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Guideline Separator Inspection

This document provides guidelines for inspecting and optimizing air separators used in cement grinding circuits. It outlines procedures for running inspections of separators, internal inspections of separator components, sampling materials and analyzing particle size distributions, and calculating key performance metrics. The guidelines cover first, second, and third generation separator technologies, providing specific inspection criteria and measurement requirements for each. The overall goal is to thoroughly evaluate separator performance and identify any areas for improvement.

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75% found this document useful (4 votes)
752 views25 pages

Guideline Separator Inspection

This document provides guidelines for inspecting and optimizing air separators used in cement grinding circuits. It outlines procedures for running inspections of separators, internal inspections of separator components, sampling materials and analyzing particle size distributions, and calculating key performance metrics. The guidelines cover first, second, and third generation separator technologies, providing specific inspection criteria and measurement requirements for each. The overall goal is to thoroughly evaluate separator performance and identify any areas for improvement.

Uploaded by

Rawat
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 25

HeidelbergCement Group

Guideline
Edition: 01

Separator Inspection and Valid as of: 2012-08-22


Optimisation
Expert Group
Process owner:
Grinding

Separator Inspection and Optimisation


Guideline

Guideline for Separator Inspection and Optimisation_2012_01.doc Page 1 of 25


HeidelbergCement Group Guideline Edition: 01

Separator Inspection and Optimisation Valid as of: 2012-08-22

CONTENT:
1 OBJECTIVES AND SCOPE ..................................................................... 3
2 TERMS AND DEFINITIONS ..................................................................... 3
3 SEPARATOR EVALUATION GENERAL REQUIREMENTS ................... 3
4 CIRCUIT OPERATION REVIEW .............................................................. 3
5 RUNNING INSPECTION .......................................................................... 4
6 INTERNAL INSPECTION ......................................................................... 5
6.1 1ST GENERATION SEPARATOR .............................................................. 5
6.2 2ND GENERATION SEPARATOR ............................................................... 8
6.3 3RD GENERATION SEPARATOR .............................................................. 9
7 MATERIAL/CIRCUIT SAMPLING .......................................................... 11
8 PERFORMANCE CALCULATIONS ...................................................... 11
8.1 CIRCULATING LOAD ............................................................................ 11
8.2 CIRCULATING FACTOR ........................................................................ 13
8.3 SEPARATOR EFFICIENCY .................................................................... 13
8.4 TROMP CURVE................................................................................... 14
8.4.1 Slope D75/D25 – Slope of Curve ................................................ 16
8.4.2 Imperfection, Is – Sharpness of Curve ..................................... 16
8.4.3 D50 - 50:50 cut size ................................................................... 17
8.4.4 Apparent Bypass (ABP) ............................................................ 18
8.4.5 CER 60  Coarse End Recovery ............................................ 20
8.4.6 Acuity limit: ............................................................................... 22
8.4.7 Summary Criteria for Good Performance of Separators ........... 23
9 SEPARATOR DIMENSIONING AND APPLICATION ............................ 23
9.1 1ST GENERATION SEPARATORS .......................................................... 23
9.2 2ND GENERATION SEPARATORS .......................................................... 24
9.3 3RD GENERATION SEPARATORS .......................................................... 24

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HeidelbergCement Group Guideline Edition: 01

Separator Inspection and Optimisation Valid as of: 2012-08-22

1 Objectives and Scope

The purpose of this document is to present the performance evaluation


criteria of air separators mainly dealing with finish grinding. It covers all the
1st, 2nd, and 3rd generation of separators. It includes both running as well as
internal inspection requirements and the sample collection plan to be carried
out for the assessment of separators. Simple performance calculations are
explained for easy understanding of readers.

