclones can then be collected by more efficient control equipment like
bag filters
and electroprecipitators.
- Cyclones are relatively inexpensive since they have no moving parts and they are easy to operate.
- The most common type of cyclone is known as reverse flow cyclone separator
2.1.2 Advantages of cyclones:
- Low capital cost
- Ability to operate at high temperatures and pressures
- Low maintenance requirements because no moving parts
- Constant pressure drop
- Can separate both solid and liquid particles, sometimes both simultaneously
2.1.3 Disadvantages of cyclones:
- Low efficiency especially for very small particles
- High operating costs in case of high pressure drop
- Subject to erosion or clogging if abrasive solids are processed.
2.1.4 Principle of operation:
- The spiral pattern of gas flow is developed by the manner in
which the gas is introduced. It enters along the side of the
cyclone body wall and turns a number of times to spiral down
(external vortex) to the bottom. Particles in the gas are
subjected to centrifugal forces which move them radially
outwards, against the inward flow of gas and towards the
inside surface of the cyclone. When the gas reaches the
bottom of the cyclone, it reverses direction and flows up the
center of the tube, also in a spiral fashion. This spiral fashion is
also called inner vortex and fine particles are carried with the
air and leave the cyclone through the immersion tube.
Solids at the wall are pushed downwards by the outer vortex
and are going out by the solids exit.
- Gravity has been shown to have little effect on the
cyclone's operation.
See the figures on the right side and below.
www.thecementgrindingoffice.com
2.1.5 Forces affecting the particles
We consider a reverse flow cyclone with a cylindrical section of radius R. Particles entering the cyclone
-
with the gas stream
are forced into a circular motion.
The forces acting on a particle following a circular path are drag, buoyancy and centrifugal force (Fd, Fb
-
and Fc).
- The balance between these forces determines the equilibrium orbit adopted by the particle.
- The drag force is caused by the inward flow of gas and acts radially inwards.
Considering a particle of diameter x and density ρp following an orbit of radius r in a gas of density ρf an
viscosity µ,
We have the tangential velocity of the particle be Uϴ and the radial inward velocity of the gas be Ur. If w
assume that
the Stokes’ law applies under these conditions then the drag force is given by:
The centrifugal and buoyancy forces acting on the particle moving with a tangential velocity component
-
Uϴ at radius r are:
We can neglect the buoyancy force.
- And at a steady state, we have:
2.1.6 Flow Characteristics

- The rotational flow in the forced vortex within the cyclone body gives rise to a radial pressure gradient.
This pressure gradient, combined with the frictional pressure losses at the gas inlet and outlet and losses d
-
to changes in flow
direction, make up the total pressure drop.
The pressure drop, measured between the inlet and gas outlet, is usually proportional to the square of gas
-
flow rate through the
cyclone.
A resistance coefficient, the Euler number Eu, relates the cyclone pressure drop Δp to a characteristic
-
velocity:
Where ρf is the gas density

- The velocity v is based on the cross-section of the cylindrical body of the cyclone:
Where Q is the gas flow rate and D is the cyclone inside diameter
- The Euler number represents the ratio of pressure forces to the inertial forces acting on a fluid element.
- Value is practically constant for a given cyclone geometry, independent of the cyclone body diameter.
2.1.7 Mechanical parts:
- Tangential inlet volute
- Cylindrical section
- Immersion tube
- Conical section
- Discharge (rotary valve, pendulum flap)
2.1.8 Cyclones families:
- Conventional
- High efficiency
- High capacity
See the figure on the right:
2.1.9 Design of the cyclones:

