Course 4 Cement Production

4.5 Classifiers
Imprint

German Cement Works Association

Research Institute of the Cement Industry
P.O. box 30 10 63, 40410 Duesseldorf, Germany
Tannenstrasse 2, 40476 Duesseldorf, Germany
Phone: +49 211 45 781
Fax: +49 211 45 78296
info@vdz-online.de
www.vdz-online.de

info@elearning-vdz.de
www.elearning-vdz.de

Issued: 7th January 2013

Contents
1 Introduction....................................................................................................... 1
2 Construction and Mode of Operation............................................................. 1
2.1 Classifier Designs and Modes of Operation ....................................................... 3
2.1.1 Static Classifiers: Static Air Classifier................................................................ 3
2.1.2 Dynamic Classifiers: Recirculating Air Classifier or Rotary Air Classifier ....... 6
2.1.3 Dynamic Classifiers: Cyclone Recirculating Air Classifier ............................... 12
2.1.4 Dynamic Classifiers: Caged Rotor Classifier (High-Efficiency Classifier)........ 14
2.2 Assessing Separation and Operation of a Classifier ........................................... 16

3 Maintenance and Inspection............................................................................ 17

4 Health and Safety Practices ............................................................................. 17

5 Factors Affecting Plant Production................................................................. 20

6 Questions on Course LB 4.5 Classifiers ....................................................... 21

i
Solutions............................................................................................................................... 22
Glossary ............................................................................................................................... 25
Index..................................................................................................................................... 26

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1 Introduction
The term classifier refers to devices in which solid particles are separated from a gas Function
flow in accordance with defined criteria, for example particle size, density or specific
surface area (classification).

Classification makes it possible to produce fractions of solids (particle size ranges) of

differing fineness. In most applications the material fed to a classifier is separated into
oversized material and fines.
One of the oldest forms of classification is the separation of chaff and grain by threshing History
(Fig. 1.0-1). This is based on the principle that particles that can become airborne (in this
case the chaff) are entrained by a wind and so separated from particles (grain) that are less
likely to become airborne.

Figure 1.0-1: Separation of Chaff and Grain using a Flail .

Classifiers are used in cement production for, among other applications, establishing a Applications within the
defined upper particle size of the cement and at the same time increasing the throughput, Cement Industry

thereby saving grinding energy. Dry classification is the only method that is cost-effective
on an industrial scale in the very fine range. Classification is therefore very important in
the cement industry and is often used in the various grinding processes (cement, raw meal
and coal grinding).
In this online course you will learn more about the basic principles of classification as well Course
as the operating principles of the designs currently used. This course will also deal specif-
ically with the field of dynamic classifiers and will describe how the separating properties
Summary
of a classifier are assessed and can be optimized if necessary.

2 Construction and Mode of Operation

Classifiers in a cement works are generally used in the grinding circuits. The task of a Functions within the
Grinding Circuit

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 2 Construction and Mode of Operation

classifier is therefore:
 to remove fine material of sufficient fineness from the grinding circuit and therefore
 to avoid agglomeration and a cushioning effect in the mill and in this way to
 improve energy efficiency during grinding, and
 to produce finished products with a defined upper particle size .
Ultrafine products can normally only be produced by separating the finest material from
the grinding circuit.
Screening Different properties of the particles may be used when separating finely distributed solid
particles or mixtures of solid particles in the gas flow. A mixture of materials may, for
example, be separated by the geometric dimensions of the particles (volume), irrespective
of the various densities of the different constituents. This is the case during screening.

Fd
Fc centrifugal force
2 Fg
Fd force of the
rising airflow

Fg force of gravity

cyclone wall
effect

entrapped
fines
Figure 2.0-1: Forces acting on Material Particles during Classification .

Operating Principles of Classification, i.e. the separation of finely distributed (dispersed) solid particles from a
Classification stream of gas or air, is based on the differing movement characteristics of different solid
particles. Particle movement is determined by forces of different strengths acting in dif-
ferent directions. These forces are mainly affected by the properties of the particles, such
as size, density, shape, etc., and the strength of the forces may therefore vary depending
on the particle. These forces are therefore used in different ways depending on the type of
classifier. The two main relevant forces are:
 forces relating to the mass of the particle
 flow forces, which act on the material particles during transport in a gas flow (Fig.
2.0-1)
Effect of the Forces The forces relating to the mass of the particle may be gravitational and/or inertial forces
or centrifugal force .
The effect of the flow force depends mainly on the size of the particle (particle diameter).
In contrast, the effect of gravity and centrifugal force on separation is determined by the
mass of the particle, i.e. its volume and density.
If the particle mass is small and the flow force acting on a particle is greater than the
opposing force of gravity or greater than the force resulting from gravity and centrifugal
force then the particle will be entrained and carried away by the airflow. If the gravitational

