Separators and

Classifiers
F3
Separators and Classifiers… What
do they do?

 In the case of the cement plant, the

separator separates fine particles from
coarse particles

 The fine particles are collected as product

while the coarse particles are sent back for
further grinding.
 What is an efficient separator?
 The trick is to make sure that the stream of
coarse particles doesn’t contain any fine particles
and, likewise, to make sure that the stream of
fine particles doesn’t contain any coarse
particles.

 An efficient separator prevents over-grinding and

the waste of energy that accompanies it.

 It also keeps product within specifications by

making sure that the correct particle size is
achieved.
 Air classifiers
 Air classifiers, cones or cyclones use the
spiral air flow action or acceleration within
a chamber to separate or classify solid
particles.

 Powders suspended in air or gas enter the

cyclone and the heavier particles spiral out
and down where they are collected.  The
air and finer particles flow up to the top
where they may be passed to another
cyclone with finer classification capability.

 A cyclone is essentially a settling chamber

where the effects of gravity (acceleration)
have been replaced with centrifugal
acceleration.
Cyclone Classifier
 Fabric Filters
 Fabric Filter systems typically consist of a
tubular bag or envelop, suspended in such
a manner that the collected particles fall
into a hopper when dislodged from the
fabric.

 Fabric Filters typically provide collection

efficiencies of 99% and even efficiencies
of 99.99% are not uncommon.
 Electrostatic separators
 Electrostatic separators use
preferential ionization or charging of
particles to separate conductors
from dielectrics (nonconductors). 
 The charged dielectric particles are
attracted to an oppositely charged
electrode and collected.  The
particles may be charged through
contact electrification, conductive
induction or high tension (ion
bombardment). 
 Electrostatic Precipitators are
common examples belonging to this
category.
CLASSIFICATION OF SOLID PARTICLES

 'Classification' is the sorting of the initial

distribution of particles to achieve a
desired degree of uniformity, according to
the chosen parameter. This might be
density, shape, or size.
 Classification is used to control or limit the
shortcomings of the previous processing
stages, for example to eliminate oversize
particles at the exit of a mill or spray drier.
 Classification techniques
Many different types of classification techniques exist and a
breakdown of the main equipment selection criteria will include:

Unit operation requirements:

 Capacity/throughput (kg/h)
 Feed material & final product quality (particle size distribution
(PSD), shape)
 Yield
 Selectivity (sharpness of cut)
 Material characteristics (abrasive, friable, compactable)

Process requirements:
 Type of process upstream of classifier (e.g. wet mill, spray drier)
 End-use of products (e.g. slurry, pellets, dry powder)
 Automation / control requirements
 Classification technologies
 Classification technologies fall into two main categories: those that use
liquid suspensions ('wet' - generally using water) and those conveyed
using a carrier gas ('dry' - generally using air):

Wet
 Hydrocyclones
 Centrifuges
 Wet dynamic classifications
 Screens / sieving
 Sedimentation

Dry
 Sieving
 Static classifiers (cyclones)
 Dynamic classifiers (single stage, multi-stage)
 Cross-flow classifiers
 Counter-flow classifiers (elutriators) 
 Classifiers can also be combined with other unit operations such as
milling.
 Benefits of Classification
 reduced load on the grinding unit
 better efficiency
 possible production of many grades of
powder from the same feedstock
 capability of producing finer products with
steeper particle size distributions from the
same grinding step
 Air classifier performance
 Air classification that achieves cut sizes of a few microns typically follows
Stokes' law. To study parameters that limit the air classifier's performance and
determine the unit's theoretical cut-size, the following equations can be derived
in the Stokes flow region:
18v
xt  (1)
s g
where, xt is the theoretical cut-size, µ is the air viscosity, v is
the airflow velocity, ρs is particle density, and g is
gravitational acceleration.
18vr r
And: xt  (2)
vp s
2

where vr is the radial air velocity, r is the separation radius, and vp is the particle's
tangential velocity.

