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Separators in the cement industry

7 Third genera on separators:

7.1 Introduc on:
- Also called: Cage separators or High Efficiency Separators.
- These separators has been developed in the beginning of the eigh es (O'Sepa from Onoda Cement).
- As the second genera on, the air flow required for the separa on is produced by an external fan.
- The separator material feed is carried out mechanically by means of suitable con nuous conveyors.
- Fines are conveyed by air in external cyclones or directly to a bag filter.
- The main separa ng device is a cylindrical rotor. The rotor is like a cage composed of blades closely spaced.
- The rotor is operated by a variable speed drive.
- The rotor speed determines swirl in the classifying zone and therefore the cut of the separator.
- The composi on of forces ac ng in the separa ng zone is showed in the figure below:

- Here a non-exhaus ve list of High Efficiency separators:

- O'Sepa (FLSmidth)
- Sepol (Polysius)
- Sepax (FLSmidth)
- SD (Sturtevant)
- Sepmaster (KHD)
- QDK (Pfeiffer)
- TSV (FCB)
- O&K (Orenstein & Koppel AG)
- PRESEP VTP (PSP Engineering a.s.)
- CTC SERIES (CEMTEC)
- Cemag (CMP AG)
- Copies from China
7.2 Advantages of 3rd genera on dynamic separators:
- Possibility of mechanical adjustments
- Possibility of very large flow rates
- Flexibility to produce products of different quali es
- Be er efficiency than the conven onal and cyclones separators
- Reduc on of mill specific consump on
- Increase of the grinding capacity
- Reduc on of the cement temperature
- Be er cement quality (Straighter RRB curve giving be er 28 days and early strengths)
7.3 Disadvantages of 3rd genera on dynamic separators:
- Difficulty to get the op mum seal system
- No constant velocity of flow and no constant centrifugal accelera on of par cles can affect the efficiency
7.4 General principle of opera on:
- The material is generally fed at the top of the separator.
- There are 2 or more feed chutes in order to improve the dispersion of the material on the distribu on plate.
- Material falls and is dispersed in the circula ng air by the distribu on plate.

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- The feed forms a thin cylindrical curtain of material in the classifying zone.
- The air stream is generated by an external fan.
- According to the type of circuit, it is possible to have 100% of fresh air, a part of the air recirculated or 100% of the air
recirculated.
- O en, there are a primary air inlet, a second air inlet and also a ter ary air inlet depending of the design.
- The airflow leaves the guide vanes almost tangen ally to the outside of the cage.
- Material is arriving in the separa on zone between the guide vanes (or louvres) and the rota ng cage.
- The par cles are driven by three forces: The centrifugal force due to the dispersing plate
* The centrifugal force due to the dispersing plate
* The drag force due to the air flow
* The gravity due to the mass of the par cule
- The drag force is trying to pull the material into the rota ng cage.
- The centrifugal force is trying to push the material toward the guide vanes.
- It is the balance of these forces which induces a regular cut size of the separator.
- This balance remaining steady because the material in the classifying zone has always the same radius of rota on,
then the centrifugal force is the same in all areas.
- On the other hand, the air and material are normally distributed uniformly, the air velocity (then, drag force) remains equal.
- The coarse material doesn't enter in the rota ng cage and goes out by gravity up to the bo om device (cone or other).
- The fine material enters in the cage and exits with the air flow by the upper or lower part of the separator.
- See the figure below (from the O'Sepa):

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Warning:
* Suppliers propose generally a version for raw and cement mill circuits where the gas and the material are going
out together of the mill and enter from the bo om of the separator.
* Some suppliers propose also special versions for circuits with pre-grinding systems (Roller Press).
* Principles of opera on described in this page only present the classical version for grinding circuits with
bucket elevator for the material feed.

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7.5 Principle of opera on for each design:
O'Sepa (FLSmidth):
- The material enters through the top of the separator.
- Material falls and is dispersed by the distribu on plate.
- The primary and secondary air creates a vortex in the separa ng zone.
- The material falls between the rotor and the louvres.
- Fines are aspirated.
- Coarse par cles are accelerated by the rotor and held by the guide vanes, which slide out of the separator through
the lower part.
- The fine material exits with the airflow through the upper part of the housing.
- As a certain number of fines par cles are entrained downwards with coarse par cles, the ter ary air flow
helps to pick up any fines in the rejects.
- The fineness of the product is adjusted by the speed of the rotor.
- Website of the separator: h p://www.flsmidth.com

- See the figure above

Sepol (Polysius):
- The material enters through the top of the separator.
- Material falls and is dispersed by the distribu on plate.
- There is one tangen al air inlet.
- The material falls between the rotor and the louvres.
- Fines are aspirated.
- Coarse par cles are accelerated by the rotor and held by the guide vanes, which slide out of the separator through
the lower part.
- The fine material exits with the airflow through the lower part of the housing.
- The fineness of the product is adjusted by the speed of the rotor.
- Website of the separator: www.polysius.com

- See the figure below:

Sepax (FLSmidth):
- The sepax differs by a body divided into two parts: dispersion and separa on parts.
- The material enters through the middle of the separator on one side.
- Air enters from the bo om of the separator.
- Material is carried with the air to the upper part of the separator.