- Dimensions:
a = Height of tangential inlet
b = Width of tangential inlet
De = Diameter of air outlet tube
S = Immersion length of outlet tube
D = Cyclone diameter
h = Length of cylindrical section
z = Length of conical section
H = Cyclone length
B = Diameter of material outlet
- On the sheet below, we can have a good idea of the standard cyclone dimensions for each family:
- Regardless of the configuration selected, we must follow the following recommendations:
a ≤ S to avoid the by-pass of the particules from the input section directly to the tube exit
b ≤ (D-De)/2 to avoid an excessive pressure drop
H ≥ 3D to keep the tip of the vortex formed by the gases inside the conical section of the cyclone
The inclination angle of the cone of the cyclone should be ≈ 7-8° to ensure a quick slide of the powder
De/D ≈ 0,4-0,5, H/De ≈ 8-10 and s/De ≈ 1 to ensure the operation with the maximum efficiency
2.1.10 Cyclones scale-up:

The scale-up of cyclones is based on a dimensionless parameter, the Stokes number,which characterizes
-
the separation
performance of a family of geometricallysimilar cyclones.
The Stokes number (Stk50) is deﬁned as:
It is interesting to find that, for well-designed and well-known cyclones, there is a direct correlation
-
between Eu and Stk50:
- For Stairmand high-efficiency cyclones: Stk50 = 1,4/10000 and Eu = 320

- For Stairmand high-capacity cyclones: Stk50 = 6/1000 and Eu = 46
2.1.11 Cyclone's efficiency:
- A model widely accepted is use for determining the efficiency of a cyclone.
- In this model, Ne is the number of revolutions the gas falling in the outer vortex.
The equation is:
See the "Design of cyclones" section to know the parameters

With the model of Lapple (1951) which is an empirical relationship in order to calculate the cut size (50%
-
of efficiency), we have:
Where:
Vi is gas inlet velocity in m/h (range in m/sec: 15-30 m/sec) and
µ is the air viscosity in kg/m.h
b is the width of the tangential inlet in m
ρp is the solid density in kg/m3
ρf is the air density in kg/m3
- The efficiency (Ƞi) of any size of particle is given by the following formula:
Where Di is the particle of reference of a range

The overall efficiency of the cyclone is a weighted average of the collection efficiencies for the various s
-
ranges and is
given by:
Where mi is the mass of particles in a certain range and

M is the total mass of particles
This efficiency can be undervalued with the concentration of solid particles in the air flow rate.
Then, when the concentration is higher than 2 gr/m3, a correction is applied:
where Ƞ1 is the efficiency found,

C1 is 2 (gr/m3),
Ƞ2 is the new efficiency and
C2 is the concentration in dust
2.1.12 Cyclone's pressure drop:
In the evaluation of a cyclone design, pressure drop is a primary consideration. Because it is directly
-
proportional to the
energy requirement, under any circumstance, knowledge of pressure drop through a cyclone is essential i
designing
a fan system.
Many models have been developed to determine the cyclone pressure drop but one of the well accepted is
-
the model
of Shepherd and Lapple (1939). The formula of Δp is:
K is a constant:
K = 16 for tangential inlet without neutral inlet vane
K = 7,5 if tangential inlet with neutral inlet vane and large cyclones
It is better to keep a pressure drop lower than 2,5 kPa.
2.1.13 Design modifications and consequences:
2.1.14 General methodology for the design of cyclones

