Separator

The Siam Cement Industry Co.,Ltd.

Separator
O

Function of Separator

Development of Separator
O Calculation of Separator
- Separator Efficiency
- Tromp Curve
O

The Siam Cement Industry Co.,Ltd.

Function of Separator
 Separator function is to separate the fine

out of the mixed product.

 Separator in cement grinding can increase

efficiency by ...
Reducing of scecific power consumption (kWh/t)
O Increasing production rate (t/h)
O

The Siam Cement Industry Co.,Ltd.

Function of Separator
 In ideal grinding system, ground material of enough

small size should immediately left as product and no

small particle circulate in the system. Grinding energy
is then applied only to the oversized material, resulting
in the highest grinding efficiency.
But in actual grinding system, particle size is usually
widely distributed from smaller to bigger than target
size.
4

The Siam Cement Industry Co.,Ltd.

Function of Separator
 Opened circuit (or straight) grinding system that

material is ground only by one loop usually has high

degree of fineness set point. There is rather high
portion of too small particle in the product. Such
system consumed extra energy in vain (or loss) to
over ground too fine particle.

The Siam Cement Industry Co.,Ltd.

Function of Separator

Nature of Grinding or Size reduction

Wide PSD (Particle size distribution)
%

Mode of set point

Size

Size of cement particle

Effective size : 3-30 u (micron)

6

The Siam Cement Industry Co.,Ltd.

Function of Separator
Size Distribution depend
on system by system
%

Mode of set point

Size
Over ground
portion
7

Effective Size Range

~ 3-30 micron

Under ground
portion

The Siam Cement Industry Co.,Ltd.

Function of Separator
Opened Circuit Grinding System

Input Material

Cement Mill

Product

The Siam Cement Industry Co.,Ltd.

Function of Separator
Opened Circuit (Straight) Grinding
O
O
O
O
O
O
O
9

Single loop of material grinding flow

Mill outlet is finished product (no coarse particle allowed)
Mill set point to be very fine blaine
High ratio of over ground portion
High ratio of energy loss
High specific power consumption
Low production rate
The Siam Cement Industry Co.,Ltd.

Function of Separator
Input
Material

Cement Mill

Opened Circuit Grinding System

%

Mode of set point

Size
Over ground
portion
= LOSS !
10

Effective Size Range

~ 3-30 micron

Under ground
portion

The Siam Cement Industry Co.,Ltd.

Product

Function of Separator
Closed Circuit Grinding System
Sep.
Product
Input Material
11

Cement Mill
The Siam Cement Industry Co.,Ltd.

Function of Separator
 In closed circuit grinding system , coarse portion

separated by separator is returned to mill inlet and

reground with new infeed material while the fine from
separator go out as finished product. Mill outlet
fineness of this system can be lower than finished
product fineness, resulting in less too fine portion
generated. The specific power consumption is less and
production rate is higher than opened circuit.
12

The Siam Cement Industry Co.,Ltd.

Function of Separator
Closed Circuit System
%

Return

Mode of set point

Input
Material

Product

Cement Mill

Size
Over ground
portion
13

Effective Size Range

~ 3-30 micron

Under ground
portion

To be returned

The Siam Cement Industry Co.,Ltd.

Function of Separator
Closed Circuit Grinding
O
O
O
O
O
O
O
O
14

Multi loop of material grinding flow

Mill outlet can contain coarse particle
Separator separate coarse and fine as return and product
Set point not to be very fine blaine
Low ratio of overground portion
Low ratio of energy loss
Low specific power consumption
High production rate
The Siam Cement Industry Co.,Ltd.

Function of Separator

37 44
15

The Siam Cement Industry Co.,Ltd.

Separating Principle
Cyclone
Separator

16

The Siam Cement Industry Co.,Ltd.

Fines

Cyclone
Cyclone

Immersion Tube
Feed
Cylindrical Part

mv2/r

Conical Part
Particle is deal with 3 kinds of forces ...
Fc = Centrifugal Force
Fg = Gravity Force
F17u = Uplifting Force

Tailings
The Siam Cement Industry Co.,Ltd.

Separating Principle of Separator

Fu
Fg

18

Fc

Particle from distributor plate

is deal with 3 kinds of forces ...
Fc = Centrifugal Force
Fg = Gravity Force
Fu = Uplifting Force

The Siam Cement Industry Co.,Ltd.

