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7/23/2019 hpgr presentations.docx
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Performance Evaluation of Different Circuit Applications of
High Pressure Grinding Rolls
(HPGR)
Hakan BENZER
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2006
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Aim
To investigate the performance of different
circuit alternatives, in which HPGR is used
in various configurations
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HPGR
1 Feed Unit2 Dosing Unit
3 Feed Regulation4 Roller 5 Motor, shaft system6 Cylindrial Roller Dri!e" #ydrauli $iston
% Frame& $ressure 'ystem 10()eration $latform
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Liner Types
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Circuit Types
Open Circuit Pre-grinding
#$*R
')litter
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Circuit Types
Hybrid Grinding +ir 'e)arator
all Mill
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Circuit Types
Closed Circuit Pre-grinding
Disagglomerator
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Circuit Types
Semi Finish Grinding
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Circuit Types
Finish Grinding
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Industrial Data Set
Sampled Circuit Types
• Open Circuit Pre-grinding (! S"mpling#
• Hybrid ($ S"mpling#
• Closed Circuit Pre-grinding (! S"mpling#
• Semi-Finish Grinding ( S"mpling#
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tudies !arried "ut
Sampling of the circuits
Determination of Size Distributions
and
Grindabilities
Mass Balancing
Performance Evaluation
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#esign and "perational
$aria%les of the!ircuits
ampled
HPGR
CaseStudy
1
CaseStudy
2
CaseStudy
3
CaseStudy
4
CaseStudy
5Roll Length (mm) 530 550 530 1450 1400
Roll Diamete (mm) 1400 1200 1400 1000 1400Roll S!eed (m"s) 1#5$ 1#4$ 1#5$ 1#50 1#%1&!eational Pessue ('a) 150 134 111 120*o+ing Ga! (mm) 10#1 13#5 22#% 3#% 22#2Po,e Da, (+*) %3% %40 551 105$ 11%Ball &ill Power #raw 'k() *+* *-./ 01- *.// *+22
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"pen !ircuit HPGR 3 !losed !ircuit Ball &ill
Grinding 4 !ase tud5 *
$0- Passing
$#22 mm
Gy!sum
2#4 t"h .ass
Clin+e 154 t"h 20#0 t"h
1#$$ mm
Cushed
HPGR
2#00 t"h
#2 mm
/un+e
/all ill
13%#$5 t"h
Dynami i Se!aato
Clin+e
/all illCiuit
50#1 t"h
&3eall
Ciuit
$%#%$ t"h
{RR 4#4
CS (+*h"t) 4#0
{RR 2$1
CS (+*h"t) 30#2
{RRCS (+*h"t) 34#2
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33 m
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"pen !ircuit HPGR 3 !losed !ircuit Ball &ill
Grinding 4 !ase tud5 *
%&%' %&'
P"rticle Sie
' '% '%%
C u m &
) P
" s s
i n g
'%%
*%
!%
+%
,%
%
.%
$%
%
'%
%
%&%%'
HPGR /eed obs&
HPGR product obs&
0& mill /resh /eedobs& C"l&
Sep& /eed obs&
Sep& re1ect
obs&
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"pen !ircuit HPGR with Partial Rec5cling
3 !losed !ircuit Ball &ill Grinding 4 !asetud5
Gy!sum
$0- Passing
/all illCiuit
2(#5
{Ci1uit
Clin+e .ass
&eall
$#{ 1%#0 mm
1# t"h 10#0 t"h
4#5 mm
RR 3#5
CS (+*h"t)
{RR %%
CS (+*h"t) 20#%
RR 235
CS (+*h"t)
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%4#5 t"h1# t"h 35#3 t"h 1# t"h
%$ m
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"pen !ircuit HPGR with Partial Rec5cling
3 !losed !ircuit Ball &ill Grinding 4 !ase
tud5
%&%' %&'
P"rticle Sie (mm#
' '% '%%
C u m &
) P
" s s i n g
'%%
*%
!%
+%
,%
%
.%
$%
%
'%
%
%&%%'
HPGR /resh /eed obs&