- 1. Select a configuration (conventional, high efficiency or high capacity)
- 2. Select a speed at inlet (15-30 m/sec)
- 3. In function of the flow rate importance, it is useful to have a 1st estimation of the cyclones number
- 4. Calculate the diameter of the cylindrical section of the cyclone D
- 5. Calculate the other dimensions of the cyclone on the basis of the table for the selected configuration
- 6. Calculate the pressure drop
7. To analyze if D and Δp are excessively large. Analyze the possibility of using various cyclones in
-
parallel.
For nc cyclones in parallel repeat items 2 and 3 using the value of Q/nc in place
- 8. Calculate efficiencies for fractions and the total
9. Compare the calculated efficiency with desired. If you do not achieve the desired value, use a larger
-
value of speed inlet
- 10. Estimate the cost of the cyclone
An example of cyclone calculation is presented on the following page.
2 Static separators:
2.2 Static separators
2.2.1Introduction:
The static separator is like the cyclone a simple mechanical device commonly used in the grinding
-
circuits to remove
relatively large particles from gas streams.
- Static separators are relatively inexpensive since they have no moving parts and they are easy to operate.
- Static separators (or grit separators) are used especially in the raw mill circuits:
2.2.2Advantages of static separators:
- Low capital cost
- Ability to operate at high temperatures and pressures
- Low maintenance requirements because no moving parts
2.2.3Main disadvantage of static separators:
- Low efficiency especially for very small particles
2.2.4Principle of operation:
- The material enters with the air stream at the bottom of the separator.
- A vortex is created in the upper part of the cone of the separator because of the blades.
The coarse material goes towards the walls because of the centrifugal force, slides to the bottom and
-
leaves the separator.
- The fine material exits through the top of the immersion tube.
- The fineness of the product is adjusted by changing the position of the blades.
When the blades are in radial position (maximum of opening), the product of the static separator will be
-
coarser.
When the blades are adjusted in a more tangential position, the product is finer because the tangential
-
velocity of the
particle increased and the cut size decreased.
When the adjustment is higher than 60-70°, the particles tangential velocity decreases due to friction
-
against the blades,
and the cut size goes up again.
2.2.5Mechanical parts:
- Conical section
- Adjustable blades (with external adjustment)
- Tails cone
- Immersion tube (fines outlet)
2.2.6Operating characteristics:
- Pressure drop usually around 150 mmH2O
- Shortening the immersion tube will give a coarser product
- Lengthening the immersion tube will give a finer product

- Leaving the blades in completely radial position will give a coarse product
- Adjusting the blades more tangentially will give a finer product and a higher pressure drop
- If the product is not coarse enough, it is also possible to remove blades (1 of 2 for example)
- Usual dust concentrations: 500-1000 gr/m3
2.2.7Diameter calculation:
- The diameter of the separator can be determined with the following formula:
2.3 V-Separators
2.3.1Introduction:
- This separator is from KHD Humboldt Wedag AG.
- The V-separator is generally used with a pregrinding system (Roller Press).
- Applications mainly for raw meal, clinker and slag.

The main objective of this separator is to remove a maximum of fines particles from the Roller Press
-
feed in order
to decrease the problems of vibrations.
The V-separator is also combined with the high-efficiency Sepmaster to give the VSK separator. This
-
combination
can be used (for example) for slag, the Roller Press being a finishing system.
2.3.2Principle of operation:
- As its name suggests, the V-separator V has a V-shaped.
- The material enters by the top and falls on a series of inclined plates.
- The largest particles fall by gravity and leave the separator at the bottom.
- Intake air feed in the separator on one side and sweeps the fine particles from the material cascading.
The separation zone is therefore between the inclined plates and a series of deflectors inclined in another
-
direction.
- The fines go out with the air to the other side. See the design below:
2.3.3Mechanical parts:
- Body
- Inclined plates
- Inclined deflectors
2.3.4Operating characteristics:
- In case of hot material (clinker), a significant cooling is possible.
- At the contrary, in case of humid material (raw meal), a significant drying is possible.
- The cut size (or fineness of the product) of the V-separator is controlled only by the airflow quantity.
- Pressure drop usually between 50 and 150 mmH2O
2.3.5Dimensioning parameters:
- Specific feed loading: 4 kg/m3 (of air flow)
- Separator air loading by m2 of separating area: 6 m3/sec
3 Dynamic separators:
3.1 Introduction:
- Dynamic separators are classified in three categories (*), the first, second and third generation.
- In first generation separators, the air flow is generated by a fan within the body of the classifier.
- In second generation, the air flow is generated by an external fan and there are cyclones.
- And finally, the third generation has a rotating cage which replaces the counterblades.
(*) We are waiting a fourth generation
- Comparison of efficiencies:
3.2 First generation separators:
3.2.1 Introduction:
- Also called: Turbo separators or conventional separators.