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 2.1 Classifier Designs and Modes of Operation

component is dominant the particle will fall downwards. If there is sufficient rotation of
the airflow and if the force resulting from the gravitational and centrifugal forces is greater
than the effective flow force, the particle will be thrown outwards against the housing wall
where its movement will be braked and it will travel downwards by gravity. From this
it can be concluded that small, light particles tend to follow the flow force, whilst larger,
heavier particles tend to follow the gravitational and inertial forces.
The force of gravity exerted cannot be changed during the classifying since the particles Influencing Variables
have a fixed material density and particle size but inertial forces and flow forces can be in-
fluenced by changing the flow conditions. Centrifugal forces can be increased by deflect-
ing and rotating the airflow, and flow forces can be reduced by lowering the air speed, for
example by enlarging the flow cross-section. The solid particles contained in the airflow
will be separated as result of this change in the balance of forces. The various individual
designs and operating principles will be discussed again in detail later.

2.1 Classifier Designs and Modes of Operation 3

The classifiers normally used in the cement industry differ in design and fields of applica- Differences
tion. The differences lie in
 the way in which the material to be classified is introduced and the nature of the
classifying air,
 the generation of the centrifugal acceleration and
 the collection of the classifier fines from the classifying air.

A distinction is made between static and dynamic classifier systems. Static, Dynamic

The main difference between these systems is the application of additional external fac-
tors affecting movement. In static separators only the airflow produced by a fan acts on the
particles. By contrast, in dynamic separators the separation can be optimized by deflecting
the gas flow or by rotation. In some designs it is also possible to dry or cool the material
in the classifier.

2.1.1 Static Classifiers: Static Air Classifier

The simplest classifier design is the static air classifier. This previously widespread de-
sign is predominantly used in air-swept grinding plants. It can be found in drying and
grinding plants, in which sufficiently large amounts of air are provided for pneumatic
transport of the material from the mill to the classifier. The static classifiers in vertical
roller mills are also considered to be static air classifiers (Fig. 2.1-1).
The advantage of the static air classifier is its simple structure. In this case separation Advantage: Simple
occurs in the air-swept housing due to the design of the housing and the fan located out- Structure

side the classifier, as a result of which the static air classifier does not require its own
drive (only to adjust the guide vane ring). Fig. 2.1-2 is a schematic view of a static air
classifier.

The material to be classified is fed to the classifier from below with the conveying airflow. Mode of Operation
The material to be classified and the conveying air flow upwards between the cone-shaped
outer housing of the classifier and the inner collection cone. The air speed is reduced by

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 2 Construction and Mode of Operation

Figure 2.1-1: Housing of an Air Separator with Adjustable Guide Vane Drive !-- Gehuse eines Strom-
sichters, mit verstellbaren Leitschaufelantrieb-->.

1 outer cone

2 guide vane ring

3 oversized material cone

4 top outlet duct

5 device for adjusting the guide vane ring

6 oversized material outlet

Table 2.1-1: Key to Fig. 2.1-2.

the continuous increase in the cross-section in this region. As a result, coarser particles
drop out of the conveying airflow. The deflection of the air by the vane ring and by the

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 2.1 Classifier Designs and Modes of Operation

5 2 4 2

2
1

Figure 2.1-2: Static Air Classifier, Schematic View .

top outlet duct in the head of the classifier offer further opportunities for collecting over-
sized material. At the same time the conveying airflow is made to rotate by the tangential
entry of the conveying air into the collection cone through the guide vane ring. The re-
sulting centrifugal acceleration assists the separation of oversized material in this region.
The separated material falls into the oversized material cone and is discharged from the
classifier.
The air that is free from oversized particles leaves the classifying chamber with the re-
maining fines via the top outlet duct. The airflow is generated outside the classifier. The
fines have to be collected from the airflow outside the static air classifier, for example in a
downstream cyclone and/or in a filter. If there is no static air classifier then all the material
discharged from the mill with the airflow has to be collected in a cyclone or filter.
During operation the fineness of the oversized material and the fines from the separator
can be adjusted by altering the air speed and therefore the amount of classifying air, i.e.
by changing the setting of the guide vane ring.

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The power consumption of the suction fan is approximately 1/3 of the power consump-
tion of the mill. For example, the suction fan will need approx. 200 kW for a 3.0 m x
6.0 m mill with a rating of 560 kW operating at 40 t/h.

Example Fig. 2.1-3 is a schematic view of a closed-circuit grinding plant with a static air classifier.
In the circuit the material discharged from the mill is separated from the airflow in the
classifier and returned to the mill again.

bucket elevator
dynamic fan
classifier filter
feed hoppers

finished product
6 fresh air static classifier

tube mill

Figure 2.1-3: Closed-Circuit Grinding Plant with Static Air Classifier for Cement, Schematic View .

2.1.2 Dynamic Classifiers: Recirculating Air Classifier or Rotary Air

Classifier

Differences from other In contrast to the static air classifier, in recirculating air classifiers or rotary air classi-
Designs fiers
 the feed material is supplied mechanically by a continuous conveyor , either from
above through a drop tube or from the side via an aerated trough conveyor.
 The air flow required for classification is generated by a fan impeller inside the clas-
sifer housing.
 The material to be classifed is fed into the classifier airflow by a distribution plate
and is distributed as uniformly and as finely dispersed as possible in the classifying
chamber.
At this point in the online course you would see an animation on the operating principle
of the recirculating air classifier.