3 Basic Forces
Kc

3
.d

Fg a Kg

3
.d

Uplifting Force Fu a Ku

2
.d

Centrifugal Force Fc a
Gravity Force

19

The Siam Cement Industry Co.,Ltd.

Centrifugal force FC
O

FC

FC = m . V2 = . d3 . . V2

r
6
Constant K = . . V2
C
6
r

(it must be assumed that the speed of the distributing plate is

constant)
o

FC = KC . d3
20

The Siam Cement Industry Co.,Ltd.

Gravity force Fg
Fg = m . g = . d3 . . g

o
Fg

21

6
Constant K = . . g
g
6

Fg = Kg

3
.d

The Siam Cement Industry Co.,Ltd.

Uplifting force Fu(force due to air current)

Fu = c . . d2 . . v2

Fu

Constant K = C . . . V
u
6 2

(it must be assumed that the air velocity is constant)

Fu = Ku . d2

For Equilibrium ; Fg = Fu . sin

Kg . D3 = Ku . D2 sin
d

= Ku . Sin
Kg

22

The Siam Cement Industry Co.,Ltd.

Separator
O

Function of Separator

Development of Separator

Calculation of Separator
- Separator Efficiency
O
- Tromp Curve
O
O

23

The Siam Cement Industry Co.,Ltd.

Development of Separator
Conventional
2nd generation : Cyclone Air Separator
3rd generation : High Efficiency Separator
- FLS - Sepax
- Fuller - O-sepa
- KHD - Sepmaster
24

The Siam Cement Industry Co.,Ltd.

Separator
Other process

Cement grinding

Gravity type
Cyclone
Multi-cyclone
Static
Dynamic

Spray tower
Smoke chamber
DSC dust settling chamber
VS-separator
Grit separator
Mechanical air separator
Cyclone air separator
High efficiency separator

25

The Siam Cement Industry Co.,Ltd.

Separator in cement grinding

Static Separator
- no moving part in separator
- separating effect depend on air flow only

Dynamic separator

26

The Siam Cement Industry Co.,Ltd.

Static
Static separator
separator

VV- Separator
Separator

Baffle Plate
Inclined Plate

27

The Siam Cement Industry Co.,Ltd.

V-Separator
Principle of Operation

Mixed air and material flow into upper part of separator to classifying
zone between inclined plates and baffle plates. Fine particle is blown up
through baffle plates while coarse particle will drop to bottom by gravity
force.

Operation

Fineness control by air flow (less air, finer)

Blaine can be up to 4500 cm2/g
Pressure drop ~ 6-15 mbar

Application

Use in high pressure grinding eg. Clinker or raw material grinding

with roller press.

28

The Siam Cement Industry Co.,Ltd.

Static
Static separator
separator

Grit
Grit Separator
Separator

29

The Siam Cement Industry Co.,Ltd.

Grit-Separator
Principle of Operation

Mixed air and material flow into bottom of separator to guide vanes
resulting in radial and tangential velocity. Classifying process occur by
centrifugal force which depended on the angle of guide vans.

Operation

Fineness control by - air flow (less air, finer)

- immersion tube (longer, finer)
- angle of guide vanes (more tangential, finer)
Blaine can be up to 4500 cm2/g
Pressure drop ~ 10 -15 mbar

Application

Air swept ball mill

Vertical roller mill

30

The Siam Cement Industry Co.,Ltd.

Separator in cement grinding

Static Separator

Dynamic separator
- has rotor inside separator
- separating effect depend on air flow
and speed of rotor

31

The Siam Cement Industry Co.,Ltd.

Dynamic Separator
Mechanical air separator (1st generation)
Classifier with counter blades and internal fan
Cyclone air separator (2nd generation)
Classifier with counter blades and external fan
High efficiency separator (3rd generation)
Classifier with rotor cage and external fan
(High efficiency separator)
32

The Siam Cement Industry Co.,Ltd.

Mechanical
Mechanical
Air
Air Separator:
Separator:
Counter
Counter blades
blades
&& Internal
Internal Fan
Fan

33

The Siam Cement Industry Co.,Ltd.