The material to be classified is dispersed in the area where the separation is created by a distribution
-
plate.
- The air flow required for the separation is produced by a fan located inside the separator itself.
- The separator material feed is carried out mechanically by means of suitable continuous conveyors.
- Separators can have one or two motors, gear reducers and shaft (one for the main fan and the second one
for the distribution plate and the conterblades).
- Here a non-exhaustive list of conventional separators:

Heyd
-
(Ch.Pfeiffer)
Sturtevant
- Whirlwind Air
Classifier
Turbopol
-
(Polysius)
- Schmidt
- Raymond
- Escher Wyss
- CV (F.L.Smidth)
- Hischmann
These separators are used for both raw material and cement.
-
3.2.2 Advantages of 1st generation dynamic separators:
- Possibility of mechanical adjustments
- Possibility of very large flow rates
- Flexibility to produce products of different qualities
3.2.3 Disadvantages of 1st generation dynamic separators:

Bad efficiency especially with high circulating loads due to: poor distribution of the material in the cross
-
section,
poor dispersion of the material in the separating air and large quantities of fine material are recirculated
in the air,
increasing the amount of fines coming with the tails.
- No (or little) possibility of cooling or drying the material.

3.2.4 Principle of operation:
- The main fan produces a stream of air circulating within the separator.
- The fan blades pull air from inside the inner cone and push it into the outer cone.
- The material is generally fed on the top of the separator (in some cases, it is laterally).
The feed material falls over the dispersion plate, which gives sufficient centrifugal force to the particles
-
to arrive
in the separation zone.
Radial slats welded on the distribution plate prevent the displacement of the material which must be
-
separated.
- The air with dispersed particles flows up and passes the rotating counterblades.
The separation is mainly realized by two forces: the centrifugal force and the drag force. The drag force
-
produced by the
airflow on a particle is proportional to the cross-sectional area of the particle, on the other hand the
centrifugal force
is proportional to the mass (volume) of the particles.
Coarse particles are centrifuged and hit the inner wall of the separator. After hitting the wall the coarse
-
fraction gets
collected into cone.
As a certain number of fines particles are entrained downwards with coarse particles, the air flow
-
returning to the separating
area has a second chance to pick up any fines in the rejects.
The air with fines flows through the fan to the fines chamber. From there, the fine particles are separated
-
from the
conveying air and collected in the outer cone.
- The air with some amount of fine material is going back to the separating zone through the air vanes.
- Separators can also have some air inlet and outlet for cooling or drying purposes.
- See the figure below:

3.2.5 Possibilities of adjustments:
Main adjustments:
Control valves: Adjustment of the control valves modifies the opening area for the air to go in the main
-
fan area.
When this opening area is reduced, the fineness is increasing (for example Sturtevant).
Position of the counterblades: If the position is closer of the inner body, the opening area for the air to
-
go
in the main area will be reduced and the fineness will increase (for example Schmidt).
Counterblades and distribution plate rotation: In some cases where there are 2 motors and two shafts, it
-
is possible
to modify the speed of rotation of the counterblades and the distribution plate. If the speed of rotation
increases,
the fineness increases (for example Heyd).
Other possible adjustments:
- To increase the main fan speed.
- To remove counterblades.
- To increase the distribution plate diameter.
- To decrease the distance between the distribution plate and the counterblades.
Summary of the adjustments and consequences:

3.2.6 Parameter of dimensioning:
- The parameter widely accepted is the specific separator load:
The values depend from a supplier to another one:
3.2.7 Different designs:
- Turbopol:
- Heyd:
- Sturtevant:
- Raymond:
3.2.8 First generation separators data sheet:
- The data sheet allows to have a good idea of the first generation separators efficiency.
- The different data are explained here below:

Separators in the cement grinding circuits
3.3 Second generation separators:
3.3
Introduction:
.1
- Also called: Cyclones separators.
As the 1st generation, the material to b
-
where the separation is created by a
distribution plate.
- The air flow required for the separatio

The separator material feed is carried o
-
suitable continuous conveyors.
- Fines are conveyed in external cyclone
- Fresh air entry and air exit to filter.

