COMPARISON

TYPES OF SEPARATOR DESIGN

1st generation HEYD or Sturtevant separators

2nd generation Cyclone separator

3rd generation QDK or High Performance cage

rotor separator

1. 1ST GENERATION SEPARATOR

The dispersing equipment - distribution plate (1) - and the classifying

equipment - the auxiliary fan or centrifugal system (2) - are in a common
casing - separation chamber (3) - for this type of separator design, which
began with the development by MUMFORD and MODI towards the end of
the last century.

The separator ventilator - the circulating fan (4) - is situated above the
separating chamber (3). The separator chamber (3), tailings cone (5), louver
ring (6) and the circulating fan (4) are encased by the separator housing.
The ring chamber between the separating chamber and separator casing is
called the precipitating chamber (8).

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OPERATION:
The material to be separated is fed onto the rotating distribution plate and
thus dispersed across the cross-section of the separating chamber. The
separating air is sucked through the material curtain thrown out by the
distribution plate via the circulating fan that works as a radial ventilator fan.
Particles of separation material that can be carried in the stream of
separation air, reach the classification area in the stream of separation air.
The spirally shaped, climbing separating air is accelerated across the
auxiliary fans here, which are attached to the auxiliary fan of the centrifugal
system, in the rotational direction of the ascending separating air spiral.

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The following forces act, in the direction of rotation, upon the particles of the
separation material:

a: gravity

b: centrifugal acceleration (inertia)

c: drag force of the separating air, which results from the cross sectional
area of the stream of particles, whose resistance co-efficient (CW-co-
efficient) gives the flow speed and the dynamic viscosity of the
separating air.

If the centrifugal component predominates, the material to be separated

collides with the wall of the separating chamber, is slowed and, following the
gravitational pull, slides back into the dispersion area and eventually reaches
the tailings cone.

Particles of the material to be separated, for which the drag force component
of the separating air predominates, come into the circulating fan in the stream
of separating air, are accelerated there and, equally effected by centrifugal
acceleration in the separating air, enter the precipitation chamber and reach
the walls of the separator casing. This is where the precipitation from the
separating air stream takes place - comparable with the precipitation of the
tailings in the separating chamber - through the so-called cyclone-type wall
effect. The separating air is returned to the separating chamber via the louver
ring.

This system, although capable, has, as proven in an uncountable number of

separator installations, some grave inadequacies which only then show
themselves to their full extent, when a high degree of fineness of product is
required and when there is pressure, particularly financial - to optimise a
grinding plant. These inadequacies can essentially be seen in the material
circuits. They are as follows:

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A: MATERIAL CIRCULATION INSIDE THE DISPERSION AREA:

The material precipitated as tailings inside the separation chamber in

the stream of separating air, i.e. the grain make-up of the material is
suited to a pneumatic transportation under the existing surrounding
conditions.

After precipitation inside the separation chamber, this material once

again reaches the stream of separation air - the process repeats itself
and a material circuit between the dispersion area and the separation
chamber begins.

Because the separating air only has a limited load capacity within the
boundaries of the existing surrounding conditions - the specific gravity
of the feed material, the flow speed and dynamic viscosity of the
separation air - the further acceptance of the separating material,
which is continually being fed into the dispersion chamber in the
stream of separation air from the dispersion plate is reduced. As a
result, a portion of the separation material passes into the tailings
cones without being separated.

B: MATERIAL CIRCUIT BETWEEN THE AUXILIARY FAN CENTRIFUGAL

SYSTEM AND THE CIRCULATING FAN:

Within the separating chamber, the area of the auxiliary fan, the rising
rotating air is accelerated through the auxiliary fan system that turns in
the same direction.

The highest speed of separation air loaded with separation material is

found in this area.

The separation of the size ranges of the separator feed material into
fines and tailings mainly occurs in this area. The mechanisms which
work here are essentially the three dimensional results of the
alternating effects between gravity, centrifugal acceleration and the
drag force of the separation air.

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An extension of the cross section occurs above the auxiliary-fan-

centrifugal-system in this type of separator design. The flow speed of
the separation air is reduced accordingly and a portion - first and
foremost the coarser portion of the feed material - falls out of the
stream of separation air and is returned to the upper part of the
separator chamber again via the auxiliary-fan system.