Fig. 2.1-4 is a schematic view of a recirculating air classifier.

Structure
Classifiers of this type consist essentially of
 the outer housing,
 the inner classifying chamber housing, which is separated from the oversized material
discharge by a louvre ring,
 the distribution plate and countervane system, and
 the fan impeller.

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3
7
6

1. fan impeller
2. distribution plate
3. countervanes
4. drop tube
5. inner cylinder
6. guide vanes
7. cone

Figure 2.1-4: Recirculating Air Classifier, Schematic View .

Modern classifiers are equipped with separate drives for the fan and the countervane
system with the distribution plate. The fan is generally driven at a constant speed, but
the speed of the countervane system with the distribution plate can generally be adjusted
continuously within a specific range. In this way, the fineness of the classifier fines is
infinitely variable (within a specific range).
The fan impeller, which functions as a radial fan, generates a closed airflow in the classi-
fier that rises in the inner classifying chamber housing, is guided outwards and downwards
between the classifying chamber housing and the outer housing, and re-enters the clas-
sifying chamber housing through the louvre ring. As the classifying air rises inside the
classifying chamber housing it passes through the region of the distribution plate and the
countervane system.

Operating Principle
The material to be classified is fed onto the rotating distribution plate and is forced out-
wards by centrifugal force (Fz) , with the result that the material is broken up. Oversized

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particles of sufficient mass are forced against the cone of the classifying chamber housing
and drop into the coarse material discharge. In the case of finer particles the drag force of
the classifying air (Fd) outweighs the combined force of gravity (Fg) and centrifugal force.
The finer particles are conveyed upward into the region of the countervane system, which
also rotates, and are separated again at this point. The countervanes accelerate the spiral
rotary flow of the classifying airflow produced by the louvre vanes. The centrifugal forces
which become effective at this point force the coarser particles of the previously separated
material against the housing wall, where they slow down and also fall downward into the
oversized particle discharge. Fine particles with a lower mass are again conveyed upward
by the drag force of the classifying air and are fed through the fan impeller, which acceler-
ates the flow of fine material and classifying air, and are then conveyed into the separating
chamber between the inner classifying chamber housing and the outer housing. The fine
particles are separated from the classifying air (with accelerated rotational flow) by the
cyclone-wall effect at the wall of the outer classifier housing as well as by the reduction in
the speed of the downward airflow. The product separated in this way trickles down into
the product cone.
8

Options for Adjusting Fineness

Changes in the Region of the Countervane System
Measures aimed at influencing the acceleration of the spiral rotary flow of the classifying
air by making adjustments in the region of the countervanes, thereby influencing the cut
size by altering the centrifugal acceleration acting on the material particles, also change
the amount of classifying air and therefore the flow velocity if the fan impeller has set
transport characteristics. During all adjustments the attempt should be made to obtain
the centrifugal acceleration required for separation with the lowest possible pressure drop.
There are various options for achieving this:
 speed of the countervane system and the transport characteristics of the fan impeller
are constant
 with no adjustment of the setting angle of the countervanes:
An increase in the number or size of the countervanes shifts the cut size into the finer
range. If it is possible to make a radial adjustment to the countervanes, a reduction in the
gap between the countervanes and the classifying chamber housing also shifts the cut
size into the finer range if the number and size of the countervanes remain unchanged.

If it is desired to shift the cut size into the coarser range, the described measures should
be reversed accordingly.
 Adjustment of the setting angle of the countervanes (only possible when the plant is
stopped):
The greatest acceleration of the spiral rotary flow of the classifying air is obtained
when the countervanes are vertical. A setting of up to approx. 45 on either side re-
duces the projected area of the countervanes. If the setting angle is less than 45 a fan
effect acts on the classifying airflow in addition to the reduced radial acceleration. If
the countervanes are inclined in the direction of rotation this assists the classifying air-
flow and the cut size is shifted into the coarser range. If the setting of the countervanes
is reversed, the classifying airflow is restricted and the cut size is shifted into the finer
range.
 Adjustment of the speed of the countervane system with constant transport charac-
teristics of the fan impeller (possible during operation)
The acceleration of the rotary flow of the classifying airflow is altered by changing

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the speed of the countervane system. If the adjustment range available is not sufficient
for operational requirements it is possible to influence the acceleration of the rotary
flow or the throttling effect of the countervane system by using the measures described
above.