2 Terms and definitions


PSD Particle size distribution
CL Circulating load
CF Circulating factor (CL + 1)
HES High efficiency separator
CER Coarse end recovery
D75 Percent passing at size 75 micron
Is Separator imperfection
ABP Separator apparent by-pass

3 Separator Evaluation General Requirements


To thoroughly evaluate a separator’s performance the following must be
accomplished:
 Operation Review: Operating and quality data needs to be gathered
and analyzed to ensure the mill was running in stable condition for
several hours prior to doing any material sampling. This data can also
be analyzed over longer time periods to investigate the stability of the
mill operation.
 Running Inspection: Includes site inspection and process
measurements
 Internal Inspection during mill stoppage
 Material/Circuit sampling and analysis of particle size distribution (PSD)

4 Circuit Operation Review


A separator performance review must include to some extent a review of the
entire mill circuit itself. Operational review should include review of a given
mill circuit under typical operating scenario and include analysis of the
following:

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HeidelbergCement Group Guideline Edition: 01

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 Operating and quality data (set points/target and process variable)


- Material rates (fresh components, separator rejects)
- Mill load measurements (power/sound/vibration)
- Separator power/speed
- Grinding aid/additive flow rate
- Water spray flow rates
- Mill discharge elevator power
- System temperatures and pressures
- Process fan power/flow rates
- Product chemistry and fineness
 Circulating load and fineness control philosophy
- Evaluate controller reliability/utilization

5 Running inspection
Inspection of the separator itself during typical operating conditions is
component of the overall evaluation. The following are components of the
running inspection.
 Measure separator airflow to be evaluated versus design requirements
and in combination with separator feed/product rates to determine grain
loading at inlet and outlet (3rd Gen)

1st Generation
- Air flow is all internal to separator. No good way to measure.
 If pulling vent draft, this can be measured.
 Amount of vent air varies with separator size, but a 16’ separator
should have around 2800 m3/hper Sturtevant
2nd Generation
- Measure air flow on the negative side of the fan
- Measure vent draft

3rd Generation
- Measure air flow inlets and outlets
- 10%-20% vent air of total separator air flow.
- Verify speed of rotor/blades
- Visually inspect material flow into/out of the separator (surging, rate
estimation vs. control room indications, rate vs. equipment
limitations)
- Check process temperatures/pressures across the separator

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HeidelbergCement Group Guideline Edition: 01

Separator Inspection and Optimisation Valid as of: 2012-08-22

6 Internal Inspection
Internal inspection of the separator when the unit is down provides opportunity
to evaluate the mechanical condition of the separator components. Differing
components among the various types of separator being evaluated (1st, 2nd or
3rd generation separator) will dictate inspection requirements. When
inspecting the wear, angles, gaps on the various internal components
reference should be made to both the separator performance and as-built
documentation to assist in determining the necessity for corrective action. As
with any operating unit, the system should be de-energized and local lock
out/tag out procedures adhered to prior to system entry. The following are
components of the internal inspection broken down by separator type.

6.1 1st Generation Separator

 Component wear is of primary concern with 1st Generation Separators.


The following components should be checked for wear.
- Fan blades
- Distribution plate/table
- Counter blades
- Control Valves
- Drum Cover
- Return Air Vanes
- Material feed cone
- Reject cone / lining - check for holes
- Product cone
 Check for build up/coating of components
- Potential problems with temperature/moisture control

 Main Fan Blade Measurements


- A: Fan Blade Distance to Outer Cone
- B: Gap between Fan Blade and top of housing
- C: Gap between Fan Blade and Valve
- W(fan): Width of Blade : may be two sizes
- H(fan): Height of Blade
 Counter Blade Measurements
- D: Gap between blade and drum cover: should be close to 0.25”
- E: Distance from Tip of blade to coarse hopper
- H(s1): Height of outer edge of blade
- H(s2): Height of inner edge of blade:
- W(s): Width of length of blade
- Overlap: Overlap of blade with drum cover (not labeled)

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HeidelbergCement Group Guideline Edition: 01

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 Miscellaneous
- Make sure counter blade pattern is balanced.
- Control Valves
 Ensure all valves are attached and moving
 Compare external valve measurement with overlap of drum
cover e.g. outer measurement is 1”, but the valve is flush with
the drum cover
- Tipping Valves
 If tipping valves are installed on the rejects or products ensure
they are functioning properly
- Return air vanes
 Ensure all return air vanes are tight and aligned properly
 It is recommended to remove return air vanes at the location
where the fresh air inlets pass into the inner cone due to the
potential for coarse product to build up and spill over to the
product side. A blank plate should be installed instead.

