How can I make dynamic separator more e
How can I make dynamic separator more efficient ?.
fficient ?.
Juan Pedro EsperónJuan Pedro EsperónIngeniero QuimicoIngeniero Quimico I heard reducing anchor of b
I heard reducing anchor of blades one can obtain lades one can obtain more final product from reject of dynamicmore final product from reject of dynamic separator and increase production without changing 1 day strenght. What do you think about it ? separator and increase production without changing 1 day strenght. What do you think about it ?
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suresh suresh suresh deolalkar suresh deolalkar
Director at Deolalkar Consultants Director at Deolalkar Consultants
three factors govern the performance1 speed 2
three factors govern the performance1 speed 2 air/material ratio 3 angle/no of blades onair/material ratio 3 angle/no of blades on rotor . designer of separator can advise
rotor . designer of separator can advise you on specific problemyou on specific problem
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o Flag as inappropriateFlag as inappropriate o o March 23, 2012March 23, 2012 bhargava bhargava bhargava rao bhargava rao
Tech Manager at Al Ghurair Tech Manager at Al Ghurair You have two factors to adjust to
You have two factors to adjust to improve the efficiency 1, static blade adjustment 2.improve the efficiency 1, static blade adjustment 2. RPM of rotor. Only upto certain RPM of rotor,
efficiency comes down. Additional deflectors can be p rovided to improve the efficiency. However, consultation with supplier is better.
o Like o Flag as inappropriate o March 23, 2012 Jagrut Jagrut Upadhyay
Process Consultant at PEC Consulting (Penta Engg. Corp.) St. Louis, Missouri.
Dynamic separators need to be operated with max air flow in order to maintain desired air velocity across the separator. In addition to above points, look for PERFECT seal between rotor and the static part of the separator. This plays a vital role.
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o Flag as inappropriate o March 23, 2012
Eduardo Sánchez likes this
Rana
Rana shahid
section incharg kiln utility and cement mills at Hail cement company
i am agree with bhargava rao and maintain wear tear of blades and roto and its parts
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o Flag as inappropriate o March 24, 2012
Hussain
Hussain Khan
at ACC Cement Company
Please once check separator seal, baled position and air damper position also.
o Like o Flag as inappropriate o March 25, 2012 Craig Craig Puljan
Maintenance Manager at Lehigh Southwest Cement Company
Hello Juan, I agree with what Jagrut is saying. Please run your fan to achieve maximum airflow through the separator and then adjust the rotor speed (RPM's) upwards in order to achieve the sharpest particle size distribution. Doing this should show some kind of production increase as you are getting particles out of the system
o Like o Flag as inappropriate o March 26, 2012 Craig Craig Puljan
Maintenance Manager at Lehigh Southwest Cement Company
that can then be replaced by fresh feed. I hope you are successful! Kindest regards!
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o Flag as inappropriate o March 26, 2012
LUIS
LUIS FUENTES
PRODUCTION MANAGER at CEMEX UK
Dear Juan Pedro....I think these are the steps...maybe you already check them...but in case not...these are in my opinion...
1.- Calculate the tromp curve, circulating charge. to decide if your eficiency is ok. 2.- Check if the air flow trough the mill and the separator is ok...measure with pitot. 3.- check if your using the right charge in the mill, and the right level of media. 4.- check if your diaphram intermediate and exit are ok, blockage, etc...if you have cyclons, static separator, bag filters if they are in good conditions...
5.- check if the residue of size of the cement is well measured and calculated or if the clinker characteristics are ok, clinker dusty, low uality of clinker, free lime, poor C3S, etc require more finest in the cement mill and consequence the TPH of the mill reducing sometimes...
6.- Check if the amount of water (in case you are using is ok) the spraying and the temeperatures in the mill are ok?
7.- check if you have false airs in the separator system....holes, gaps.,etc.
8.- check if the mechanical equipment is in good conditions, blades, vibrations, temperatures, oil, speed, dampers, etc...
o Like o Flag as inappropriate o March 26, 2012 Jagrut Jagrut Upadhyay
Process Consultant at PEC Consulting (Penta Engg. Corp.) St. Louis, Missouri.
Hello Juan, Thanks to Craig for specifically mentioning about sep arator's speed. I would also like to offer following comments, which might be useful.
It is generally accepted that high efficiency separators lead to a good performance of grinding circuits and considerable saving of energy, The cause for a production increase through the improvement of separator efficiency can be analysed as follows:
* to the improved separation characteristics, the amount of fines returned to the mill with the rejects decreases considerably which avoids over grinding and wasting of grinding energy at the mill. This mechanism is facilitated by the intensification of air sweeping through the mill and the temperature reduction inside the mill which can be often observed when using modern high efficiency separators.