Mechanical
Mechanical
Air
AirSeparator:
Separator:
Counter
Counterblades
blades
&&Internal
InternalFan
Fan

1. fine chamber
2. tailings cone
3. air vane
4. inside drum
5. fineness
6. gear control
valve rod
7. main shaft &
distributing hub
8.distributing plate
34

Sturtevant
Sturtevant Air
Air Separator
Separator
9. fan cone
10. counterblades
11. main fan blades
12. feed spout &
intake cone
13. tailings outlet
14. fine outlet
15. air inlet
16 air outlet

The Siam Cement Industry Co.,Ltd.

Mechanical
Mechanical
Air
AirSeparator:
Separator:

Infeed
Fan shaft

Counter
Counterblades
blades
&&Internal
InternalFan
Fan

Internal fan blade

Internal air flow
Guide vane
Baffle plate
Coarse

35

Fine

The Siam Cement Industry Co.,Ltd.

Mechanical
Mechanical Air
Air Separator
Separator :: Counter
Counter blades
blades && External
External Fan
Fan

36

The Siam Cement Industry Co.,Ltd.

Dynamic-Separator (counter blades & internal fan)

Mechanical Air Separator - 1st Generation
Principle of Operation

Material feed into top of separator then to dispersion plates.

Internal air circulation generated by internal fan blow up
material to the wall where big particle is drop down and return
as coarse while the fine is hit by counter blades and drop down
in outer chamber as fine product.

Operation

Fineness control by - Speed of counter blades (less speed, finer)

- number of counter blades (more , finer)
Blaine can be up to 4500 cm2/g
Pressure drop ~ 10 -15 mbar

37

The Siam Cement Industry Co.,Ltd.

Cyclone-Air
Cyclone-Air Separator
Separator :: Counter
Counter blades
blades && External
External Fan
Fan

(2nd Generation)
38

The Siam Cement Industry Co.,Ltd.

Dynamic-Separator (counter blades & external fan)

Cyclone Air Separator - 2nd Generation
Principle of Operation

Material feed into top of separator then to dispersion plates. Air flow
induced by external fan blow up material to counter blades. Classifying
process occur as that in internal fan type but the fine is collected by
external cyclones.

Operation

Fineness control by - air flow (less air, finer)

- Speed of counter blades (less speed, finer)
- number of counter blades (more , finer)
Blaine can be up to 4500 cm2/g
Pressure drop ~ 10 -15 mbar

39

The Siam Cement Industry Co.,Ltd.

High
High Efficiency
Efficiency Separator:
Separator: Rotor
Rotor cage
cage && External
External fan
fan

40

The Siam Cement Industry Co.,Ltd.

FULLER
FULLER O-SAPA
O-SAPA

41

The Siam Cement Industry Co.,Ltd.

High
High Efficiency
Efficiency Separator:
Separator: Sepmaster
Sepmaster

42

The Siam Cement Industry Co.,Ltd.

High
High Efficiency
Efficiency Separator:
Separator: Sepmaster
Sepmaster
43

The Siam Cement Industry Co.,Ltd.

High
High Efficiency
Efficiency Separator:
Separator:
Rotor
Rotor cage
cage && External
External fan
fan

FLS
FLS SEPAX
SEPAX SEPARATOR
SEPARATOR
44

The Siam Cement Industry Co.,Ltd.

High
High Efficiency
Efficiency Separator:
Separator:
Rotor
Rotor cage
cage && External
External fan
fan

FLS
FLS SEPAX
SEPAX SEPARATOR
SEPARATOR
45

The Siam Cement Industry Co.,Ltd.

46

The Siam Cement Industry Co.,Ltd.

Sepax Separator
47

The Siam Cement Industry Co.,Ltd.

Configuration in cement grinding process

48

The Siam Cement Industry Co.,Ltd.

Dynamic-Separator (rotor cage & external fan)

Principle of Operation
Material feed into top of separator then to dispersion plates above
rotor cage. Air flow induced by external fan blow up material to distribute
and fall into rotor cage where classifying occurred. The fine is collected
by external cyclones.

Operation
Fineness control by - air flow (less air, finer)
- Speed of rotor cage (less speed, finer)
Blaine can be up to 4500 cm2/g
Pressure drop ~ 10 -15 mbar
49

The Siam Cement Industry Co.,Ltd.