A portion of the material returned in this way is broken on the wall of

the separator casing and reaches the separator tailings or the material
circuit between the dispersion and separation chambers.

Another portion is lifted by the rising stream of separation air, reaches

the area of reduced flow speed again, partially falls out and arrives
back in the upper part of the separator chamber. Thus, a material
circuit also begins here.

It should be emphasised at this point that the separating process is not

completed above the separation chamber.

Attempts at optimisation of this form of separator design, which had

the goal of increasing the flow speed above the auxiliary fan in order to
prevent the fall out of material from the stream of separation air and
thus the formation of the material circuits, were unsuccessful because
the separator fines became so coarse that the increase in the speed
surrounding the auxiliary fan could not be corrected within acceptable
limits. In particular, the percentage of so-called "refractors" grew to an
extent that could no longer be controlled.

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1st generation separator: internal material circuit

C: MATERIAL CIRCUIT WITHIN SEPARATING AIR:

The separating air, laden with separator fines, reaches the so-called
precipitating chamber, which concentrically surrounds the separating
chamber, via the circulating fan. The separating air, laden with fines
departs from the circulating fan that acts as a radial fan and is
operated with a circumferential velocity of approx. 40 m/s, and enters
the precipitating chamber.

The predominantly tangential discharge of separating air continues

here and the separating air reaches the louver ring area via the
alternating currents that are aimed in a downward direction and thus
back into the area of the low-pressure suction created by the
circulating fan. The separating air is tangentially returned, via the
louver ring or guiding blade ring, to the separating chamber.

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The precipitation of fines from the separating air occurs inside these
downwardly directed alternating currents; also via centrifugal
acceleration. The fine particles are pressed onto the wall of the
separator casing by the centrifugal forces and slide downwards in the
form of a boundary layer between the casing wall and the separation
air into the fines discharge.

It is obvious that this form of precipitation of fines from the separating

air cannot be particularly effective.

Accordingly, tests of the precipitation performance merely result in an

efficiency in the order of between 40 and 70 %, with the
understandable trend that the effective precipitation worsens with
increasing fineness of the separator fines.

The separating air which is inadequately cleansed arrives in this way

with an accordingly high basic loading of fines via the louver ring back
into the separating chamber and thus into the dispersion chamber.

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No further explanation is necessary to realise that the three material circuits

described here limit the effective capacity of this system of separation
because of the limited loadability of the separating air, particularly as the
separating air volume current can hardly be increased. An increase in the
stream speeds in the fines separation chamber results in a reduction of the
effectivity of precipitation, i.e. the basic fines loading increases further and
the separator effectivity decreases accordingly.

It should be noted that this form of separator design achieved good results
for a construction size of approx. 5 m casing diameter and a fineness of
finished product, expressed in mass related specific surface area, of up to
approx. 3.500 cm²/g according to Blaine. Corresponding to increasing
diameter, a decrease of the capacity e.g. represented in the assessment
process according to F.K. Tromp can be established for larger casing
diameters.

The appearance of this can mainly be attributed to a reduction of the fines

precipitation from the separating air in the precipitation chamber via the so-
called cyclone-type wall effect.

Comparable observations have also been made for cyclones with increasing
diameter.

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2. 2ND GENERATION SEPARATORS

2nd generation separator: cyclone separator

The interdependence of the separator diameter with the capacity of the

separator led to the development of the cyclone separator towards the end of
the 1960's.

This development came from a patent from the company WEDAG. Mr Heinz
Jäger (Bochum) was given as inventor.

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The basic thought behind this invention was the storage of the fines,
inadequately precipitated in the separator's precipitation chamber, in a
separate precipitation aggregate with a significantly higher effectivity.
Cyclones offered the following for this purpose.
Effective precipitations in the range of 90 to 97 % are achieved in this
aggregate for sensible dimensions.

As the circulating fans installed in the 1st generation separators are not able
to create pressure systems according to the system's pressure losses -
separator, precipitation cyclones and connecting pipes - the circulating fan
was installed as a separate aggregate outside the separator preferably in the
area with the lowest dust loading i.e. behind the precipitation cyclones. This
arrangements also allows the use of stream technical, optimised radial fans
with a high degree of effectivity.