HPGR disch"rge obs&Sep& /eed obs&
Sep& re1ect obs&
Product obs&
C"l&
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H5%rid Grinding 4 !ase tud5 6
Clin+e
102#1 t"h
Gy!sum
%#52 t"h 442#$ t"h
2(#(
{Ci1u
it
5%#35 t"h $0- Passing
13#2 mm
43#1 t"h
&3eall10$#0 t"h
2 mRR 455
CS (+*h"t)
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21#00 t"h
151#$ t"h
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H5%rid Grinding 4 !ase tud5 6
'%%
*%
!%
+%
,%
%
.%
$%
%
'%
%
%&%%'
Clin2er obs&
Gypsum obs&
HPGR disch"rge obs&Sep& /eed obs&
Sep& re1ect obs&
Product obs&
C"l&
%&%' %&' '
P"rticle Sie
'% '%% '%%%
C u m &
) P
" s s i n g
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!losed !ircuit HPGR 3 !losed !ircuit Ball
&ill Grindin 4 !ase tud -
HPGRCi1uit
Clin+e
122#21 t"h
Gy!sum
# t"h
$0- Passing 5$ t"h
/all illCiuit
55 t"h
%$ t"h
1$#5 mm
&3eall
Ci1uit
Disagglomeato
4%% t"h
2$ m
132 t"h
{
RR 30$
CS (+*h"t) $#0
{RR 2#15
CS (+*h"t) 13#%
{RR %%1
CS (+*h"t) 21#%
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%0 m
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!losed !ircuit HPGR 3 !losed !ircuit Ball
&ill Grinding 4 !ase tud5 -
%&%' %&'
P"rticle Sie (mm#
' '% '%%
C u m &
) P
" s s i n
g'%%
*%
!%
+%
,%
%
.%
$%
%
'%
%
%&%%'
HPGR /resh/eed obs&Sep& /eed obs&
Sep& re1ect obs&
Sep& /ine obs&
C"l&
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!losed !ircuit HPGR 3 !losed !ircuit Ball
&ill Grinding 4 !ase tud5 -
3 c t u " l 4 / / i c i e n c y
P"rticle Sie (mm#
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emi 3 7inish Grinding 4
!asetud5 +
HPGRCi1uit
Gy!sum
4#5 t"h
Clin+e 114#55 t"h
$0- Passing
12# mm
1#2 t"h
31 m11#14 t"h
SP6222#21 t"h
{&3eall
53 m
GR7D
Ci1uitSPR.&R
{RR 243
CS (+*h"t) #$
RR 41%
CS (+*h"t) 23#0
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5$#$ t"h
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emi 3 7inish Grinding 4
!asetud5 +
%&%' %&' '
P"rticle Sie
'% '%% '%%%
C u m &
) P
" s s i n g
'%%
*%
!%
+%
,%
%
.%$%
%
'%
%
%&%%'
Clin2er obs&
Gypsum obs&
Sep& /eed obs&
Sep& re1ect obs&
C"l&
Sep& /ine c"l&
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emi 3 7inish Grinding 4
!asetud5 +
3 c t u " l 4 / / i c i e n c y
'
%&*
%&!
%&+
%&,
%&
%&.%&$
%&
%&'
%
%&%%' %&%' %&' '
P"rticle Sie (mm#
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Result
s
HPGR Ciuit
RedutionRatio(8$0"P$0)
HPGR Ciuit
S!ei9inegyConsum!tion
(+*h"t)
&eall
CiuitRedutionRatio
(8$0"P$0)
&eall Ciuit
S!ei9inegyConsum!tion
(+*h"t)CaseStudy 1 4#4 4#05 : 34#1Case
Study 2 3#5 $#3 235 2#5CaseStudy 3 : : 455 2#$5CaseStudy 4 30$ $#02 %%1 21#%5CaseStudy 5 243 #$0 41% 23#03
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Results
-he effiieny ur!es indiated that for the losediruit #$*R a))liations, air lassifiers .ereo)erated .ith high /y)ass ratios
-he grid se)arator .as found to /e ineffiient fordisagglomeration of flaes e. tehnologyse)arators are /eing used no. -hey are muh more
effeti!e
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Results
!ompressed %ed %reakage
t ' % ( ) #
.%
$
$%
%
'
'%
-
%
- ', 5 '$& mm
- ''& 5 *& mm
- &, 5 .&+ mm
- '&'! 5 ' mm
- %&, 5 %& mm
% %& %&. %&, %&! ' '& '&.
4cs (26h7t#
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Results
8mpact %reakage
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Results
!omparison %ed vs impact
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!onclusion
'%%
*%
!%
+%
,%
%
.%
%&%' %&' '
P"rticle Sie (mm#
C u m &
)
P " s
s i n g
6i
(26h7t#
4cs
(26h7t#
HPGR Circuit '& !