 Equation (1) describes the theoretical cut-size based on elutriation. Increasing or

decreasing the classifier's air-flow velocity (v) adjusts the cut-size. Equation (2)
describes the theoretical cut-size based on centrifugal cut-size based on
centrifugal-free and forced vortex airflows.
Principles of air classifier operation

 Air classifier operation is based on airflow. The airflow concepts of

elutriation, free vortex, and forced vortex are used either
separately or in combination in the design of today's classifiers.

 Elutriation is the process of separating by washing, in this case

using air as the washing medium.
 The airflow raises the fine particles against gravity to a fines

collector. Being too heavy to be carried upwards, the coarse

particles decelerate and fall with gravity, against the flow, into
the coarse fraction collector.
 The cut point can be adjusted by increasing or decreasing

airflow velocity within the housing.

 Elutriation is a crude method of separation that is seldom used

alone. It can, however, greatly improve the effectiveness of the

vortex methods when added as a pre-separation stage.
Principles of air classifier operation
- Free Vortex

 Free vortex methods involve airflow moving in a

decaying circular pattern towards an outlet, as in
a cyclone.
 Coarse particles are thrown to the periphery

and are removed to a coarse fraction collector.

The fines are drawn inwards to the outlet with
the airflow.
 Particle size is controlled by varying the

airflows and the dimensions of the housing.

 Using a free vortex technique results in

relatively inefficient classification.

Principles of air classifier operation
- Forced Vortex
 The forced vortex, on the other hand, is a more
complicated method that achieves more precise particle
size control.
 As in the free vortex design, air is drawn from the

outer edges of a housing, but a driven vaned rotor is

added to 'force' the circular motion of the airstream
and the entrained feed particles.
 In this design the coarse particles are thrown to the

periphery, but the fine particles pass through the

rotor vanes and escape to outlet.
 Precision in separation is gained by varying the

airflow velocity and also the rotor speed. This enables

an infinitely variable separation to be made within the
limits of the classifier.
Principle of air separators
 Separators for different
applications.
 Dynamic Separator Type SKS - for use in closed circuit
ball mill applications

 Static Separator Type LS - for use in Ball Mill and Roller

Press circuits

 Static Separator Type V - for use in Roller Press circuits

to remove the fines from the pressed product

 Combination Dynamic and Static Separator Type VSK -

for use in finish grinding Roller Press circuits
Static Separator Type LS
Static Separator Type V
 Highlights of the “V” Separator

 Fineness control by airflow

 Cut size from 100μ to 1.5mm

 No moving parts
 How V-separator woks
 The V-separator (static cascade sifter) has a
housing with an inlet at the top for material to be
filtered and an outlet at the bottom for the coarse
fraction of the material.

 Between the inlet and the outlet runs a channel

(sifting zone) defined between a pair of barriers
equipped with cascade-like deflectors which point
towards the outlet.

 Air is forced in a cross-current through the sifting

zone, between the deflectors, and towards a second
outlet, for fine material, at the top of the housing.
When material enters the housing through the inlet
it tumbles down the sifting zone under force of
gravity, fine particles are blown out of the sifting
zone and by the air stream up to the second outlet.
Dynamic Separator Type SKS
Dynamic Air Separators
 Dynamic Air Separators-Working
 Material is fed sideways on a spreader disc in the separating
chamber. The spread material is divided into grits fines by a
re circulating air current created by inbuilt fan fall on the inner
cone and fines get separated from recirculating air by cyclonic
action. Counter vanes with adjustable length are fitted above
the spreader plate to control fineness of the fines. The fan,
spreader disc and the counter vanes can be driven by a single
drive.