The geometry of the separating chamber of this form of separator design is

comparable with that of the 1st generation separators. The same
mechanisms work here. Accordingly, comparable material circuits are also
developed. These are:

a: Material circuit between the dispersion and classification zones

b: Material circuit between the centrifugal auxiliary fan system and the
separation air
outlet to the precipitation cyclone.

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2nd generation separator: cyclone separator

internal material circuits

The material circuit - rest dust to precipitation cyclone and separation

chamber - may be neglected and considered non-existent for this observation
due to the decidedly low content of solids.

Even just the return of the almost completely cleansed separation air to the
separation chamber - the rest dust content generally lies in an order of
magnitude of less than 15 g/m³ - resulted in separators of this form of design
requiring approx. one third of the quantity of separation air of separators of
the 1st generation with a comparable throughput.

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As an almost identical separating chamber diameter is present for

comparable throughput performances, the stream speed in 2nd generation
separators is in the order of 30 - 40 % of the stream speeds for 1st
generation separators.

The reduction of stream speeds directly affects the granulometry of the

separator fines, particularly in the upper end of the range of the grain sizes.
There are considerably lower sieve residues for comparable specific surface
areas of the fines compared with 1st generation separators, e.g. on the 0.09
mm sieve.

Cyclone separators gained entry to the cement and related industries from
the end of the 1960’s. From the mid 1970’s onwards, they had largely
become the standard separator, particularly for installations with larger
throughput.

Based on the separation of cement, it can be said that this form of design
gives very good results for the separating out of products comparable with
PZ35F or up to approx. 3,200 cm²/g according to Blaine.

A distinct improvement of separation results for qualities comparable with

PZ45F of up to approx. 4,000 cm²/g according to Blaine, from the 1st
generation can be proven and was shown in the separation tests according
to the method of F.K. Tromp.

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3. 3RD GENERATION SEPARATORS

Despite the great improvement in separator performance that was confirmed

in that cyclone separators became the standard separator on the market, the
separation results for the separation of high and very high quality cement or
other very fine products, e.g. filler, remained unsatisfactory.

Increased demand on quality, the general trend towards finer and finer
products which was observed in the market and competition in both product
technical and economic areas led to the development, to industrial maturity,
from the early 1980’s, of the principle of spiral wind separation as described
as early as 1939 by RUMPF.

OPERATION PRINCIPLES OF 3RD GENERATION

SEPARATORS
In separators of this form of design, the separation of the separator material,
which is given into a tangentially directed stream of separation air that
undergoes central suction, occurs through the interaction between the forces
of inertia and resistance as well as gravity. The cyclograph picture of the
separation air has a spiral form between the tangential entrance and the
central suction.

To roughly simplify, the forces working on the particles of the separation

product that is fed into this stream can be broken down into a centrifugal
component, radially inwards directed and the gravitational component.

The spatial results of these components decide whether a particle of

separation material ends up in the coarses’ discharge or inwards in the fines
discharge.

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3rd generation separator: QDK form of design

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COMPOSITION OF 3RD GENERATION SEPARATOR

- QDK FORM OF DESIGN
The material feed occurs from above onto a distribution plate that, through its
supporting structure, concurrently represents the upper covering of the cage
rotor. The mainly central feed guarantees an even distribution of the
separation material onto the distribution plate and thus an even distribution
into the annular gap between the cage rotor and the air return ring.

In this area, a moving veil of material in the form of a downwardly pointed

orbit is further accelerated and aerated by the separating air entering in the
same rotational direction.

The guide vein ring which represents the outer boarder of the separating
chamber with its tangentially fitted air return veins and the spirally shaped
separation air entry canal guarantees an even distribution of the separation
air across the entire area of the separating chamber.

Agglomerates, or insufficiently dispersed material, which reaches the outer

area of the separating chamber via the centrifugal forces are further loosened
by the mechanical contact with the tangentially installed air return veins and
are once again fed into the separation area via the separation air entering
through the air return veins.