Changes to the Transport Characteristics of the Fan Impeller

The flow velocity and therefore also the drag force of the classifying air is influenced by
changing the transport characteristics of the fan impeller. Depending on the design the
measures necessary for this may be carried out either only when the plant is stopped or
also during operation . The following are possible:
 changes to the speed of the fan impeller Manipulated Variables
 changes to the effective surface area of the fan blades of the fan impeller
 covering the intake cross-section of the fan impeller by using adjustable shutters
 adjustment of the attachment angle of the blades on the louvre ring
In most rotary air classifier designs it is possible to combine several control options. In
this way the separating characteristics of the classifier can be adapted to operational re-
9
quirements within a wide range.
It is appropriate to consider the classifier not as an individual unit but in conjunction with
the grinding plant owing to the interaction between them. The quality of the separation
depends not only on the structural configuration of the classifier but also on the loading of
the classifier, and the optimum quality is achieved within the design range. At a greater
classifier loading, i.e. greater classifier feed mass flows, the quality of the classifying
(characterized in particular by the sharpness of cut and the proportion of unclassified
material) may be reduced considerably. Insufficient comminution within the mill and the
resulting increase in circulating mass flow may lead to excessive classifier loading.

Operation
The mode of operation of the recirculating air classifier depends on:
 design, size and fineness setting
The advantage of a recirculating air separator is its compact structure, as both the
classifying and collecting processes take place inside the housing. However, as the di-
ameter of the housing increases it becomes more difficult to distribute the feed material
uniformly in the classifying air and the sharpness of cut decreases. Too many coarse
particles then pass into the fines. As with screening, the sharpness of cut decreases in
classifiers with decreasing cut size (finer classifier setting).
 properties of the feed material (amount, fineness, moisture and tendency to adhere)
As the amount of feed increases, so does the loading; the particles obstruct one another
in the classifying air; separation becomes less sharp (until the fine and coarse materials
are of equal fineness). If the loading is too low (for example because the classifier is
too large for the mill) then oversized material may be carried over into the fines.
The classifier can therefore only separate satisfactorily if there is a sufficiently high pro-
portion of fines in the feed material.

In plants with a high recirculating load (raw meal, high-grade cements) approximately
30 % fines should be contained in the feed, otherwise 60 %. Raw meal is not separated
as effectively as cement owing to its residual moisture and tendency to adhere.

The following requirements must therefore be met in order to achieve satisfactory classifier
operation:

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 the feed must be distributed uniformly over the cross-section of the classifying cham-
ber, i.e. optimum dispersion (effect of grinding aids).
 the classifying airflow containing the material to be classified must be deflected and
restricted as effectively as possible.
 a specific minimum time is necessary in order to separate fines and oversized material.
Ultrafine ParticleRange On the whole this system reaches the limits of its capability quickly when classifying in
the ultrafine range. Its separating effect is very poor in this range and it is also necessary to
operate with high circulating loads. It is therefore normally used in grinding for coarser
finenesses (raw meal) and is used less for classifying during cement grinding.

Further Areas of Application of the Recirculating Air Classifier

In closed-circuit grinding plants with bucket elevators for raw meal and cement. The
classifiers may therefore take on the following secondary functions:
 Drying of raw meal: direct drying of raw meal by using heated classifying air (Fig.
2.1-5). External fan for supplying heated air. Also utilization of kiln exhaust gases and
10 cooler exhaust air. Separate air heaters may also be used. The used classifying air
must be discharged and dedusted.

5
8

3
6 1
4
7
2

Figure 2.1-5: Recirculating Air Separator, Equipped for Drying the Separator Feed, Schematic View .

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1 hot air inlet

2 guide vane ring for hot air

3 guide vane ring for recirculating classifying air

4 hot air

5 recirculating classifying air

6 hot air distribution chamber

7 exhaust air pipe

8 cooling shell with temperature monitoring for the lower bearing

Table 2.1-2: Key to Fig. 2.1-5.

 Cement cooling: direct cooling (Fig. 2.1-6) by an external fan and air cooler in the
outer pipeline is only rarely used. Improved cooling is achieved by using water to cool
the finished product as it slides down in the outer chamber of the classifier.

1 11

Figure 2.1-6: Recirculating Air Separator, Equipped for Cooling the Separator Fines, Schematic View .

1 cooling air inlet

2 cooling air

3 recirculating classifying air

4 fines collection chamber

5 waste air pipe

Table 2.1-3: Key to Fig. 2.1-6.

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2.1.3 Dynamic Classifiers: Cyclone Recirculating Air Classifier

Another type of dynamic classifier is the cyclone recirculating air classifier.

Similarities Cyclone recirculating air classifiers are comparable to rotary air classifiers with regard
to design and mode of separation. Features in common with recirculating air separators
include:
 distribution plate in the classifying chamber
 airflow in the classifying chamber from bottom to top
 countervane system above the distribution plate

feed

12

fines

tailings

Figure 2.1-7: Cyclone Recirculating Air Classifier, Example of a Schematic Representation .

Features and Advantages

The differences between recirculating air classifiers and cyclone recirculating air classi-
fiers lie in the external arrangement of the circulating air fan and the way fine material is
collected.