 If the fineness is to be varied without stopping the separator,

separator fan is driven by a constant speed motor and the
spreader disc and counter vanes are driven by a variable
speed drive. By varying its speed, fineness can be infinitely
adjusted. This separator is still preferred for coarse separation
(90 micron size) due to lower specific power consumption,
and can be used for raw material grinding applications.
High Efficiency Separators
 Description
 Material is fed at the center of a distribution plate
installed on top of a rotor. The air flow created by an
external fan enters horizontally and flows through a
curtain of the material falling from the distribution plate.
Heavier particles get separated under the effect of
gravity and centrifugal force. Fines get carried away with
the air by drag force. The dust laden air leaves separator
and fines get separated in cyclones arranged outside the
separator. Clean air can be recirculated or dedusted.
The rotor is driven by a variable speed drive to facilitate
on line fineness control.
 Salient Features
 External highly efficient fan for air
recirculation.
 External, efficient separating cyclones for
fines separation.
 Cylindrical selection zone gives longer
time for fines separation.
Static – Dynamic Separator (SEPOL)
VSK – Separator (KHD Humboldt)

Highlights of the “VSK”

Separator:

 Combination of “V” and

“SKS” Separators

 Two separation zones

controlled by airflow and
separator rotor speed
 Fabric Filters- Principle
 When a dust-laden gas passes through a
fabric the particles get trapped due to
different mechanisms.

 Important mechanisms by which the

particles are separated from gas stream
are usually inertial impaction, direct
interception and diffusion.
 Inertial Impaction

 Inertial Impaction occurs when the particle with high inertia

follows a fluid streamline, but as it approaches the fiber its
trajectory departs from the fluid streamline around the fibre.
 Some particles will impact onto the filter medium and be caught
due to their inertia driving them into the filter media. The air-
stream, because of its relatively low density and inertia, changes
direction and flows around the fibers
 Direct Interception

 In particle collection mechanism of interception,

the particles have less inertia and almost follow
the streamlines around the obstruction.
 The particles clear the obstacle but their outer
peripheries come in contact with the fiber and get
intercepted.
 Diffusion

 Diffusion here refers to the random motion of small particles,

also known as Brownian motion. This motion is caused by
collisions with gas molecules, Particles in the size range of 0.1
micron and smaller do not tend to follow the air-stream.. The
random path of the particle increases the chance it will strike the
filter and be captured.
 In a normal fabric filter, particles smaller than the
apertures in the fabric are trapped by
impingement on the fine “hairs” which span the
apertures.
 Typically, the main strands of the material may
have a diameter of 500 μm, spaced 100–200 μm
apart. The individual textile fibres with a
diameter of 5–10 μm crisscross the aperture and
form effective impingement targetscapable of
removing particles of sizes down to 1 μm.
 Filtration efficiency
 In the course of operation, filtration efficiency will be low
until a loose “floc” builds up on the fabric surface and it is
this which provides the effective filter for the removal of
fine particles.
 The cloth will require cleaning from time to time to avoid
excessive build-up of solids which gives rise to a high
pressure drop.
 The velocity at which the gases pass through the filter
must be kept low, typically 0.005 to 0.03 m/s, in order to
avoid compaction of the floc and consequently high
pressure drops, or to avoid local breakdown of the filter
bed which would allow large particles to pass the filter.
 Types of bag filter

 There are three main

types of bag filter.
 The simplest, consists
of a number of
elements assembled
together in a “bag-
house”. This is the
cheapest type of unit
and operates with a
velocity of about 0.01
m/s across the bag
surface.
Fabric Filter Baghouse
 A more sophisticated and
robust version incorporates
some form of automatic
bagshaking mechanism
which may be operated by
mechanical, vibratory or air-
pulsed methods.
 A heavier fabric allows
higher face velocities, up to
0.02 m/s, to be used and
permits operation under
more difficult conditions than
the simpler bag-house type
can handle.
 The third type of bag
filter is the reverse-jet
filter.
 With face velocities of
about 0.05 m/s and
with the capability of
dealing with high dust
concentrations at high
efficiencies, this type of
filter can deal with
difficult mixtures in an
economic and compact
unit.
 Advantages and Disadvantages-Mechanical-
shaker baghouses
Advantages:  Disadvantages
 Have high collection  Have low air-to-cloth ratio
efficiency for respirable dust (1.5 to 2 ft/min)
 Can use strong woven bags,  Cannot be used in high
which can withstand temperatures
intensified cleaning cycle to  Require large amounts of
reduce residual dust buildup space and filter bags
 Simple to operate  Consist of many moving parts
 Have low pressure drop for and require frequent
equivalent collection maintenance
efficiencies  Can result in reduced
cleaning efficiency if even a
slight positive pressure exists
inside bags
 Reverse-air baghouses
Advantages Disadvantages
 Have high collection  Have low air-to-cloth ratio (1
efficiency for respirable dust to 2ft/min)
 Are preferred for high  Require frequent cleaning
temperatures due to gentle because of gentle cleaning
cleaning action action
 Have low pressure drop for  Have no effective way to
equivalent collection efficie remove residual dust buildup
 Cleaning air must be filtered
 Require personnel to enter
baghouse to replace bags,
which creates potential for
toxic dust exposure
 Reverse-jet baghouses