Finally, yet importantly, the high sharpness of selection of this separator can
be attributed to this mechanical loosening of agglomerates. The fines, carried
into the inside of the cage rotor in the stream of separation air is sucked in a
downward direction with the separation air and, in the basic concept of the
QDK separator, fed across an elbow on the quickest route to the precipitation
of from the separation air possibly from the design of the installation.

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POSSIBILITIES FOR INFLUENCING THE GRAIN

MAKE-UP OF THE SEPARATOR FINES:
These are mainly:

a: changes in the centrifugal component

b: changes in the inwardly-directed resistance components which work

on the resistance coefficients of the particles and the dynamic
viscosity of the separation air on the particles of separation material
via the cross section of separation particles of the stream speed of the
separation air.

This influence is with few exceptions usually performed below the cage rotor,
which works as a radial fan, in 3 generation separators.

For a generally constant stream of separation air, the stream speed of the
separation air in the separation gap between the air return ring and the cage
rotor and finally the previously mentioned interaction between the centrifugal
and resistance components are influenced by the circumferential speed of
the rotor.

Under the evaluation of the mechanisms and connections relevant to the

separation, it is clear that the form of the separation chamber’s geometry of
the air return vein ring, the rotor and the separation air feed is of immense
importance for the functioning ability and the separation properties of this
form of separator design. The conversion of this knowledge as well as the
knowledge about the limits and possibilities of this form of separator design
constitute the manufacture’s expertise.

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INTERNAL MATERIAL CIRCUITS IN 3RD

GENERATION SEPARATORS
If, for the separation of fines in cyclones, the unimportant rest dust after the
cyclones is disregarded, as in the observations of the 2nd generation or
cyclone separators, the material circuits which interfere with the separation
process because of the limited carrying capacity of the separation air, can not
come into being, neither in the distribution zone, the actual separation
chamber nor in the separation gap or in the fine discharges in 3rd generation
separators.

This means that for a sensible geometric design of the separator and for the
use of these installations within the limits of the allowable specific loading,
the portion of fine material fed into the separator in the feed material is
almost completely carried away in the fines.

This important advantage of this separation system has a direct influence on

the feasibility of the grinding installation before the separator and also a
direct influence on the properties of the fines.

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USE OF 3RD GENERATION SEPARATORS -

DESIGN FORM QDK
Let us first take a look at the grave inadequacies of the 1st and 2nd
generation separators. The internal material circuits limit the complete
capture of separator material particles in the area of grain separation nearing
the grain separation of the fines due to the limited carrying capacity of the
separation air.

A portion of the grain size range thus gets into the separator coarses and
thus back into the mill. That is, this material, which is actually of the fineness
of the finished product, is ground again on its way through the mill.
Accordingly, the separator feed material is notably finer for a comparable
fineness of separator fines for separators of the 1st and 2nd generation.

The observation of the particle size distribution of the separator fines shows a
reduced portion of very fine grains in the fines of 3rd generation separators
compared with 1st and 2nd generation separators, for comparable specific
surface areas.

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 COMPARISON OF 3RD AND 1ST GENERATION SEPARATORS
1. Feed material 2. Coarse material/rejects 3. Fines/finish product
rd
• 3 generation separators 1370 cm²/g acc. to Blaine 740 cm²/g acc. to Blaine 3800 cm²/g acc. to Blaine
• 1st generation separators 1616 cm²/g acc. to Blaine 1218 cm²/g acc. to Blaine 3637cm²/g acc. to Blaine

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A WORKING EXAMPLE OF A CEMENT MILL IS USED

FOR THE CLARIFICATION OF THESE STATEMENTS:
In the given case, two HEYD separators of the 1st generation were replaced
in a cement mill.

The process technical changes in the grinding of PZ45F can be seen in the
separator evaluation according to F.K. Tromp and the changes in the particle
size distribution from the grain group block diagrams.

The increase in the throughput during the production of cement of the quality
PZ45F - specific surface area approx. 3,800 cm²/g according to Blaine- was
18 %.

It should be noted that no changes were made to the grinding charge filling of
the mill. The results may thus be directly compared.