The fan that moves the air is a more ef
-
considerably reduced dust loading.
These separators have a better separati
-
fan and the cyclones.
- Comparison between cyclones and con
The diagram here below shows the spe

in order to achieve a certain percentag
Cement Data Book).
For example, to get 20% residue on 30
-
produce a cement at 3200-3900 Blaine
separator with cyclones 3000-3600 Bla
- Here a non-exhaustive list of cyclones
3.3
Advantages of 2nd generation dynamic separators:
.2
- Possibility of mechanical adjustments
- Flexibility to produce products of diffe

- Better efficiency than the conventiona
- Less power consumption
- Reduced wear on the separator interna
3.3
Disadvantages of 2nd generation dynamic separators:
.3
- More space needed
- Less efficient than cage separators
3.3
Principle of operation:
.4
- The material is fed at the top of the sep
Material falls and is dispersed in the ci
-
plate.
The air stream is generated by an exter
-
there is a regulated fresh air inlet
in the part of the duct going to the sepa
There is an exit where air is removed t
-
maintain a constant underpressure
inside the system.
The coarse material is separated by asp
-
goes out via the bottom conical device
As a certain number of fines particles
-
coarse particles, the air flow returning
separating area has a second chance to
The air with some amount of fine mat
-
separating zone through the air vanes.
The fine material exits by the top of th
-
into the cyclones through the gas pipe.
The material is separated in the cyclon
-
of these.
The cleaned air (the dust content is gen
-
recirculated via the fan.
It has been observed that the air flow s
-
is in the order of 30% of the
air speed for conventional separators.
3.3
Possibilities of adjustments:
.5
Main adjustments:
- Speed of counterblades
- Fan speed
- Fan damper
- To remove or increase the counterblad
- To increase the distribution plate diam

To decrease the distance between the d
-
counterblades
3.3
Parameter of dimensioning:
.6
- The Specific Separator load
The values depend from a supplier to a
3.3
Different designs:
.7
- Wedag ZUB (KHD):
- Cyclopol (Polysius):
- SKET (ZAB):
3.3
Second generation separators data sheet:
.8
The data sheet allows to have a good i
-
separators efficiency.
- The different data are explained hereb
3.4 Third generation separators:

Introd
3.4.1
uction:
- Also called: Cage separators or Hig
These separators has been develop
-
(O'Sepa from Onoda Cement).
As the second generation, the air fl
-
produced by an external fan.
The separator material feed is carri
-
suitable continuous conveyors.
Fines are conveyed by air in extern
-
filter.
The main separating device is a cy
-
cage composed of blades closely sp
- The rotor is operated by a variable
The rotor speed determines swirl in
-
the cut of the separator.
The composition of forces acting in
-
the figure below:
- Here a non-exhaustive list of High

- O'Sepa (FLSmidth)
- Sepol (Polysius)
- Sepax (FLSmidth)
- SD (Sturtevant)
- Sepmaster (KHD)
- QDK (Pfeiffer)
- TSV (FCB)
- O&K (Orenstein & Koppel AG
- PRESEP VTP (PSP Engineerin
- CTC SERIES (CEMTEC)
- Copies from China
3.4.2 Advantages of 3rd generation dynamic
- Possibility of mechanical adjustme
- Flexibility to produce products of d
- Better efficiency than the conventio
- Reduction of mill specific consump
- Increase of the grinding capacity
- Reduction of the cement temperatu
Better cement quality (Straighter R
-
early strengths)
3.4.3 Disadvantages of 3rd generation dynam
- Difficulty to get the optimum seal
No constant velocity of flow and n
-
of particles can affect the efficienc
3.4.4 General principle of operation:
- The material is generally fed at the
There are 2 or more feed chutes in
-
the material on the distribution plat
Material falls and is dispersed in th
-
plate. The feed forms a thin cylindr
of material in the classifying zone.
The air stream is generated by an e
-
circuit, it is possible to have 100%
a part of the air recirculated or 100
Often, there are a primary air inlet,
-
air inlet depending of the design.
The airflow leaves the guide vanes
-
of the cage.
Material is arriving in the separatio
-
louvres) and the rotating cage.
The particles are driven by three fo
-
the dispersing plate, the drag force
due to the air flow and the gravity
- The drag force is trying to pull the
The centrifugal force is trying to pu
-
vanes.
It is the balance of these forces wh
-
separator. This balance remaining
because the material in the classify
of rotation, then the centrifugal for
in all areas. On the other hand, the
distributed uniformly, the air veloc
(then, drag force) remains equal.
The coarse material doesn't enter in
-
gravity up to the bottom device (co
- The fine material enters in the cage
upper or lower part of the separato
- See the figure below (from the O'S
Warning: Suppliers propose genera