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HeidelbergCement Group Guideline Edition: 01

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6.2 2nd Generation Separator

 Similar to a 1st generation, the following wear items should be checked


– Fan blades
– Distribution plate/table
– Counter blades
– Air Vanes
– Material feed cone
– Reject cone / lining
– Product cone
– Additional wear inspections
 Cyclones : tipping valves
 External Fan / Damper
 Check for coatings
– Potential problems with temperature control
 Check position and number of blades

Counter blades

External fan
Air vanes Distribution plate

External cyclones

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HeidelbergCement Group Guideline Edition: 01

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6.3 3rd Generation Separator

 Evaluate the wear on the following components:


- Rotor / Distribution plate
- Guide vanes
- Sealing of rotor between fixed and rotating part
- Separator lining
- Exit duct
 Coating is sign of problems in the mill or with maintaining operating
temperature above dew point
 Material blocking gas paths
- Excessive material  velocity problem
- Trash  media or other present
 Adjustment of inlet damper blades.
 Adjustment of guide vanes  maintain proper angles throughout the
circumference (if applicable)
 Rotor Seal: Adjustment of gap between fixed and rotating part should
be to minimum tolerance

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HeidelbergCement Group Guideline Edition: 01

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 Rotor Seal
o important to minimize the gap between the rotor cage and housing
o Installed to avoid coarse Material (Reject) from outside to be sucked
into the inner Rotor (Air + Product Mix)
o Can be seen with magnifying glass in product (sometimes)
o Will result in an abnormal particle size distribution displayed by a
peak of coarse material found in product (called a “Camel-Back” in
PSD curves)
o Not adjustable

Example of “Camel-Back”

Density Distribution

100

90

80
Cumulative Distribution (%)

70

60

50

40

30

20

10

0
1 10 100 1000
-10
Paticle Size (microns)

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HeidelbergCement Group Guideline Edition: 01

Separator Inspection and Optimisation Valid as of: 2012-08-22

7 Material/Circuit Sampling

Material sampling around the mill system gives valuable information about
grinding and separator performance
 Sample materials around the separator during a stabile/steady state (at
least 2 sets) to determine separator efficiency, build a tromp curve, and
evaluate mass flow meter accuracy. The following samples are taken.
– Separator feed
– Separator rejects
– Separator product
 Separator product may be different than Final product
depending on the circuit.
– Mill product
 This may be different than separator feed depending on
system layout
– Dust Collector material (Mill sweep dust)
 Review the fineness of the dust to determine optimum re-
introduction point
– If material is finer than product should re-introduce
into product stream
– If material is coarser than product should re-
introduce with separator feed
 Analysis of the samples for Blaine and full PSD or at least critical size
fractions
– It is recommended to use a wet method laser analysis to
determine the most reliable/accurate PSD for further analysis.
Global experience with air jet analysis has shown that this
method is unreliable.

8 Performance Calculations

8.1 Circulating Load


 Circulating Load = Separator Rejects divided by Separator Product
 CL is related to separator loading
– % of rejects vs. % of finished product

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HeidelbergCement Group Guideline Edition: 01

Separator Inspection and Optimisation Valid as of: 2012-08-22

Circulating Load Based on % Passing Circulating Load Based on Residues


Sieve X on Sieve X

px  f x f x  px
CL  CL 
f x  rx rx  f x
 f = Separator Feed  fx = Separator Feed Residue
 p = Separator Product  px = Separator Product Residue
 r = Separator Tailings  rx = Separator Tailing Residue
 Or Fineness = Blaine Value  Fineness = % retained on size X

Separator feed

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HeidelbergCement Group Guideline Edition: 01

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8.2 Circulating Factor

CF  CL  1

 CF = Separator Feed divided by Separator Product


 CF is related to the loading on the mill system.
– % of total separator feed that is leaving circuit as product
– Number of passes material has to make through the mill before
exiting as product.