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COMPARISON OF 3RD & 1ST GENERATION

SEPARATORS:

Tromp curves

Product type: PZ 45 F
Fineness: 3rd generation separator: 3.800 cm2/g acc to Blaine
1st generation separator: 3.637 cm2/g acc to Blaine

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Influence on the Properties of the

Separator fines:
On the basis of separation with a high rate of effectivity - the proportion of
fines contained in the separator feed material is almost completely carried
out in the separator fines - an ″over grinding“ of the finished product returned
to the grinding aggregate via the separator coarses does not occur.

Based on these connections, the separator fines are in the range of very fine
grains i.e. in the range from 0 to approx. 6 my with a reduced portion of very
fine grains.

The following observations could be made, to date, for the observation of the
effects of the properties of cement:

These observations are based on grinding installations where no, or only

very slight, changes were made to the composition of the grinding charge
filling after the installation of QDK-separators.

These observations are further based on comparable specific surface areas.

Because in the appropriate industrial installations, the results of which were

considered in this observation, products that can be sold are produced and
appropriate measures are taken immediately for diversions from the product
specific standards, there are no longer term statistical values available. Thus,
recognisable trends from during the commissioning period have been merely
related.

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- Portland cements with a specific surface area of up to 3,500 cm²/g

according to Blaine:

For cement mills with a length to diameter relationship of less than 2.8,
the water demands to achieve the given spread was slightly higher in
the concrete aptitude test. A minimal decrease in the early strength
was accordingly established.

This trend could not be established with any degree of certainty for
grinding installation with a length to diameter relationship of greater
than 2.8.

- Portland cements with a specific surface area of approx. 3,500 to

approx. 4,500 cm²/g according to Blaine:

No significant changes whatsoever in the water demands and the

strengthening process could be established for these qualities of
cement.

- Portland cements with a specific surface area of greater than 4,500

cm²/g according to Blaine (high Blaine cements):

A significant reduction in the water requirements and thus, for

comparable specific surface areas, the increase in compression, also
in the early strength, in the first 24 hours, can be particularly
established for these cement qualities.

At the same time, a delayed early set is noticed for these cement
types. The working time is thus extended.

It can be generally said that, the working properties of cements of this

quality that are produced with the use of a 3rd generation separator,
are considerably better.

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These results are founded in the changed particle size distribution for
these cement qualities compared with separators of the 1st and 2nd
generation. The reduction of the very fine grains, particularly in the
range from 0 to approx. 6 my, has a positive effect on the properties
because this portion bonds with a significant portion of the mix water
due to its large surface area.

This portion of the grains participates disproportionally little in the

strengthening process, as a significant proportion is already hydrated
in the finished product. The water required for this comes partially from
the moisture in the mill ventilation air and partially from the moisture
content of the sulphate ingredient.

Finally, the take up of moisture is further helped by the increased

circulation that is a forced result of the use of separators with low
efficiencies.

A further aspect can be seen in that the particle size distribution

approaches the idealised “densest possible sphere packing“ via the
reduction of the portion of very fine particles. That is, there is an
increased number of particle contact points, whereby the mix water
appears to represent reduced interstice volumes.

It should also be noted that the statement which led to this circular problem,
that a minimal reduction in the early strength can be adjusted due to the
increased water requirements for cement types of quality PZ35F and for the
use of mills with a length to diameter relationship of less than 2.8, is certainly
justified, is however based on the running with a separation air throughput in
the range of the maximum separation air throughput meant for the particular
type of separator. An adjustment of the grain structure of the separator fines
to the requirements can be achieved without any problems through a
reduction of the separation air throughput.

It is also possible to influence the grain structure via a fitting adjustment of

the ball charge composition.

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3RD GENERATION SEPARATORS –

USE IN RAW MEAL GRINDING

3rd Generation separators were able to gain acceptance in the grinding of

cement. This is not the case in the area of the grinding of raw meal in
combination with ball mills. Only a very few 3rd generation separators are in
use in this area world wide. This reason for this is multifaceted.

One reason for this is that from the early 1970’s, rolled bowl mills became
accepted for new installations for large and larger throughputs compared with
ball mills. These mills are, in their basic design, generally fitted with
integrated cage rotor separators that work according to the functioning
principle of the 3rd generation separators. The proof as to the suitability for
the use of this form of separator design in raw meal separator is brought
forward by this alone.