* virtue of the improvement in cement quality, for the modified particle size distribution, the possibility of reducing the specific surface area of cement a rises. A high surface area of cement promises the possibility of an increase in the production rate. This is due to possibility of sever over grinding in the mill, especially when grinding aids are not used.
* more influence of high efficiency separators on t he properties of the cement would be the reduction of mill
–
inside temperature. In conventional grinding circuits mill–
inside temperatures were too high, and several types of c ooling procedures were introduced in the circuits. In modern type HESs, a large amount of cooling air can be efficiently introduced in to the circuit.This explains as to why the separator should be maintained in a manner in what it should be.
Alteration of the volume of separating air:
As a general rule, the separator achieves the maximum possible throughput and the best possible efficiency at the maximum volume of separating air. If the volume of separating
air is reduced, the product becomes finer, with the throughput and efficiency being
lower!! It might in some cases be subsequently found that the volume of separating air is insufficient, so that a fresh air has to be installed in the air duct between the circulating air fan and the separator. If this is done, it should be ensured that that the fan capacity is adequate with regard to volume and pressure. In practical life, you will experience that you can achieve the same residues on a particular sieve, with relatively lower Blaine, when a properly maintained separator is optimized well.
o Like o Flag as inappropriate o March 26, 2012 Luis Luis Lardizabal
Process Engineer in Portland Cement Industry
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o Flag as inappropriate o March 26, 2012
Separator performance
without Tromp curve what is the way to judge the separator performance by seive analysis of rejects,feed & fines. what is the normal range of residues on 212,90,63,45,32 mic for better efficiency of a separator in coarse,feed & fines & why?(for cement as well as raw meal) what is the optimum efficiency of a high efficiency separator? raj
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138 posts
TimePosted 3 years ago lalbatros says
Re: Separator performance
xxxx,
If you have residues on {212, 90 , 63, 45, 32} µm for feed, coarse and fine, and if your product is not too fine - as compared to 32µm - , then you could evaluate a Tromp curve.
If you have less data, you have less chances to evaluate your separator, and vice-versa. However, the main question is: what do you mean by "optimum efficiency"?
On a Tromp curve, you can observe the so-called "bypass level".
The bypass level indicates how much % of fine particles go to the coarse stream. This measures, of course, and un-wanted behaviour or an "un-efficiency".
If the bypass is 40%, and if the production is 100 t/h, then, naïvely speaking, this means that 40 t/h of good product is returned to the mill.
This could be, naïvely, translated as an efficiency of 100/140 = 70% and would indicate that the production could be increased by 40 t/h if the separator would be 100% efficient. Actually, the
impact of the bypass is lower but it increases with the fineness of the product (circulation factor). This can be understood by a model of the complete grinding circuit.
My message is: to evaluate a seperator you do need to evaluate the Tromp curve. The least you could get from the Tromp curve is the bypass factor.
If you don't have enough information for that, you cannot evaluate the separator. Michel
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224 posts
TimePosted 3 years ago xxxx says
Re: Separator performance
my question is what is the normal range of these residues for coarse,feed & product so that i can compare for any improvement in the system raj
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138 posts
TimePosted 3 years ago lalbatros says
Re: Separator performance
There is no answer to this question. It depends on what you are producing.
For "system improvement", is it not enough to check the quality of the product and the productivity t/h ?
If your focus is on "separator improvement", then it is all about the Tromp curve. Here is some sample data to illustrate my point:
finish product 3500 Blaines, (P32,P45,P63,P90,P212) = (78%, 90%, 97%, 99.3%, 100%) where P=1-R feed 2450 Blaines, (P32,P45,P63,P90,P212) = (53%, 67%, 80%, 90%, 99.6%) reject 1200 Blaines, (P32,P45,P63,P90,P212) = (23%, 39%, 61%, 79%, 98.9%) Plant Circulating load: 1.8 Separator bypass: 10% cut diameter: 40µm (x50) (x75= 26µm, x50= 40µm, x25= 63µm) imperfection: 46% (=(x75-x25)/2/x50) Mill
residues reduction factors: (= residue mill outlet / residue mill inlet) @32µm = 40%
@45µm = 58% @63µm = 76% @90µm = 87% @212µm = 100% (!)
(this is calculated from residues and circulating load)
I don't see how you could use these data and compare them to your own data. What is your product?
What is the product fineness? What is you circulating load?
To evaluate your separator, you need the Tromp curve, even with very few points. The bypass is one point of the Tromp curve that can be evaluated even with few data.