Pl"nt ' ',&' $*
Pl"nt *& ,
Closed Circuit HPGR-C"se Study .Pl"nt 'Pl"nt
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!ase tudies Limestone and
Clinker
()en iruit eerise .ith different ore ty)e
$ressure ffet 'ide ffet
Open Circuit Roller Press
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Open Circuit Roller Press
Grinding Limestone
Roller 8i"meter (mm# ''%Roller Length (mm# '%%%
9otor Po:er (26# %%
Roller Speed (rpm# $&!
C"p"city (t7h# $%%
S"mpling
Period
G"p (mm# Pressure (0"r# 9otor (3# C"2e
Thic2ness
(mm#Set Le/t5Right 9o;ing5Fi<ed
'
'.
+- '.* !! +&!$
!% ',% *, +&%!$ *% '+* '%$ !&-.
. '%% %* ''* +&,-
-
',
+% '.% *% *&-+
, !% ',% *. !&*
+ '%% '*. '%$ *&$+! ''% $ '', *&.'
Open Circuit Press Grinding
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Open Circuit Press-Grinding
Limestone
100
%0
60
40
20
0
1 10 100 1000 10000 100000
Patile Si;e (m)
feed 14 mm "5 /ar 14 mm %0 /ar 14 mm &0 /ar 14 mm 100 /ar
C u m # - P a s s i n g g
O Ci it P G i di
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Open Circuit Press-Grinding
Limestone
100
%0
60
40
20
0
1 10 100 1000 10000 100000
Patile Si;e (m)
feed 16 mm "0 /ar 16 mm %0 /ar
16 mm 100 /ar 16 mm 115 /ar
C u m #
- P
a s s i
O Ci it P G i di
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Open Circuit Press-Grinding
Limestone
<=lem /as>n> ('a)
2"" mm
2&3 mm
y 41263 7 1265
R2 0&&21
1100
1050
1000&50
&00
%50
%00
"50
"00
650
600
y 256&" 73"%%&
100 120 140 160 1%0 200 220 240
&!eating Pessue ('a)
P o , e 1 o
n s u m ! t i o n ( + *
)
)*+(?@Gi
Ait+eBn> al oto0
Open Circuit Press Grinding
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Open Circuit Press-Grinding
Clin2er
Roller 8i"meter (mm# ''%
Roller Length (mm# '%%%
9otor Po:er (26# $'
Roller Speed (rpm# ',&!
S"mpling
Period
Pressure
(0"r#
9otor
(3#
C"2e
Thic2ness
(mm#
' '*, *+% $%=*
$% ''% *=-*
$ '!% !, $.=,
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Open Circuit Press-Grinding
Clin2er
.ane /oyu (m)
/esleme
eG-
ilmi+i i/ C u m u l a t i 3 e P a s s i n g -
100
&0
%0
"0
60
50
40
30
20
10
1 10 100 1000 10000 100000
Patile Si;e (mm)
Feed
30& mm 1&6 /ar
2&6 mm 230 /ar
343 mm 1%0 /ar
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Open Circuit Press-Grinding Clin2er
h) "t(etis!aa
e+ al>nl>A> (mm)
32%
326
C a ! a 1 i t y ( t " h )
332
330
3242& 30 31 32 33 34 35
Ca+e .hi+ness (mm)
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Open Circuit Press-Grinding Clin2er
/as>n? ('a)
)
m(m>A>ln>la
+e
C a + e . h i 1
+ n e s s ( m m )
35
34
33
32
31
30
2&
150 1"0 1&0 210 230 250
Pessue (/a)
i i i di li 2
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Open Circuit Press-Grinding Clin2er
/as>n? ('a)
!)m
a(> a !e
mo ot
ma!l.o
. o t a l o t o 2 m ! e e ( a m ! )
Pessue (/a)
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Open Circuit Press-Grinding Clin2er
Roller 8i"meter (mm# '.%
Roller Length (mm# +!%
9otor Po:er (26# '.%%
Roller Speed (rpm# %