A further explanation can perhaps be seen in the following perspective:

Raw meal grinding installations deliver a finished product with mainly

constant fineness of grinding resulting from the chemism, the mineralogical
composition and the burning process in use. Large scale changes in the
fineness of grinding, as in cement mills, are generally not normal.

The reputation that the use of a 3rd generations separator is only truly
justified for the separation of very fine products remains even today. Raw
cement mills with sieve residues on the 90 my sieve in the range of 10 to
20 % represents a comparatively coarse product.

In addition, because of the minimal number of the raw mill grinding

installation fitted with these separation systems, the potential optimisational
possibilities with respect to the increase in throughput and economical
considerations are not so well known as for cement mills.

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The condition that hardly any definite knowledge about the process technical
influences on the burning process associated with these separators
generated raw meals is also based in the fact that only a few raw meal
grinding installations are fitted with these separators.

It must be taken into account here, that the burning process reacts
particularly sensitively to influences that come into the oven system through
changes in the chemism and the mineralogy. For this reason, it is difficult,
and only possible through long term statistical observation, to definitively
assign this type of influence to the grain structure of the raw meal.

Knowledge collected to date points to a positive effect on the burning

process, exerted by the reduced portion of extremely fine grains also present
in raw meal. The explanation for this is probably to be seen as lying in the
corresponding reduced dust circuit in the system’s heat-exchanger-oven-
deduster and in the associated decrease in the tendency to form a coating in
the heat-exchanger.

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USE IN RAW MEAL GRINDING –

POSSIBILITIES FOR INCREASING THROUGHPUT

Raw meal mills executed as crushing plant circuit mills are often fitted with
grinding balls with a length to diameter relationship of less than 2. This
relationship can be based on the dimensions of the mill tube from “flange to
flange“ or alternatively on the length of the individual, separately functioning
grinding chambers.

Mills of this type e.g. as “double rotaries“ from POLYSIUS, FCB and others or
alternatively inside raw meal mills comparable with the HISCHMANN / O&K
raw meal grinding systems with serially connected pre-crushing are used.

The basic idea behind the philosophy used here, is to remove the grinding
material which is receptive to fineness of finished product with in the grinding
areas as quickly as possible from the grinding system so as to avoid an
unnecessary over grinding and burdening of the grinding areas.

Accordingly, relatively large material circuits begin in this type of grinding

installation. They are often of the order of 4 to 5 times as large (Basis: tailings
+ fresh material / fresh material). It stands to reason that a significant
increase in throughput can be achieved through the exchange of separators
with low degrees of efficiency for high performance separators of the 3rd
generation.
A further aspect can often be seen in the presence of grave drying problems
in addition to separation problems, for raw meal grinding installations of this
type, which are usually set up as dry grinding installations.

Insufficient drying disables the flow properties of the grinding material within
the grinding chamber and, in addition, the procession of size reduction.
Further, the dispersability of the separator feed material is limited inside the
separator. Both occurrences lead to a decrease of the throughput.

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For these aspects, 3rd generation separators open up perspective which were
hardly thought of with previous forms of design.

Prognosis as to realistic increases in throughput and improvement of the

working relationships are however not possible until after a thorough analysis
of the original problem and the individual surrounding conditions.

Increases in throughput for previous design forms for comparable fineness of

grinding in the order of approx. 20 %, and greater, considering the obviously
improved availability, have been achieved.

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INSTALLATIONS AND PROCESS TECHNICAL

ASPECTS OF THE SEPARATION CONCEPT QDK

The sales chances for a new type of separator were tested in the form of a
market assessment as the development of the QDK concept advanced. The
results of this assessment determined the over all concept of this separator
system.

The following points resulted, based on the world wide situation in the
cement industry:

In many parts of the world, the installed production capacity is greater than
the demand for cement. A change in this situation can not be see in the near
future.
New cement plants are rarely being built at the moment. The few current
projects usually have a provisional time of up to 5 years to placing of order.
Similarly, new grinding installations are also only being erected in small
numbers at present.