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 2.1 Classifier Designs and Modes of Operation

Specific features of the cyclone recirculating air classifier are shown in Fig. 2.1-7: Features
 Classifying air fan outside the classifier housing.
 The air laden with the fines is discharged in the upper part of the classifying chamber
through tangential openings into several cyclones (2 to 6), where the majority of the
fine material is collected.
Efficient Collection of the Fines Advantages
The recirculating air fan, which exhibits greater efficiency and is able to create greater
underpressure than the slow-running fan impeller installed inside the separator, makes
it possible to collect the fines from the classifying air in high efficiency cyclones. This
collection process does involve high pressure drops, but is far more efficient than fine
material collection in conventional rotary air classifiers. The circulating classifying
air is therefore largely free from fine particles when it is fed back into the classifying
chamber.
Classifying Air Circuit
The classifying air may be kept within the circuit or released into the atmosphere after
dedusting. 13
Better Separation Efficiency
The separation efficiency (proportion of unclassified particles) and the sharpness of
cut are generally better than with recirculating air classifiers.
Recirculation of Fines is Avoided
Recirculation of fines, predominantly in the very fine particle range, which has a neg-
ative effect on the classifying process and in rotary air classifiers is caused by insuf-
ficient fine material separation, is virtually eliminated in this design. This means that
cyclone recirculating air classifiers are generally operated with smaller quantities of
recirculating air than rotary air separators of comparable throughput and achieve bet-
ter separation results, i.e. better separation efficiency (lower proportion of unclassified
particles) and better sharpness of cut in the very fine particle range. Cyclone recir-
culating air classifiers are therefore particularly suitable for use in the production of
high-grade and very high-grade cements. It should also be noted that since the amount
of classifying air can be adjusted within a wide range it is also possible to influence
the particle size distribution as well as the specific surface area of the fines.
Higher Specific Classifying Chamber Loadings are Possible
It is possible to operate this type of classifier with a greater specific classifying cham-
ber loading than conventional rotary air classifiers owing to the larger quantities of
classifying air and the more favourable separation characteristics. The drop in the
quality of classification as a function of classifying chamber loading is considerably
less pronounced owing to the greater amount of classifying air and the ability to adjust
this amount over a wide range. As with conventional rotary air classifiers, it is also
possible to carry out drying and cooling in cyclone recirculating air classifiers.

Options for Adjusting the Fineness of the Classifier Fines

Basically, in addition to the ability to adjust the amount of classifying air over a wide
range, the same adjustment options as for rotary air classifiers are also available in cyclone
recirculating air classifiers. The two adjustment options changes to the speed of the
countervane system and changes to the amount of classifying air are sufficient under
normal operating conditions, i.e. when classifying normal cement and raw meal finenesses.

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2.1.4 Dynamic Classifiers: Caged Rotor Classifier (High-Efficiency

Classifier)

Distribution Nowadays caged rotor classifiers are nearly always used in new cement grinding plants.
They provide the greatest output of fines and the lowest proportion of unclassified parti-
cles. In caged rotor classifiers the countervane system is replaced by a caged rotor.

Operating Principle
The effective classifying process begins as soon as material is fed into the system. The ma-
terial is fed onto the distribution plate via feedpipes, which depending on the producer can
be located at different positions. Often the material is fed via two symmetrical feedpipes
to ensure a uniform distribution of the material.
Due to the conical shape of the distribution plate, the material flows are accelerated with
minimal relative movement between the material and the distribution plate and are thrown
14 down into the dispersing zone . The material flow is thrown against an impact ring so
that even materials that are difficult to disperse can be broken up before they enter the
classifying zone.

The classifying zone is a narrow cylindrical space between the guide vanes and the
rotating caged rotor or rotor fitted with blades.

The classifying air flowing in tangentially is guided accurately into the classifying zone
by the inlet spiral and the adjustable guide vanes. The classifying air flows through the
curtain of material in cross-flow and separates out the desired fine material.
Following rules are essential: The higher the amount of separating air, the higher is the
acceleration of the particles towards the cage. With higher speed the chance to pass the
rotating cage into the fines rises. Smaller/finer particles thereby are easier accelerated than
big/coarse ones. With rising rotational speed of the cage, the speed of more and more
particles will not be high enough, so they will be caught by the staves of the cage and
flung outward. These rejected particles will be taken downwards through gravitation and
end up as rejects.
The fine material is separated from the classifying air either by high-performance cy-
clones or by a filter depending on the particular classifying plant. The amount of classi-
fying air may be varied either by an inlet vane control system or a frequency converter on
the fan drive.
The infinitely variable control of the circumferential speed of the caged rotor, which can
reach up to 40 m/s, makes it possible to achieve fine classification up to 10,000 cm2/g.

If the amount of separating air is severely reduced while the rotating speed of the cage
remains very high, the rejects and the amount of recirculating material can significantly
increase resulting in a collapse of the whole grinding system.

Examples of Plants
 Normal Configuration
Normal configuration of a high-efficiency classifier as part of a grinding plant for ce-
ment clinker (Fig. ??). This configuration is used if additional cooling of the product
is required. Only a relatively small filter is needed.