*a) 8mm9 $ressure 8/ar9 $o.er 8:9 Ca)aity 8t;h9 < ')lit
040&2001 1sur!ey 22&5 1014% %3"50 155%4 5000
040&2001 2sur!ey 2205 &&2& %&664 20&2& 3000
040&2001 3sur!ey 216" &%34 %4&13 215%6 2000
040&2001 4sur!ey 21%% 10010 %5"10 20300 100
0%0&2001 1sur!ey 2024 1145% &01"0 1010" 5000
0%0&2001 2sur!ey 2005 &"41 %2215 11&52 5000
0%0&2001 3sur!ey 20&& &&2% %3450 1364% 5000
1"042002 %5/ar 1%04 10%5% &20"% 2%142 0
1"042002 &5 /ar 2043 13%46 1136%6 2&0%6 0
1"042002 105 /ar 2006 15514 12436" 2&0% 0
Open Circuit Press-Grinding
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Open Circuit Press Grinding
Clin2er
SideEfect
Fresh Feed
'ide$rodut
HPGR
Central$rodut all
Mill Feed
Open Circuit Press-Grinding
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Open Circuit Press GrindingClin2er
Side Efect
.ane /oyu (mm)
esleme
=e
<50 =enar
0,01 0,1 1 10 100
?eG-i
ml i+i i/
C u m u l a
t i 3 e P a s s i n g -
100&0%0
"0605040302010
00,001
FeedCae
'ide ffet
Patile Si;e (mm)
Open Circuit Press-Grinding
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Open Circuit Press Grinding
Clin2er
Pressure Efect
.ane /oyu (mm)
001 01 1 10 100
ne?eG-
ilmi+i i/
/esleme
C u m u l a t i 3 e P a s s i n g -
100&0%0"0605040302010
0
0001
Feed%5 /ar
&5 /ar
105 /ar
Patile Si;e (mm)
O Ci it P G i di Cli 2
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Open Circuit Press-Grinding Clin2er
Pressure – Energy correlation
/as>n? ('a)
)*
+(@?G
ma
.o!l
. o t a l P o
, e ( + * ) 1300
125012001150110010501000&50&00%50%00
&0 100 110 120 130 140 150 160
Pessue ('a)
H b id G i di
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Hybrid Grinding
olu 212
2&%5
olu 1
6123636
=a>an32
26%2
Se!# 7isinin E/DFye /es# ismi (-)
)
-(i
mite+.@
i ne4
mi i/
S ! e 1 i 9 i 1 4 n e
g y C o n s u m ! t i o n
( - )
3"
35
33
31
2&
2"
25
0 5 10 15 20 25 30 35
Se!aato Reet to the HPGR -
Cl d Ci it
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Closed Circuit
?>+l>+ (mm)
"t(
etisa!a C a ! a 1 i t y ( t " h ) y 1&,1"&
25,%16
"50
"00
650
600550
500
450
400
20 25 30Ga!
35 40
Cl d Ci it
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Closed Circuit
m
m(+>l+>?
/as>n? ('a)
G a ! ( m m
)
403%36
3432302%262422
20%0 &0 100 110 120 130 140
Pessue (/a)
Cl d Ci it
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Closed Circuit
/as>n? ('a)
3
25 R R
5 0
4
35
2
15
&0 100 110Pessue (/a)
120 130 140
i i i
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Comp"rison o/ Circuit Types
&!en CiuitPeginding
Hy'idGinding
Closed Ciuit Semi 8inishPeginding Ginding
irim ner?i -@etimleri 8<9
+AB De!ren @tmeli
#i/rit De!re =a)alB De!ren @tmeli
EarB 'onDe!re
S!ei9i negy Consum!tion (-)
100
%0
60
40
20
0
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3>R S4P3R3T>O?
T4CH?OLOG@ AS48 FOR CL3SS>F>C3T>O?
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3>R S4P3R3TORS
• ST3T>C
• 8@?39>C
B F>RST G4?4R3T>O?
B S4CO?8 G4?4R3T>O?
B TH>R8 G4?4R3T>O?