Dynamic-Separator (rotor cage & external fan)

High efficiency separator
Principle of Operation
Same as previous, but material feed into middle part of separator to
dispersion plates. Air flow induced by external fan blow up material to
rotor cage located at the top of separator. Since mixer of air and material
is less turbulence, classifying process is then higher in efficiency. The fine
in this process is collected bag filter or external cyclone.

Operation

Fineness control by - air flow (less air, finer)

- Speed of rotor cage (less speed, finer)
Blaine can be up to 4500 cm2/g
Pressure drop ~ 10 -15 mbar

50

The Siam Cement Industry Co.,Ltd.

Separator
O

Function of Separator

Development of Separator

Calculation of Separator
- Separator Efficiency
- Tromp Curve

51

The Siam Cement Industry Co.,Ltd.

Calculation of Separator
- Separator Efficiency
- Circulation Load
- Circulation Factor
- Tromp Curve
52

The Siam Cement Industry Co.,Ltd.

Circulation Factor : C
Rm (%)
Rg (%)

G (T/H)
F (T/H)

M (T/H)
C
Rf (%)

F (T/H)

F = Mill Feed
M = Separator Feed
G = Coarse Return
Rf = Residue of Fine
Rm = Residue of Separator Feed
Rg = Residue of Coarse Return
C = Circulation Factor

53

The Siam Cement Industry Co.,Ltd.

Circulation Factor : C
Rm (%)
Rg (%)

G (T/H)
F (T/H)

M (T/H)
C
Rf (%)

F (T/H)

Circulation Factor :
1. By weight
C= M
F
Material Balance : M = F + G
C = F+G
F

54

The Siam Cement Industry Co.,Ltd.

Circulation Factor : C
Rm (%)
Rg (%)

G (T/H)
F (T/H)

M (T/H)
C
Rf (%)

F (T/H)

Circulation Factor :
2. From Sieve Residues
M x Rm = F x Rf + G x Rg
M x Rm = F x Rf + G x Rg
F
F
F
C x Rm = Rf + (C-1) x Rg
C = Rg Rf
Rg Rm

55

The Siam Cement Industry Co.,Ltd.

Circulation Load : CL
Rm (%)
Rg (%)

G (T/H)
F (T/H)

M (T/H)
C
Rf (%)

F (T/H)

Circulation Load :
CL = G x 100
F
Material Balance : M = F + G
CL = (M F) x 100
F
= (C 1) x 100

56

The Siam Cement Industry Co.,Ltd.

Circulation Load : CL
M (T/H)
F
G (T/H)
F
F (T/H)
F

57

F (T/H)
F

C (T/H)

C - 1 (T/H)

1 (T/H)

1 (T/H)

The Siam Cement Industry Co.,Ltd.

Separator Efficiency
Separator efficiency calculated on the basis of power consumption
The ratio between the power consumption and the reduction of the obtained
residue is :
E = W log R1
R2
where E = consumption of specific power

kWh/t(nt)

W = grindability index with respect to sieve in question,i.e. the specific

power (kWh/t) necessary to reduce the residue by the factor 10.
R1 = initial residue on specified sieve
R2 = final residue on specified sieve
58

The Siam Cement Industry Co.,Ltd.

Real Separator
59

Ideal Separator
The Siam Cement Industry Co.,Ltd.

Separator Efficiency
Kwh/t

Es (Straigth grinding)
Bmax

Ec (Closed circuit grinding

with actual separator)
Eci (Closed circuit grinding
with ideal separator)

Separator Efficiency ( Vs) = B/Bmax

60

The Siam Cement Industry Co.,Ltd.

Closed Circuit Grinding with

Ideal Separation Eci
1
Ro

C
Rt

C S 1
Rf
Rm

C-1
Rg = 1
Eci = C x W x Log Rt
Rm
Eci = C x W x Log Ro + C - 1
Rf + C - 1
61

The Siam Cement Industry Co.,Ltd.

Closed Circuit Grinding

Ec
1
Ro

C
Rt

C S 1
Rf
Rm

C-1
Rg
Ec = C x W x Log Rt
Rm
Ec = C x W x Log Ro + (C 1) x Rg
Rf + (C 1) x Rg
62

The Siam Cement Industry Co.,Ltd.