where the gas and the material are
together of the mill and enter from
Some suppliers propose also specia
grinding systems (Roller Press).
Principles of operation described in
version for grinding circuits with
bucket elevator for the material fee
3.4.5 Principle of operation for each design:
3.4.5.1 O'Sepa (FLSmidth):
- The material enters through the top
- Material falls and is dispersed by th
The primary and secondary air crea
-
zone.
- The material falls between the roto
aspirated. Coarse particles are acce
rotor and held by the guide vanes,
through the lower part.
The fine material exits with the airf
-
housing.
As a certain number of fines partic
-
coarse particles, the tertiary air flow
helps to pick up any fines in the rej
- The fineness of the product is adju
- Website of the separator:
- See the figure above

3.4.5.2 Sepol (Polysius):
- There is one tangential air inlet.
The material falls between the roto
-
-
housing.
3.4.5.3 Sepax (FLSmidth):
The sepax differs by a body divide
-
separation parts.
- The material enters through the mi
- Air enters from the bottom of the s
- Material is carried with the air to th
Material enters in the classification
-
guide vanes.
Coarse particles are accelerated by
-
and slide up to the rejects cone.
Fines are aspirated with air flow th
-
through the upper part of the separ

3.4.5.4 SD (Sturtevant):
- The tangential air inlet is in the upp
- Various tangential air inlets can be
-
- Some models have horizontal louv
-
housing.
3.4.5.5 Sepmaster (KHD):
- The material enters from the top of
- The air stream is generated by an e
-
-
housing.
- Motor and reducer are on the botto
3.4.5.6 QDK (Pfeiffer):
-
-
housing.
TSV
3.4.5.7 (FCB)
:
-
housing.
3.4.5.8 O&K (Orenstein & Koppel AG):
-
-
housing.
3.4.5.9 PRESEP VTP (PSP Engineering a.s.):
- There is one or various tangential a
-
-
housing.
3.4.5.10 CTC SERIES (CEMTEC):
-
housing.

3.4
Possibilities of adjustments:
.6
Main adjustments:
- Speed of rotating cage
- Fan speed
- Fan damper
- To remove or increase the cage blades
- To adjust the seal gap at the minimum

3.4
Possible causes of malfunction:
.7
- Wear of the cage blades
- Guide vanes not adjusted
- Guide vane system partially blocked (c
- Wear of the seal
- Seal not well adjusted (big gap, impac

Material deposits due to insufficient ai
-
guide vanes
3.4
Parameter of dimensioning:
.8
The following parameters are widely accepted for a Portland cement (95-5):
- Pressure drop across separator: 200-25
- Installed separator power consumption
- Installed fan power consumption: ±2,5

Ratio cage diameter - cage height: from
-
supplier
Specific air load in the feed (ratio tonn
-
material - air flow in m3/h): max. 2,5 k
Specific air load in the fines (ratio tonn
-
material - air flow in m3/h): max. 0,8 k
specific rotor load (ratio tonnage per h
-
m2 of the rotating cage): max. 12 t/h.m
- Circumferencial speed: 5-30 m/sec
- Air speed through cage: 4 m/sec
- See the calculator to size a third gener
(*) Only for a first and rough estimatio