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- Material enters in the classifica on area between the rotor and the guide vanes.
- Coarse par cles are accelerated by the rotor, held by the guide vanes and slide up to the rejects cone.
- Fines are aspirated with air flow through the rota ng cage and exit through the upper part of the separator.
- The fineness of the product is adjusted by the speed of the rotor.
- Website of the separator: h p://www.flsmidth.com

- See the figure below:

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SD (Sturtevant):
- The material enters through the top of the separator.
- Material falls and is dispersed by the distribu on plate.
- The tangen al air inlet is in the upper part of the separator.
- Various tangen al air inlets can be realized.
- The material falls between the rotor and the louvres.
- Fines are aspirated.
- Coarse par cles are accelerated by the rotor and held by the guide vanes, which slide out of the separator through
the lower part.
- Some models have horizontal louvres.
- The fine material exits with the airflow through the upper part of the housing.
- The fineness of the product is adjusted by the speed of the rotor.
- Website of the separator: sturtevan nc.com

- See the figure below:

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Sepmaster (KHD):
- The material enters from the top of the separator.
- The air stream is generated by an external fan.
- The material falls between the rotor and the louvres.
- Fines are aspirated.
- Coarse par cles are accelerated by the rotor and held by the guide vanes, which slide out of the separator through
the lower part.
- The fine material exits with the airflow through the upper part of the housing.
- The fineness of the product is adjusted by the speed of the rotor.
- Motor and reducer are on the bo om of the device.
- Website of the separator: www.khd.com

- See the figure below:

QDK (Pfeiffer):
- The material enters through the top of the separator.
- Material falls and is dispersed by the distribu on plate.
- There is one tangen al air inlet.
- The material falls between the rotor and the louvres.
- Fines are aspirated.
- Coarse par cles are accelerated by the rotor and held by the guide vanes, which slide out of the separator through
the lower part.
- The fine material exits with the airflow through the upper part of the housing.

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- The fineness of the product is adjusted by the speed of the rotor.
- Website of the separator: www.chris anpfeiffer.net

- See the figure below:

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TSV (FCB):
- The material enters through the top of the separator.
- There is one tangen al air inlet.
- The fine material exits with the airflow through the top of the housing.
- The fineness of the product is adjusted by the speed of the rotor.
- Website of the separator: www.fivesgroup.com

- See the figure below:

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O&K (Orenstein & Koppel AG):

- The material enters through the top of the separator.
- Material falls and is dispersed by the distribu on plate.
- There is one tangen al air inlet.
- The material falls between the rotor and the louvres.
- Fines are aspirated.
- Coarse par cles are accelerated by the rotor and held by the guide vanes, which slide out of the separator through
the lower part.
- The fine material exits with the airflow through the lower part of the housing.
- The fineness of the product is adjusted by the speed of the rotor.
- See the figure below:

PRESEP VTP (PSP Engineering a.s.):

- The material enters through the top of the separator.
- Material falls and is dispersed by the distribu on plate.
- There is one or various tangen al air inlets.
- The material falls between the rotor and the louvres.
- Fines are aspirated.
- Coarse par cles are accelerated by the rotor and held by the guide vanes, which slide out of the separator through
the lower part.
- The fine material exits with the airflow through the lower part of the housing.
- Website of the separator: www.pspeng.cz

- See the figure below:

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CTC SERIES (CEMTEC):
- The material enters through the top of the separator.
- There is one tangen al air inlet.
- The fine material exits with the airflow through the top of the housing.
- The fineness of the product is adjusted by the speed of the rotor.
- Website of the separator: h p://www.cemtec.at

- See the figure below:

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Cemag (Cement and Mining Processing (CMP) AG)

- The material enters through the top of the separator.
- Material falls and is dispersed by the distribu on plate.
- There are two tangen al air inlets.
- The material falls between the rotor and the guide vanes.
- Fines are aspirated inside the rotor.
- Coarse par cles are accelerated by the rotor and held by the guide vanes, which slide out of the separator through
the lower part.
- The fine material exits with the airflow through the lower part of the separator.
- Website of the separator: ww.cmpag.com

- See the figure below:

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