Separator Efficiency
ENERGY REDUCTION : B = Es - Ec
Es
MAX ENERGY RED : Bmax = Es - Eci
Es
SEP.EFFICIENCY : Vs = B
Bmax
B = Bmax x Vs
63

The Siam Cement Industry Co.,Ltd.

Separator Efficiency
C x log Ro+100-(c-1)
Rf+100.(c-1)
Bmax = 1 log Ro
Rf
Vs

B x 100 = (Es-Ec) x 100

Bmax
(Es-Eci)

log Ro - c x log
Rf
Vs =
log Ro - c x log
Rf
64

x 100

Ro + (c-1) x Rg
Rf + (c-1) x Rg
Ro + (c-1) x 100
Rf + (c-1) x 100

x 100

The Siam Cement Industry Co.,Ltd.

75
33
65

The Siam Cement Industry Co.,Ltd.

Separator Efficiency (Vs)

1st generation : 20 - 50%
2nd generation : 40 - 69%
3rd generation : 65 - 85%

66

The Siam Cement Industry Co.,Ltd.

Separator
O

Function of Separator

Development of Separator

Calculation of Separator
- Separator Efficiency

- Tromp Curve
67

The Siam Cement Industry Co.,Ltd.

TROMP CURVE

The curve that show % of fractional

recovery (probability) of a given size to
escape separator as coarse or return

68

The Siam Cement Industry Co.,Ltd.

Benefit of TROMP CURVE

69

To find out Separator Efficiency in many ways eg.

Cut size
Sharpness of separation
Leakage (or Bypass)
Tail
Imperfection
The Siam Cement Industry Co.,Ltd.

70

Normal Value
Vs = 75-85%
K = 0.5-0.6
Delta = 0-10%

The Siam Cement Industry Co.,Ltd.

Instruction of TROMP CURVE

1. Take 3 point sample (FEED, FINES, COARSES)
2. Analyze Particle Size Distribution (PSD)
3. Calculate CIRCULATION FACTOR
4. Calculate TROMP VALUE
5. PLOT graph
6. Calculate SHARPNESS, CUT POINT and
BY PASS
71

The Siam Cement Industry Co.,Ltd.

Performance Test
O

Separator efficiency
* Particles size analysis of sample within
grinding system
- Separator feed (Rm)
- Separator fine (Rf)
- Separator tailing or Reject (Rg)

72

The Siam Cement Industry Co.,Ltd.

Performance Test
PSD
feed
%P

fines
%P

rejects
%P

1
3,60
4,90
1,90
2
6,10
8,30
3,50
4
11,00
14,70
6,30
8
18,50
25,40
10,10
16
31,20
44,90
14,40
24
39,70
58,80
16,10
32
47,80
71,10
19,10
48
60,60
87,00
28,10
64
67,70
92,60
37,10
96
81,80 100,00
59,50
200
95,10 100,00
89,00
TOTAL: 463,10 607,70 285,10

73

100,00
90,00
80,00
70,00
passants en %

dim.

60,00

feed %P
fines %P

50,00

rejects%P
40,00
30,00
20,00
10,00
0,00
1

10

100

1000

dimensiondesparticules

The Siam Cement Industry Co.,Ltd.

CIRCULATION FACTOR calculation

Ctotal =
where f

m -

74

( f - g)
( m - g)
Summation of all % pass of FINAL
PRODUCT
Summation of all % pass of
RETURN PRODUCT
Summation of all % pass of
SEPARATOR FEED PRODUCT
The Siam Cement Industry Co.,Ltd.

TROMP VALUE Calculation

tr d1 + d2
2

g1 - g2

1 - 1 x 100 %

m1 - m2

g
% PASS of RETURN
m % PASS of SEP. FEED
tr d1 + d2 - TROMP VALUE of size d1 + d2
C
75

(Total) CIRCULATION FACTOR

The Siam Cement Industry Co.,Ltd.

CUT SIZE ( X 50)

The size of particle that has the same
probability to be cut to the fine or to the
coarse. (That is = 50%)
Cut Size = D50

76

The Siam Cement Industry Co.,Ltd.

SHARPNESS (K)
The slope of Tromp curve define from
25% to 75% probability which show how good
of size separation (max value = 1)
K =

D25
D75
77

D25
D75
- Particle size of tromp value = 25 % (Mn)
- Particle size of tromp value = 75 % (Mn)
The Siam Cement Industry Co.,Ltd.