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 2.1 Classifier Designs and Modes of Operation

3 4
5
2

6 6

15

Figure 2.1-8: Caged Rotor Classifier with Single Air Input in a Grinding Plant for Cement, Schematic
View .

1 tube mill

2 bucket elevator

3 dynamic separator (caged rotor classifier)

4 filter

5 fan

6 feed silo

Table 2.1-4: Key to Fig. 2.1-8.

 Compact configuration with good product cooling by a high-efficiency classifier with
single air input in a grinding plant for cement (Fig. 2.1-8). This configuration is used
if the fine material is collected using filters. This model dispenses with cyclone sepa-
rators for the fine material.

Options for Adjusting Fineness

In a caged rotor classifier with a specific basic setting of the classifier fan the fineness can
be adjusted by making small changes to the caged rotor speed. The recirculating air setting
can be kept constant during classification of a product. The product fineness can also be
influenced, but to a lesser extent, by adjusting the amount of feed. As a rule a grinding
plant with a caged rotor classifier is first started up and then the finenes is adjusted during
operation by making small changes to the caged rotor speed.
cooling of the product in the classifier without using a separate cooler Advantages
dedusting of the mill by the classifier
only one source of finished product

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5
3 6
4

7 7
2

16

Figure 2.1-9: Caged Rotor Classifier in a Grinding Plant for Cement, Schematic View .

1 tube mill

2 static classifier

3 dynamic classifier (caged rotor classifier)

4 bucket elevator

5 filter

6 fan

7 feed silo

Table 2.1-5: Key to Fig. 2.1-9.

smaller installation dimensions

lower loading on the building due to lighter classifier weight

2.2 Assessing Separation and Operation of a Classi-

fier
Assessing the Separation Performance of a Classifier
Sampling In order to assess the separation performance of a classifier it is necessary to take samples
of the classifier feed, oversized material and fines, followed by particle-size analysis of
these samples. The shapes of the particles and their settling velocities during classification
serve as separation characterisics.
The shape of the particle-size distribution curve obtained from the analysis characterizes
the distribution of oversized material and fines in the classified product. The classifier
circuit is then balanced by comparing the mass flows of the feed material , the oversized
material and the fines as well as their particle-size distributions.

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 The ratio between the proportions of a particular particle size in the oversized and feed
materials is referred to as the selectivity, from which the proportion of fines can be
deduced.

The dependence of the selectivity on the particle size is called the separation curve.
For each of these particle sizes a separation curve indicates the ratio of the amount
present in the oversized material to that present in the feed material. The separation
characteristics of a classifier are therefore illustrated in the separation curve, also known
as the Tromp curve.

Assessing the Operating Mode

The operating mode of a classifier is also characterized by its recycle ratio. The greater
the recycle ratio, the lower is the fine material mass flow and the greater is the oversized
material mass flow.
The feed material mass flow can be determined from the fine material mass flow and the 17
recycle ratio in order to assess whether a classifier is correctly loaded.

3 Maintenance and Inspection

Wear in Dynamic Classifies
In contrast to static classifier systems in which only the conveying airflow flows through
the separator housing, causing little abrasive wear, dynamic classifiers are subjected to
considerable wear owing to their high dynamic loadings.
The high airflow velocities and the strong cyclone-wall effects produced lead to severe
wear of the materials. The inner walls and components of the classifier are therefore
provided with wear-resistant materials (Fig. 3.0-1).
These wearing parts must be checked regularly and replaced if necessary (Fig. 3.0-2). If
these parts were to become detached unexpectedly they could cause serious damage.
The high speeds of the components in dynamic classifiers themselves may also cause wear
of the materials (caged rotor in a classifier, distribution plate and countervane system).
These moving parts must also be checked regularly in order to prevent damage. The caged
rotor shaft, the bars of the caged rotor and the seals between the cage and the housing are
particularly susceptible (Fig. 3.0-3).

4 Health and Safety Practices

Personal protective equipment (PPE) must be worn when working on or in reaction vessels
or conveyors within a grinding plant of any type. This protective equipment consists of
 protective clothing
 hard hat
 gloves
 protective goggles
 protective breathing mask
 safety harness
Reaction vessels are generally:
 mill tubes

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 4 Health and Safety Practices

18

Figure 3.0-1: View into the Outer Region of a Caged Rotor Classifier fitted with Wear-Resistant Plates
.

 vertical roller mill housings

 high pressure roller mill housings
 classifiers (static and dynamic)
 cyclones
 fabric filter housings
 electrostatic precipitator housings
 pipelines
Conveyors are generally:
 bucket elevators
 conveyor screws
 chain conveyors
 bucket conveyors
 belt conveyors
 Sicon conveyors
 hopper discharge devices (e.g. Saxlund)
 conveying and metering belt weighfeeders
 thrust feeders
 disc feeders
 rotary feeders
 loosening equipment in working hoppers
 specialist machinery (such as screens or Mogensen Sizers)
The following measures must be taken before and during work:
 Production supervisors and managers give and receive information regarding any work
taking place.
 Once work has been performed and completed this must be communicated by the
workers who carried out the work.