Advantages Disadvantages
 Have a high collection  Require use of dry
efficiency for respirable dust compresses air
 Can have high air-to-cloth  May not be used readily in
ratio (6 to 10ft/min)
high temperatures unless
 Have increased efficiency special fabrics are used
and minimal residual dust
buildup due to aggressive  Cannot be used if high
cleaning action moisture content or humidity
 Can clean continuously levels are present in the
 Have small size and fewer exhaust gases
bags because of hgih air-to-
cloth ratio
 Electrostatic Precipitators

 Electrostatic Precipitators use electrostatic forces to

separate dust particles from exhaust gases.  A number
of high-voltage electrodes are placed between grounded
collecting electrodes.  The contaminated gases flow
through the passage formed by the discharge and
collecting electrodes.

 The airborne particles receive a negative charge as they

pass through the ionized field between the electrodes. 
These charged particles are then attracted to a grounded
or positively charged electrode and adhere to it.

 The collected material on the electrodes is removed by

vibrating the collecting electrodes either continuously or
at a predetermined interval.
 Main Components
 The four main components
of all electrostatic
precipitators are-
 Power supply unit, to provide
high-voltage
 Ionizing section, to impart a
charge to particulates in the
gas stream
 A means of removing the
collected particulates
 A housing to enclose the
precipitator zone
 ESP-Advantages
 They have high efficiencies (exceeds 99.9% in some
applications)
 Fine dust particles are collected efficiently
 Can function at high temperatures (as high as 700
degree F – 1300 degree F)
 Pressure and temperature changes are small
 Difficult material like acid and tars can be collected
 They withstand extremely corrosive material
 Low power requirement for cleaning
 Dry dust is collected making recovery of lost product
easy
 Large flow rates are possible
 ESP-Disadvantages
 High initial cost
 Materials with very high resistivity are
difficult to collect
 They can be larger than baghouses (fabric
collectors) and cartridge units, and can
occupy greater space
 Material in gaseous phase cannot be
removed by electrostatic method
 Dust loads may be needed to be reduced
before precipitation process (precleaner
may be needed)
 Efficiency Improvements
 The efficiency of
electrostatic
precipitators can be increased by:

(i) larger collection surface areas and

lower air flow rates give more time and
area for dust particles to collect
(ii) increased speed of dust particles
towards collection electrodes
(iii) using hybrid ESP
 Hybrid Filters
 Hybrid filters are modified ESPs
having added final fabric filtration
fields in the same, existing casing.
 The advantage of this system is the
synergy between the two systems
that reduces the pressure loss in the
fabric filter section.
 Function of hybrid filters
 The flue gas first flows through an electrostatic
precipitator, in which a large percentage of the
dust load is separated off by means of the electric
filter principle.
 Then, the pre-cleaned flue gas passes through a
fabric filter unit, in which the remaining particles
are separated.
 Due to pre-cleaning by the electrostatic
precipitator, the fabric filter will be loaded with
considerably fewer dust particles.
 The advantage for the plant operator is, that the
filter media are exposed to fewer mechanical
impacts which can result in longer service lives.
Conceptual Drawing of Hybrid
Filters
Thank You