IMPERFECTION ( I )
Degree of skewness of slope of Tromp
curve define from 25% to 75% probability
which show how skew of size separation
I

D25
D75
78

D75 - D25
2 x D50
- Particle size of tromp value = 25 % (Mn)
- Particle size of tromp value = 75 % (Mn)
The Siam Cement Industry Co.,Ltd.

Tail
Ratio or trend of fine particle that is
separated to be the coarse
(due to agglomeration)
Remedy
Use grinding aid (chemical)
Use more air ratio
Improve dispersion effect
Lower temperature
79

The Siam Cement Industry Co.,Ltd.

BY PASS
Portion of fine material that leak to the
coarse due to imperfect of separator mechanical

80

The Siam Cement Industry Co.,Ltd.

FACTORS THAT EFFECT BY PASS

1. DISPERSION OF MATERIAL IN SEPARATOR
2. FINE PARTICLE THAT CIRCULATE IN AIR FLOW
3. SEPARATOR TYPE
4. CIRCULATION FACTOR
5. SPECIFIC AIR LOAD (>=2 Kg/m3)
C x (T/H) x 1000
< = 2.0 Kg/m3
Air Flow(m3/min) x 60
81

The Siam Cement Industry Co.,Ltd.

Efficiency Comparison of SEPARATORS

symbol Unit Larox FLS-REC O-SEPA FLS-SEPAX Sepmaster
Circulation C
1.3
1.9
2.7
2.5
2.1
Factor
Sep. Eff. Vs
%
35
66
74
71
83
Cut Size X50
u
66
42
22
36
40
Sharpness K
- 0.36 0.42
0.52
0.58
0.36
By Pass
d
%
10
14
11
9
13
82

The Siam Cement Industry Co.,Ltd.

Separator Comparison
Separator Efficiency

By-pass

1st generation : 20 - 50%

1st generation : 30 - 60%

2nd generation : 40 - 69%

2nd generation : 20 - 40%

3rd generation : 65 - 85%

3rd generation : 0 - 15%

Imperfection
1st generation : > 50%
2nd generation : 30 - 50%
3rd generation : 20 - 30%

83

The Siam Cement Industry Co.,Ltd.

Performance Test
Test result : provide information to :
O Adjustment of separator settings
O
O

Modification inside separator

O

84

Circulation load
Separating air flow , fan speed ,etc
Mechanical adjustment ,etc

The Siam Cement Industry Co.,Ltd.

Performance Test
Test result : provide information to
O Dedusting/cooling efficiency
From sampling within grinding system
O Means of judgement :
- Mass flow/gas flow measurement
- Dust granulometry
- Heat balance
O

85

The Siam Cement Industry Co.,Ltd.

Performance Test
Test result : provide information to
Adjustment of ventilation rate,air/gas flow
O Modification on
O

dedusting equipment
O material flow system
O

86

The Siam Cement Industry Co.,Ltd.

Sepax Performance
1.Sepax filter
2.Sepax inlet
3.Cyclone inlet
4.Fan inlet
5.Duct before damper
6.Cyclone top
7.Fan outlet
8.Cyclone top
9.Cyclone inlet
10.Dispersion area

P3,9

P 6,8 P 1
P2
P 10
P7

P5

P4

Measuring Point of Pressure & Temperature

87

The Siam Cement Industry Co.,Ltd.

Particles Size Distribution

RRSB Diagram
Particle size (um)

%Residue

1
1
5
15
30
50

10

80
90
95
99
99.5
99.8

100

200

Feed
Fine
Tailing

PSD (KW 1 ; CM No. 3)

88

The Siam Cement Industry Co.,Ltd.

%Fractional Recovery

Separator Efficiency
Tromp Curve

100
90
80
70
60
50
40
30
20
10
0

10

100

Particles Size (um)

1000

Tromp curve (KW 1 ; CM No. 3)

89

The Siam Cement Industry Co.,Ltd.

%RF

Separator Efficiency
Separating Efficiency Curve (%Recovery of Fines)

100
90
80
70
60
50
40
30
20
10
0

%RF

10 Particles Size (um) 100

1000

Sep. efficiency curve (KW 1 ; CM No. 3)

90

The Siam Cement Industry Co.,Ltd.

End of session
91

The Siam Cement Industry Co.,Ltd.