On the other hand, existing mills are being increasingly optimised under the
pressure to improve competitiveness and to fit in with increasing demand on
quality. The exchange of out dated separators for 3rd generation separators
is an important measure towards this goal.

Thus, a separator concept which is to be developed should be fitting to the

situation in the market. This results in the demand for the highest possible
degree of flexibility in planning in both new and existing installations, in
addition to the demand for a performance fitting to the investment costs.

A further demand is to view the separating installation as merely part,

although an important one, of the grinding installation, i.e. the demanded
flexibility must take the complete installation as a complex system into
consideration.

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Taking these points into consideration, the following demands were placed
on the development of a marketable separation concept which is supposed to
create an attractive alternative to the competitor’s separation systems:

1. Convincing functioning of the separator

2. Reliable and uncomplicated machine technical assembly

3. Flexibility in planning; in particular in existing installations

4. Possibilities for assimilation in the technical process in an

installation through the connection of multiple functions

To 1: The parameters “sharpness of selection“ and “fines spacing“ and the

possibility of influencing the fineness and where necessary the particle
size distribution of the separator fines are decisive for the assessment
of a separator.

For the development of a new separation concept, the state of

technical development could not be used as a goal, rather had to be
taken as the starting point. For this reason, the geometric form of the
separation area and of the dispersion area were given particular
attention.

The nature of development is so that it advances as long as the driving

impulse still exists. The superiority of a system shows itself in no other
way so exactly as in its ability to fit in with the changing surrounding
conditions.

Today, the machine factory CHRISTIAN PFEIFFER BECKUM is able

to solve all separator technical tasks for the cement and related
industries on a high level with the separator of the design form QDK.
At the same time, the previous statement is confirmed, as long as the
tasks can change, the development is not complete.

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To 2: We were able to fall back upon over 50 years experience in separator

design for the development of the constructive design and the
selection of important components, as well as wear protection.
Particularly attention drawing was thus the constructive form of the
drive and bearing unit of the cage rotor , the dispersion unit and the
sealing between rotor and fines discharge.

Further, in order to insure a high degree of work place safety, the use
of a bearing guidance system which is not limited to measuring
temperature rather also records the condition on the bearing and the
oscillation relationship, was included.

Obviously, a system of this type is fitted with automatic lubrication

supply.
Further points of importance include an easy accessibility and the
exchangeability of worn parts.

The constructive form of a separation system can of course only be

limited to the most sensible form of the individual components
according to machine technical points. As the functioning is based on
stream technical principles, the demands on the stream technology
must also be sufficient. A constant feed flow into the separator, of both
separation product and separation air, is the basic prerequisite for
achieving the “high performance“ characteristic separation parameter.

To 3: The first step towards the development of a separation system is the

development of an optimal separator geometry, the introduction of the
separation air, the establishment of load limits and the limits for usage.

Next, construction sizes are assigned according to the different

performance ranges. It should be noted here that:

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Because surface areas develop in the second power but in the third
power, a change in the measurements of the construction sizes is not
possible, or only possible with considerable concessions in the
performance ability.

Thus a suitable geometry, fitting to the individual construction sizes,

must be established. The establishment of the concept occurred
parallel to this development.

The QDK-separator concept was developed with consideration of the

situation at the time, that considerably more existing installations were
renovated than new ones built.

The basic advantage of the 3rd generation separator is that the spatial
requirements are considerably smaller than for 1st and 2nd generation
separators with comparable throughput.

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SEPARATOR CONSTRUCTION SIZES FOR

COMPARABLE THROUGHPUTS

Despite this, the planning of a 3rd generation separator can be

plagued by problems under the given spatial surrounding conditions.
These problems however, usually lie in the arrangement of the fines
precipitation from the separation air. For this reason, cyclones are
installed in the standard version of the QDK. Accordingly, the
arrangement of the cyclones took place flexibly.

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The following are a few examples of forms:

In addition, it is possible to precipitate fines in the filter installations,

with and without separation air return:

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To 4: The represented possibility of fine precipitation in filter installations,

both with and without the return of the separation air, is one of the
simplest forms of connection of multiple functions. In addition to this, it
is possible to cool the separation air. In the case of partial separation
air return, the quantity of which is controlled by measuring the
temperature in the separator fines stream, it is also possible, within
limits, the possibility of maintaining a defined temperature of finished
product.