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 19

Figure 3.0-2: Visible Wear of the Caged Rotors and of the Separating Plate Mount .

 All mill drives must be isolated on the high-voltage side before access. This must be
recorded.
 The operating safety of auxiliary drives used for positioning must be checked before
use.
 Fans, conveying and discharging equipment, metering machines, classifiers and crush-
ers must be disconnected on all poles and be secured against reconnection. The worker
responsible prevents reconnection by arranging padlocks on the switches of the repair
switch boxes and these are removed once work is completed.
 Safety lookouts must be used where necessary.
 Radio equipment or intercoms should be used if visual contact with a safety lookout
cannot be ensured.
 Different surfactants/grinding aids are used to combat the tendency for agglomeration
of mill feed in tube ball mills and to improve dispersion of the feed in classifiers.

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 5 Factors Affecting Plant Production

20

Figure 3.0-3: View from Above into a Caged rotor Classifier showing Replacement of the Worn Seal
Between the Cage and the Housing.

The necessary handling instructions detailed in the relevant safety data sheets must be
observed.
 Stearic acids and Mesamol are used as air-entraining agents in hydrophobic cement.
The instructions given in safety data sheets must be observed.
 Water injection is used in tube ball mills for many reasons:
 conditioning of the exhaust gas for electrostatic precipitators after cement mills;
water injection is therefore relevant to the environment.
 cooling the cement to temperatures below 60 C; water injection is therefore rele-
vant to health and safety at work.
 combating agglomeration during cement grinding in tube ball mills; water injection
is therefore relevant to quality and output.

5 Factors Affecting Plant Production

The main variables that affect the production operation of grinding plants are:
 time availability of the plant
 output availability of the plant
The influencing variables are interrelated and determine the efficiency of the production
plant, i.e. the influence on possible emissions, quality and energy consumption.

Time Availability of the Plant

The availability coefficient of the plant is affected by preventive maintenance:
 Basic repairs are carried out annually.
 Downtime is planned weekly for immediate repairs.
 Damage and unforeseen breakdowns necessitate immediate repairs.

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Output Availability of the Plant
Measures to secure output availability affect:
 assurance of the product quality
 minimization of the energy consumption
 minimization of the wear and corrosion
This basically means that
 regular measures must be carried out to safeguard the classifying efficiency of classi-
fiers of different types and
 regular measures are taken to assess the condition of the plant.
Grinding plants can be safeguarded and operated with a high level of availability if the
above measures are carried out diligently and staff are well-trained or plants are automated,
thus minimizing wear.

6 Questions on Course LB 4.5 Classifiers 21

You can test your knowledge by answering the following questions.

Question 6.0 A:
1. Explain the mode of operation of a static air classifier in a combined grinding and
drying mill for cement raw materials.
2. How is the fineness of the classifier fines adjusted in a static classifier?
3. Explain the options for adjusting the classifier fines from a cyclone recirculating air
classifier during operation.
4. What further options are there for adjusting fineness in a cyclone recirculating air
classifier when it is stopped?
5. Why do the sharpness of separation and, in particular, the separation efficiency of a
recirculating air classifier decrease with large housing diameters?
6. Explain the special features of a caged rotor classifier (high-efficiency classifier) as
compared to a cyclone recirculating air classifier.
7. What are the advantages and disadvantages of using a caged rotor classifier with
single air feed in a grinding plant for cement?
8. What specific health and safety measures are necessary when working on and, in
particular, inside a classifier?
9. Describe the tests carried out on a classifier, the analyses that need to be carried out
and the expected results required to determine the operating condition of a classifier.
Solutions see p. 22

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 6 Questions on Course LB 4.5 Classifiers

Solutions
Solution for 6.0 A:

5 2 4 2

22
1

2
1

Figure 0.0-1: Static Air Classifier, Schematic View .

1. The material to be classified is fed to the classifier from below with the conveying
airflow. The material and the conveying air flow upwards between the outer housing
and the collection cone. The air speed is reduced by the continuous increase of the
cross-section and deflection of air by the vane ring and by the top outlet duct in
the classifier head, causing the separation of oversized material. At the same time
the conveying airflow is caused to rotate by the tangential entry of the conveying
air through the guide vane ring. The resulting centrifugal acceleration assists the
separation of oversized material. The air, which is free from oversized material,
leaves the classifying chamber with the fines via the top outlet duct. The fines have
to be collected from the airflow outside the classifier in a cyclone or filter.
1.outer cone