8.3 Separator Efficiency

Separator Efficiency Based on % Separator Efficiency Based on %


Passing Sieve X Residues on Sieve X

x 
px  (fx  rx) px 1
 100    100
100  p x  f x  rx 100  px 1
x    100    100
fx  (px  rx) fx CFx 100  f x  p x  rx 100  fx CFx

 ηx = Separator Efficiency  ηx = Separator Efficiency


 f = Separator Feed  f = Separator Feed
 p = Separator Product  p = Separator Product
 r = Separator Tailings  r = Separator Tailings
 Blaine value could be used in place of
% passing

Typical Separator efficiency


 HES > 80%
 1st /2nd generation > 60%

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HeidelbergCement Group Guideline Edition: 01

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The efficiency formula can also be applied over a range of PSD data using the
summation of the individual sieve sizes. The following data shows an average
efficiency calculation based on % passing across a range of sieve sizes.

particle size distribution

Part.-Size Fines (f) Feed (a) Grits (g)

[mm] [D%] [D%] [D%]

50.00 97.75 90.31 80.39

42.00 95.50 86.62 74.77

36.00 92.13 82.01 68.69

30.00 88.00 76.94 62.84

25.00 83.65 71.98 57.75

21.00 77.49 65.52 51.78

18.00 68.57 57.06 44.63

15.00 60.77 50.02 39.00

Totals 663.86 580.46 479.85

Separator Effieiency 62.53%

8.4 Tromp Curve

A tromp curve is created using the PSD analyses from the separator feed,
rejects, and products and is another tool for analyzing a separator’s
performance. It is a curve showing probability of particle size ‘x ‘ going into
coarse fraction. Recommendation for highest accuracy is to use wet laser
analysis for PSD determination and development of the Tromp curve .
 Criteria to evaluate a Tromp-Curve
– Slope D75 / D25: measures the slope of curve
– Imperfection, Is: measures the sharpness of separation.
– Cut size, D50: is particle size with 50:50 probability to go with
fines or with coarse product
– Apparent Bypass: minimum probability of the fines that goes to
separator rejects
– CER60: “Coarse End Recovery” at 60 micron (% material >60
micron in product – unwanted)
– Acuity limit: particle size at which selection is initiated.

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HeidelbergCement Group Guideline Edition: 01

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From PSD-Table to Tromp-Curve:


Separator Separator Separator
Feed Rejects Product
Sieve Size Cumulative Weight Per Cent Passing
Micrometers f r p
192 100 100 100
128 97.3 96 99.8
96 89.4 84.3 99.5
64 74.4 63.8 99.2
48 61.3 46.7 98.3
32 38.5 18.2 87
24 27.5 8.1 74.6
16 22 7.5 56.1
12 17.7 6.8 44.7
8 15.1 6.5 34.3
6 12.5 6.1 27.9
4 10.1 5.6 21.4
3 8 4.6 16.9
2 6.3 3.9 12.7
1.5 4.6 3.1 9.5
1 4 2.6 7.8

Tromp Curve - Example 1

100

90

80

70
% Recovery

60

50

40

30

20

10

0
1 10 100 1000
Particle Size, Micrometers

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HeidelbergCement Group Guideline Edition: 1.0

Separator Inspection and Optimisation Valid as of: 2012-08-08

8.4.1 Slope D75/D25 – Slope of Curve


 This is the ratio of the 75% recovery particle size (microns) and the 25%
recovery particle size (microns).
 Perfect Separation 1.0
 Excellent Separation 1.0 to 1.5
 Good Separation 1.5 to 1.8
 Fair Separation 1.8 to 2.1
 Poor Separation >2.1

- Conventional Separator it is typically > 2.