In addition, the following connections are possible:

- DRYING WITHIN THE SEPARATOR:

Instead of the separation air, hot gasses are fed into the
separator.
A partial or complete exchange of the separation air is also
possible here. The range of the separation air exchange occurs
dependant on the separation air temperature or the
temperature of the finished product.

This type of switch has uses particularly in grinding raw meal.

Both oven exhaust gases and hot gases from a hot gas
producer or a mixture of gasses (oven exhausts + hot gasses
from a blast furnace) can be used here.

The use for the simultaneous drying and grinding of granulated

blast furnace slag or granulated blast furnace slag cement is
equally thinkable. In particularly when the granulated blast
furnace slag component is pre-crushed in a high pressure roller
press and directly fed into the separator.

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- USE OF THE MILL VENTILATION AIR AS PART OF THE SEPARATION

AIR:

In this case, the mill ventilation air is fed in directly as part of the
separator circulation air. The mill ventilation air throughput
required for mill operation is guaranteed via a low pressure
measuring device which works on a control damper between
the mill ventilation air pipe and the inlet into the separator.
The portion of the separator circulation air which corresponds to
the portion of the mill ventilation air is led away via a filter. The
advantage of this switch come from the avoidance of the loss of
pressure of a pre-precipitation installed in the extrusion of the
mill dedusting - a static separator- and in the case of raw meal
grinding, a cyclone precipitator after the double rotor grinding
system with a very large mill ventilation air throughput.

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HIGH PERFORMANCE SEPARATOR

ADVANTAGES OF OUR QDK

PRODUCTION ASPECTS:
• Possible production increase up to 20 % by exchanging at 1st
generation separator against a QDK separator.

• Optimised and better separating efficiency.

MAINTENANCE ASPECTS:
• V-belt transmission.

• A cartridge containing all bearings guarantees a long lifetime and

protection against dust.

• Easy accessibility to all separator parts.

• Complete protection against wear.

• Central lubrication system and bearing supervision.

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 Comparison – Types of Separator Design

QDK SEPARATOR’S LOAD RATIO

CEMENT:

Separator feed rate/separation air 1.8 kg/m³

Separator product/separation air

3,000 cm.2/g acc. to Blaine 0.75 – 0.8 kg/m³

4,000 cm.2/g acc. to Blaine 0.55 – 0.6 kg/m³
5,000 cm.2/g acc. to Blaine < 0.5 kg/m³

RAW MEAL

3,000 cm.2/g acc. to Blaine 2.2 kg/m³

Raw meal 12 – 14 % 90 Mm 0.55 kg/m³

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SEPARATOR DIMENSIONING

1. Basic Data:
• Feed material
• Particle size distribution of coarse material
• Density of fine material

2. Specific Load
• Specific coarse material feed

Max. 1.8 – 2.0 kg feed material

m³ separation air

• Specific fine material feed

Max. 0.8 kg feed material

m³ separation air

• Specific cage surface load

Approx. 10 kg feed material

m³ separation air

3. Separator Type

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Comparison – Types of Separator Design

SEPARATOR EVALUATION –
PARTICLE SIZE DISTRIBUTION

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Comparison – Types of Separator Design

SEPARATOR EVALUATIONS

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 Comparison – Types of Separator Design

STANDARD WEAR PROTECTION

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 Comparison – Types of Separator Design

SAMPLING POINTS WITHIN MILL SYSTEM

SAMPLING QUANTITIES AND ANALYSIS

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AIR MEASUREMENT POINTS

Points Pressure drop Measurement

Mill Ventilation
A1 Ambient ∆p mill T, pa
A2 Mill exit ∆p static sep T, p
A3 Static sep. exit ∆p filter T, p
A4 Filter exit ∆p fan T, p, V
A5 Fan exit T, p

Separator Ventilation

B1 Ambient/Inlet ∆p separator T, pa
B2 Separator exit ∆p cyclones T, p
B3 Cyclone exit ∆p fan T, p, V
B4 Fan exit T, p

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