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 2.guide vane ring
3.oversized material cone
4.top outlet duct
5.device for adjusting the guide vane ring
6.oversized material outlet
2. During operation the fineness of the oversized material and fines from the separator
may be adjusted by altering the air speed and therefore the amount of classifying
air, for example by changing the position of the guide vane ring.
3. a) the amount of classifying air can be adjusted over a wide range using the external
classifying air fan
b) changes to the countervane system
speed
4. changes to the countervane system
number and size of the countervanes (only when stopped)
gap between countervanes and the classifying chamber housing (only when stopped)
setting angle of the countervanes (only when stopped)
23
5. If material loading of the classifying air is too low, for example because the sepa-
rator is too large for the mill, oversized material may be carried over into the fines
because the material to be classified is inadequately dispersed. The separation be-
comes less sharp.
6. Special Features:
a) countervane system replaced by a caged rotor.
b) distribution plate directly above the caged rotor
c) the material to be classified is fed onto the distribution plate via two feedpipes,
resulting in more uniform distribution of the material. Material in the dispersing
zone is thrown against an impact ring so that material can be broken up more effec-
tively before it enters the classifying zone.
d) the classifying zone is a narrow cylindrical space between the guide vanes and
the rotating caged rotor
e) classifying air flowing in tangentially is guided through the curtain of material in
cross-flow by inlet spirals and adjustable guide vanes.
Oversized material is carried downward by gravity. Fine material is collected from
the classifying air by high-performance cyclones or filters.
f) the amount of classifying air is adjustable.
g) the speed of the caged rotor is adjustable.

7. a) cooling of the product in the classifier without using a separate cooler

b) dedusting of the mill by the classifier
c) collection of fine material in a filter
d) no need for collecting cyclones
e) only one source of finished product
f) smaller dimensions
g) lighter classifier weight
h) lower loading on the building
i) amount of classifying air should be adjustable independently of mill dedusting.

8. a) production supervisors and managers must be informed

b) all drives must be isolated on the high-voltage side and secured against recon-
nection by the workers responsible. This must be recorded!
c) the operating safety of auxiliary drives must be checked before use

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 6 Questions on Course LB 4.5 Classifiers

d) fans, conveying and discharging equipment, classifiers and crushers must be dis-
connected at all poles and secured against reconnection
e) safety lookouts must be used where necessary
f) the instructions detailed in the safety data sheets for grinding aids and, where
necessary, for air-entraining agents must be observed!
g) once work has been completed this must be reported by the workers who carried
out the work
h) the system should be released for use again by the workers responsible

9. a) Laboratory:
 simultaneous sampling of the classifier mass flows at short time intervals
 production of analysis samples from the cumulative samples
 particle size distributions of
 classifier feed material
 oversized material
 fines
24
 dust in the conveying air
 finished product
 production of a sample of the finished product
b) Operation:
 energy consumption
 of the classifier
 of the conveying routes
 of the dedusting equipment
 throughput mass flows (normally only possible at belt weighfeeders for the feed
material)
c) Results:
 classifier separation curve and from this:
 sharpness of separation
 proportion of unclassified material, i.e. separation efficiency
 product yield
 recycle ratio
 specific energy consumption
 particle-size distribution of the fines
 possibly standard cement properties
 possibly concrete properties
Questions see p. 21

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Glossary
agglomeration
The process by which small particles stick together to form larger particles.
centrifugal acceleration
force directed radially outwards; occurs during the circular movement of a body
centrifugal force
Centrifugal force. The outward force that acts on a body in circular motion.
centrifugal force
Physical force that acts upon a body moving along a curvilineal path
continuous conveyor
Mechanical, pneumatic or hydraulic conveying system, in which the material is moved either continuously or
intermittently from the feed point to the discharge point, possibly at variable speed (e.g. a belt conveyor)
cushioning effect in mills
Fluctuations produced by the non-uniform feeding of coarse fractions into the grinding system are partially
attenuated by grinding units and are not passed on directly to subsequent process steps.
cyclone
Device which separates particles from gas using centrifugal force 25
cyclone wall effect
Effect by which particles are separated more effectively at the housing wall due to stronger centrifugal forces
acting on the particles as a result of deflected flows.
disperse
to distribute a material in a liquid or a gas
dispersing zone
Region of a classifier in which fine material is dispersed, i.e. is distributed in the surrounding gas
feed material mass flow
The quantity of mill feed that is introduced into a mill per unit of time (e.g. tonnes per hour).
fine material mass flow
Material that is discharged as product owing to its fineness. The classification into fine material and oversized
material is carried out by a classifier.
mass force
for example gravity, inertial force
maximum particle size
Maximum acceptable particle size
oversized material mass flow
Material that remains in the mill circuit and is not discharged owing to its size. The classification into fine
material and oversized material is carried out by a classifier.
particle size distribution
The frequency distribution of different particle sizes. A combination of different degrees of fineness is known as
a wide particle size distribution or a wide particle range.

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 Index

A
agglomeration 2

C
centrifugal acceleration 3
centrifugal force 2, 7
continuous conveyor 6
cushioning effect in mills 2
cyclone 5, 14
cyclone wall effect 8

D
disperse 14
dispersing zone 14

26
F
feed material mass flow 16
fine material mass flow 16

M
mass force 2
maximum particle size 2

O
oversized material mass flow 16

P
particle size distribution 16

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