Forces"cting
m: particle massg: acceleration due to gravity
∆δ : particle-air density difference
*ra!itation
Drag Fore
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G =
m& g &∆δ
(u −
v) D = c&a&δ &
c: drag coefficient
a: projected particle
area u: air velocity
v: particle velocity µ
δ
: air viscosity
f: functiondp: particle diameter
.her e
c =
f
d p (u − v)
µ
dr: rod diameter
Centrifugal
Fore C =mvr
d p ' E = '+
Gm)at Fore 8effiieny ofa)ture9
d −
d
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r '+
p d r
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D3?4 T@P4 ST3T>C S4P3R3TOR
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PL3?T L3@OATED3?4 T@P4 ST3T>C S4P3R3TOR
HPGR
8yn"mic
Sep"r"tor
St"tic
Sep&100
&0
0"ll 9ill
"0
60
50
40
30
20
10
01 10 100 1000
$artile 'i>e8Hm9
%0
$ a r t i t i o n C o e f f i i e n t
D-S4P3R3TOR
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D S4P3R3TOR
the 9eed is dieted do,nthough 'a99les to meet theising ai 9lo,# .he ,ea+om!ats ae 'o+en as theyollide ,ith the 'a99les andthe 9ine and oase !atilesae li'eated# .he oase!atiles an not 'e aied'y the ai 9lo, and slidedo,n to go 'a+ to the
ginding olls# .he 9ine!atiles ae entained in theai and s,e!t u!,adsthough a 9uthe set o9'a99les#
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/affles
PL3?T L3@OATED S4P3R3TOR
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1I'e)arator Filter Disharge
2Roller Disharge3I'e)aratJr Re?et4I'e)aratJr Fine
2 14
!!
"!
3 #!
$!
%!
&!
'!
(!
)!
!
!
*! !*! !!*! !!!*!
P"rticle Sie(m#
P " r t i t i o n C o e / / i c e n t
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F>RST G4?4R3T>O? 8@?39>C S4P3R3TOR
8ist Geneation
D
R
C8K9
*
High negy(u!li9t o9 mateial)
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S4CO?8 G4?4R3T>O? S4P3R3TOR
Seond Geneation
L+D
R D
G C
*
7ntemediate negy(u!li9t o9 mateial)
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TH>R8 G4?4R3T>O? 8@?39>CS4P3R3TORS
.hid Geneation
C D
* R R(D
G8Gm)at9
Lo, negy(dis!laement o9
mateial)
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PL3?T L3@OATE8@?39>C S4P3R3TORS
Filter
0"ll 9ill9ech"nic"l
Cl"ssi/ier
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8@?39>C S4P3R3TORS-Per/orm"nce Comp"rison
100
&0
%0
"0
60
First *eneration
50
'eond *eneration
40#igh ffiieny 'e)arator
30
20
10
0
1 10 100 1000
$artile 'i>e 8Hm9
<
$ a r t i t i o n C o e f f i
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CO9P3R>SO? OF TH4 8>FF4R4?T T@P4 S4P3R3TORS
Common characteristics of dynamic air separators are ;
- internal rotors that are also feed distribution plates,- airflows generated by internal or external fans,
- collision plates that assist rejection of coarse particles ,
Precision d%(microns# 0yp"ss ()# Feed R"te73ir u"ntity
St"tic %& ,% I'&%
'st gener"tion %&$-%&. % % '
nd gener"tion %&-%& '-% '-$ '&,
$rd gener"tion %&,-%&+ '%-' -' &%-&
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CO90>?3T>O? OF TH4 ST3T>C 3?8
8@?39>C-DSJ S4P3R3TOR Feed
Fines +ir +ir
#ot gasor
Fresh +ir
Dynami 'e)arator Re?et
Coarse $artiles
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PL3?T L3@OATEDSJ S4P3R3TOR
Cy1lone
S Se!aato Podu1t
Gas
Ra,
0ateial 100
&0
%0.u'e 0ill
"0
60High Pessue
Ginding Rolls 50
40
30
20
10
0
1 10 100
PatileSi;e(m)
- P a t i t i o n C o e 9 9 i 1 i e n t
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POSS>0L4 S4P3R3TOR 38KAST94?TS 3?8 TH4>R 4FF4CTS
SEP+,+-., ,esulting Change
-/pe of +d0ustment B/ pass 1ines.utput
1ineness
M+23 1+3
More blades or larger diameter
1e4er blades or small diameter
5igher speed
SELEC-., BL+DES
More blades
1e4er blades
5igher speed 6if double shaft7
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POSS>0L4 S4P3R3TOR 38KAST94?TS 3?8 TH4>R 4FF4CTS
D2+P5,+GM or 8+L8ES
9 opening
SEP+,+-., 1EED ,+-E
8aries 4ith the mill
circuit t/pe
SEP+,+-., 1EED
123E3ESS
8aries 4ith the mill
circuit t/pe
,.-., SPEED :
+2, 1L.; :
+))lies only to 2nd and 3rd generations