- High Efficiency Separator is between 1.2 to 1.8

Tromp Curve - Example 1


D75/D25 = 34 / 22 = 1.54
100

90

80

70
D75 = 30.6
% Recovery

60

50

40

30
D25 = 23.4
20

10

0
1 10 100 1000
Particle Size, Micrometers

8.4.2 Imperfection, Is – Sharpness of Curve


 This is the ratio of the Delta of the 75% and 25% recovery particle sizes
(microns) and the 50% recovery particle size (microns).

D75 - D25
I=
2 D50
Separator inspection and optimisation Page 16 of 25
HeidelbergCement Group Guideline Edition: 01

Separator Inspection and Optimisation Valid as of: 2012-08-22

- Is = 0 Perfect Efficiency
- Is up to 0.3 considered high efficiency
- Is up to 0.5 considered good efficiency
- Is up to 0.7 considered fair efficiency

34  22
Is Tromp Curve - Example
 0.23
1
2 * 26
100

90

80

70
D75 = 34
% Recovery

60

50
D50 = 26
40

30

20
D25 = 22
10

0
1 10 100 1000
Particle Size, Micrometers

8.4.3 D50 - 50:50 cut size


 D50 is equal to particle size diameter (microns) which corresponds to a
probability of 50% for one particle submitted to classification (i.e. not by-passes)
to go with the fine or the coarse product.
- Typical around 25 micron (20 to 35 micron)
- Depends on product type and fineness
- The finer the D50 for the same product type the higher the probability of bad
separation.

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HeidelbergCement Group Guideline Edition: 01

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Tromp Curve - Example 1

100

90

80

70
% Recovery

60

50
D50 = 26
40

30

20

10

0
1 10 100 1000
Particle Size, Micrometers

8.4.4 Apparent Bypass (ABP)


 ABP is defined as the lowest point on the Trump Curve.
 General Rule of Thumb for normal circulating factors:
- Excellent Performance < 5 % (for HES)
- Good performance < 10% (for HES)
- Acceptable < 20 % (for HES)
- Excellent Performance < 20 % (for old style Separators)
- Good performance < 30% (for old style Separators)
- Acceptable < 35 % (for old style Separators)

Apparent Bypass is a function of circulating factor. A reference chart based on


circulating factor for different separator types is given below.

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HeidelbergCement Group Guideline Edition: 01

Separator Inspection and Optimisation Valid as of: 2012-08-22

10

9
2nd Generation
8
Circulation Factor (c=A/F)

3rd Generation
7

5
1st Generation
4

0
0 10 20 30 40 50 60 70 80
Bypass [% ]

Sample Should-be state (t=const) Should-be state (u=const.)

By-pass also gives an indication of potential to increase mill output by either improving the
performance of separator or by modification of separator to an extent between by-pass/2
(optimistic) and by-pass/3 (conservative).

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HeidelbergCement Group Guideline Edition: 01

Separator Inspection and Optimisation Valid as of: 2012-08-22

Tromp Curve - Example 1

100

90

80

70
% Recovery

60

50

40

30

20

10

0
ABP = 5
1 10 100% 1000
Particle Size, Micrometers

8.4.5 CER 60  Coarse End Recovery


 The percent of material with 60 micron size that is sent back to mill. This
material is too coarse for final Product.

- Excellent Performance > 95 % (for HE - Separators)


- Good performance > 90% (for HE - Separators)

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HeidelbergCement Group Guideline Edition: 01

Separator Inspection and Optimisation Valid as of: 2012-08-22

Tromp Curve - Example 1

100
CER60 = 96
90
%
80

70
% Recovery

60

50

40

30

20

10

0
60
1 10 100 1000
Particle Size, Micrometers

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HeidelbergCement Group Guideline Edition: 01

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8.4.6 Acuity limit:


Acuity limit is the abscissa value of the apparent by-pass. It is a limit under which
separator cannot see difference between particle sizes. The selection process starts
above this point.

Tromp Curve - Example 1

100

90

80

70
% Recovery

60

50

40

30

20

10
Acquity limit = 10
0
1 10 100 1000
Particle Size, Micrometers

Acuity limits for good separation:


 1st generation: >20 µm
 2nd generation: 15-20 µm
 3rd generation: <15 µm

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HeidelbergCement Group Guideline Edition: 01

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8.4.7 Summary Criteria for Good Performance of Separators

Parameter 1st Generation 2nd Generation 3rd Generation

Slope, D75/D35 <2.1 <2.0 <1.7

Imperfection, Is >0.45 <0.4 <0.3

Apparent by-pass, % <50 <30 <10

Acuity limit, µm >20 <20 <15

9 Separator Dimensioning and Application

9.1 1st Generation Separators

 Dimensioning
– Vary from supplier to supplier
– Rule of Thumb values:
Cement fineness Specific product load per Housing Cross Section
2,500 cm²/g 2.2 – 3.6 t/h*m²
4,500 cm²/g 1.0 – 1.5 t/h*m²
Specific load is related to finished product (t/h) and the cross section area (m²) of
the outer cylindrical casing (Separator diameter)

 Applications
– Product: Separator efficiency is good for coarser products < 3500 cm²/g
Blaine
– Fineness range: 3000 – 5000 cm²/g acc. Blaine
– (Above app. 3500 cm²/g: Loss of mill capacity due to the bad
separator efficiency)
– Grinding plants (raw, cement)

 The level of fines in the separator rejects can be seen if the rejects / grits are
checked for their Blaine value
– To produce cement with a 3500 cm²/g Blaine, the typical / good blaine value
of the rejects returning to the mill is approximately 1500 - 2500 cm²/g

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9.2 2nd Generation Separators

 Dimensioning
– Vary from supplier to supplier
– Rule of Thumb values:
Cement fineness Specific product load per Housing Cross Section
3000 cm²/g 8 t/h*m²
4000 cm²/g 5 t/h*m²
5000 cm²/g 4 t/h*m²
Specific load is related to finished product (t/h) and the cross section area (m²) of
the outer cylindrical casing (Separator diameter)

 Applications
 Product: Separator efficiency is good for medium fineness products < 4000
cm²/g Blaine
 Fineness range: 3.000 – 5.000 cm²/g acc. Blaine
(Above app. 4.500 cm²/g: Loss of mill capacity due to the bad separator
efficiency)
– Grinding plants (raw, cement)

 The level of fines in the separator rejects can be seen if the rejects / grits are
checked for their Blaine value
– To produce cement with a 3500 cm²/g Blaine, the typical / good blaine value
of the rejects returning to the mill is approximately 1000 - 2000 cm²/g

9.3 3rd Generation Separators

 Dimensioning
– Vary from supplier to supplier
– Rule of Thumb values:
Cement fineness Specific product load per Rotor Cage Surface
3,000 cm²/g app. 12 t/h*m²
5,000 cm²/g app. 6 t/h*m²
8,000 cm²/g 2.5 – 3.0 t/h*m²

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HeidelbergCement Group Guideline Edition: 01

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– Based on separator exit airflow the following grain loadings are tolerated
 < 2.5 kg/m3 based on total feed to separator
 <1.0 kg/m3 based on product
– Specific airflow >12500 m3 air/m2 cage surface area (gross)
– Pressure drop 2 – 2.5 mbar
– Separator motor ~0.5 kWh/t, fan 2-2.5 kWh/t.
 Applications
- Product: Separator efficiency is good for finer products < 8000 cm²/g Blaine
- Fineness range: 3000 – 8000 cm²/g acc. Blaine
- Grinding plants (raw, cement, slag)
 The level of fines in the separator rejects can be seen if the rejects / grits are
checked for their Blaine value
- To produce cement with a 3500 cm²/g Blaine, the typical / good blaine value
of the rejects returning to the mill is approximately 700 - 1200 cm²/g

Guideline for Separator Inspection and Optimisation_2012_01.doc Page 25 of 25

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