To avoid dust emissions, the separator
-
(±50 mmH2O). In order to maintain th
an additional filter must be installed in
additional air flow corresponds to ±10
separator air flow.
3.4
.8. O'Sepa (FLSmidth):
1
- Material feed: central from top (2 or 4
- Number of air inlets: 3
- Ratio cage diameter - cage height: 1,7
- Sizing chart (from the O'Sepa brochur

3.4
.8. Sepol (Polysius):
2
- Material feed: central from top
- Sizing chart (from the Sepol brochure)
3.4
.8. Sepax (FLSmidth):
3
- Material feed: lower part
- Ratio cage diameter - cage height:

- Sizing chart (from the Sepax brochure
3.4
.8. SD (Sturtevant):
4
- Number of air inlets: 1 to 8
- Sizing chart (from the Sturtevant broch

3.4
.8. Sepmaster (KHD):
5
- Sizing chart (from the Sepmaster broc

3.4
.8. QDK (Pfeiffer):
6
- No sizing chart available in the brochu
3.4
.8. TSV (FCB):
7
- No sizing chart available in the brochu

3.4
.8. PRESEP VTP (PSP Engineering a.s.):
8
- Number of air inlets: 1 or various
- Sizing chart (from the brochure):

3.4
.8. CTC SERIES (CEMTEC):
9
- Material feed: from top
- Sizing chart (from the brochure):

3.4.9 Types of circuits:

-The flowsheets of main types of circuits with high-efficiency separators are shown herebelow.
-There are a lot of other possible variants depending on the needs.
-Cases for raw meals circuits will be presented in the chapter dedicated to high-efficiency separators for
meal circuits.
-Cases with pre-grinding systems will be presented in a different presentation.
3.4.9.1 Separator with bag filter and separated mill ventilation:
Comments:
-The mill ventilation is separated
-Right circuit if important need of cooling
-The static separator in the mill ventilation circuit is optional
-The product of the separator goes directly to the bag filter
-The big advantage is that it is possible to set each circuit separately
-This circuit requires more space and more initial investment
-This circuit requires more maintenance
3.4.9.2 Circuit with common bag filter:
Comments:
-The ventilation is common
-Possibility of cement cooling is limited
-Ventilation settings can be limited due to antagonistic objectives
-Problems of the cement mill can disturb the performance of the separator
-This circuit requires less space and less initial investment
-This circuit requires less maintenance
-Other flow-sheet:
3.4.9.3 Circuit with separator cyclones:
Comments:
-The mill ventilation is separated
-Right circuit if cooling is not necessary
-The product of the separator goes directly to cyclones
-The big advantage is that it is possible to set each circuit separately
-This circuit requires more space and more initial investment
-This circuit requires more maintenance
3.4.9.4 Circuit with separator cyclones and common ventilation:

Comments:
-The ventilation is common
-Right circuit if cooling is not necessary
-The product of the separator goes directly to cyclones
-Ventilation settings can be limited due to antagonistic objectives
-Problems of the cement mill can disturb the performance of the separator
-Uncommon circuit
3.4.10 Special designs for raw mill circuits:
-Some suppliers propose versions for airswept mill circuits where there is no bucket elevator.
-For all these separators, there is a common inlet for gas and material at the bottom of the separator.
-The principle of operation remains the same.
-The Sepax has the particularity to have also a feed inlet in case of bucket elevator (Mill with central dis
-Idem for the Sepmaster SKS-L from KHD.
-Some examples below:
3.4.11 Types of raw meal circuits:
-Airswept mill circuit:
-Central discharge mill circuit (Double rotator):
-Tandem circuit:
3.4.11 Example of dimensioning:

-Expected production: 130 t/h
-Cement: 3000 Blaine
-Specific air load in the fines: 0,75 kg/m3 is chosen
-Calculated air flow: 130000 divided by 0,75 = 173333 m3/h
-Estimated circulation factor (Feed/Fines): 2
-Feed production: 130 multiplied by 2 = 260 t/h or 260000 kg/h
-Specific air load in the feed: 260000 divided by 173333 = 1,5 kg/m3 (it is ok because < 2,5 kg/m3)
-Specific rotating cage load: 10 t/h.m2
-Rotor separating area: 130 divided by 10 = 13 m2
-Ratio cage diameter - cage height: we choose 1,5
-We calculate with the formula: π.D.L and D = 1,5.L
-Result: π.1,5.L.L=13 => L = 1,66m
-Diameter of the cage: 1,66 multiplied by 1,5 = 2,49m or 2,50m
-Speed through the cage: 173333 divided by 3600 divided by 13 = 3,7 m/sec (it is OK because < 4 m/sec
-Different solutions are possible in function of the customer wishes:
-O'Sepa N-3000
-Sepol SV-250 (but the air flow is lower than 173333 m3/h)
-Sepax 400 in function of the air flow
-Sturtevant SD 120 in function of the airflow
-Sepmaster 2500 in function of the cage diameter
See the calculator to size a third generation separator (*):
(*) Only for a first and rough estimation!

3.4.12 Third generation separators data sheet:
-The data sheet allows to have a good idea of the third generation separators efficiency.
-The different data are explained herebelow:
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SEPARATORS IN THE CEMENT GRINDING CIRCUITS

But what are separators?

Basically, separators separate fine particles from coarse particles.

An efficient separator prevents overgrinding and as consequence a waste of energy.

Static separators are divided in three sub-categories:

- Static (or grit) separators

Dynamic separators are also divided in three sub-categories:

- Turbo separators (also called: first generation)

- Cyclone separators (also called: second generation)

Each type of separator will be developed in the following pages.

2.1.6 Flow Characteristics

Where ρf is the gas density

2.1.9 Design of the cyclones:

2.1.10 Cyclones scale-up:

- For Stairmand high-efficiency cyclones: Stk50 = 1,4/10000 and Eu = 320

See the "Design of cyclones" section to know the parameters

Where Di is the particle of reference of a range

Where mi is the mass of particles in a certain range and

where Ƞ1 is the efficiency found,

2.1.14 General methodology for the design of cyclones

An example of cyclone calculation is presented on the following page.

SEPARATORS IN THE CEMENT GRINDING CIRCUITS

2.2 Static separators

- Low capital cost

- Ability to operate at high temperatures and pressures

- Low maintenance requirements because no moving parts

2.2.3Main disadvantage of static separators:

- Low efficiency especially for very small particles

- Adjustable blades (with external adjustment)

- Immersion tube (fines outlet)

- Pressure drop usually around 150 mmH2O

- Shortening the immersion tube will give a coarser product

- Lengthening the immersion tube will give a finer product

- Usual dust concentrations: 500-1000 gr/m3

- This separator is from KHD Humboldt Wedag AG.

- The V-separator is generally used with a pregrinding system (Roller Press).

- Applications mainly for raw meal, clinker and slag.

- As its name suggests, the V-separator V has a V-shaped.

- In case of hot material (clinker), a significant cooling is possible.

- Pressure drop usually between 50 and 150 mmH2O

- Specific feed loading: 4 kg/m3 (of air flow)

- Separator air loading by m2 of separating area: 6 m3/sec

SEPARATORS IN THE CEMENT GRINDING CIRCUITS

(*) We are waiting a fourth generation

- Also called: Turbo separators or conventional separators.

for the distribution plate and the conterblades).

- Here a non-exhaustive list of conventional separators:

3.2.2 Advantages of 1st generation dynamic separators:

- Possibility of mechanical adjustments

- Possibility of very large flow rates

- Flexibility to produce products of different qualities

3.2.3 Disadvantages of 1st generation dynamic separators:

- No (or little) possibility of cooling or drying the material.

3.2.4 Principle of operation:

- See the figure below:

Other possible adjustments:

- To increase the main fan speed.

- To increase the distribution plate diameter.

Summary of the adjustments and consequences: