Industrial Processes: "Separation and Classification of Solids"
Industrial Processes: "Separation and Classification of Solids"
GROUP REPORT
PASATIEMPO, MARJORIE
AQUINO, DHAYANE
HISTORY
People have utilized methods of separating and purifying material to improve the
quality of life since ancient times. Separation techniques are used in a wide range of
processing industries, and they are frequently encountered by practicing engineers.
Because many of these separations require the removal of discrete particles or droplets
from a fluid stream, separation techniques involving solids have been studied within the
general topic of powder and particle technology in recent years.
Beddow has studied the most important dry separation processes used in the
processing industry (1981). The removal of particles from dust-laden air in milling
processes, the recovery of the dried product in spray dehydration, and the cleaning of
grains prior to processing are all major applications of dry separation techniques in food
processing. Dry separation techniques used in food processing operations to remove
discrete particles suspended in a fluid or constituting part of a mixture of two or more
separate food solid components are covered in this chapter.
INTRODUCTION
The chemical, petroleum refining, and materials processing industries all rely on
separation procedures, which utilize physical, chemical, or electrical forces to isolate or
concentrate specified parts of a mixture. Separation technologies offer prospects for
waste reduction and more effective use of energy and raw materials, in addition to the
critical process roles they play in each of these industries.
Separation refers to the methods used to separate one material from another.
Separations are a regular occurrence in the chemical industry. In reality, a significant
amount of processing equipment is dedicated to separating one phase or one material
from the other.
Diffusional separation
Mechanical separation
Is used for the separation of heterogeneous mixtures. These are based on the
physical differences between the particles such as size, shape or density. It can be
applied for separating solids from solids, solids from liquids and also solids from gases.
Sieving, or sifters
o Sievers are devices for separating wanted elements from unwanted
material or for characterizing the particle size distribution of a sample,
typically using a woven screen such as a mesh or net or metal.
o A strainer is a form of sieve used to separate solids from liquid. Sieving is
a simple technique for separating particles of different sizes. Coarse
particles are separated or broken up by grinding against one-another and
screen openings. Depending upon the types of particles to be separated,
sieves with different types of holes are used.
o Applications:
Sieves are also used to separate stones from sand. Sieving plays
an important role in food industries where sieves (often vibrating)
are used to prevent the contamination of the product by foreign
bodies.
Mechanical screening
o Often just called screening, is the practice of taking granulated ore
material and separating it into multiple grades by particle size.
o Applications:
Process control in aggregates and mining
Screens serve as a process control to protect process
equipment, possibly a boiler for power generation, or to
maintain the finished characteristics of a product such as
asphalt or concrete.
Means to split feed stream in recycling and waste\
Screening is often used as a means to split the feed stream
between separate processing lines. Because of limitations in
downstream sorting capacity, whether manual (picking
stations) or mechanical (sensor sorters or magnetic
separators), multiple processing lines are often required to
handle the volume of the feed stream
Plant maintenance and cleanliness
Fine material can be removed from the process and treated
separately, greatly reducing maintenance concerns
throughout the plant. Fines collect in other machinery,
creating health and explosion hazards and ferrous fines
create problems in magnetic sortation processes.
Operating cost reduction and increased capacity
There is often a fraction of raw material that is already
properly sized. In a size reduction process such as crushing,
grinding, shredding or shearing, feeding finished product
unnecessarily into a reducer creates avoidable wear and
power consumption. Size reduction machines are often the
most expensive wear related operating cost in a plant, as
well as the largest consumers of power. Pre-screening the
material or scalping reduces unnecessary operating costs
and increases plant capacity.
Magnetic separation
o This method involves the separation of magnetic substances from non-
magnetic substances by means of magnet.
o Takes advantage of physical property of magnetism, so it useful only for
certain substances such as ferromagnetic (materials strongly affected by
magnetic fields) and paramagnetic (materials that are less affected, but
the effect is still noticeable).
o Applications:
Waste management, low-magnetic field separation in water
purification and separation of complex mixtures.
To remove metal contaminants from pharmaceutical product
streams.
Magnetic cell separation. It is currently being used in clinical
therapies, more specifically in cancer and hereditary diseases
researches.
These techniques are combined with PCR (polymerase chain
reaction), to increase sensitivity and specificity of results.
Mining iron, as it is attracted to a magnet. In the machine, the raw
ore is fed onto a conveyor belt which passes underneath two pairs
of electromagnets under which further belts run at right angles to
the feed belt.
Leaching
o In the process industry, leaching is a popular method of liquid-solid
separation. It is the process of dissolving chemicals in a liquid to remove
them from a solid, either naturally or through an industrial process.
Leaching is a crucial method for selectively extracting materials from a
species by using a mass separating agent.
o Leaching is a versatile separation technique that can be observed in
nature as well as employed by humans. It frequently makes use of a liquid
solvent and a solid with a soluble fraction to create a separation
interaction between the two phases, allowing only the soluble portion of
the solid to be extracted.
o Applications:
Leaching is applied in the metals processing industry to remove the
desired metals from their ores, which are usually formed by many
unwanted components. Gold, for instance, is leached from its ore
using an aqueous cyanide solution.
In the chemical processing industry, leaching has a variety of
commercial applications, including separation of metal from ore
using acid, and sugar from sugar beets using hot water.
CLASSIFICATION OF SOLIDS
Classifiers are machines that sort materials according to their size, shape, and
density. The two product streams resulting from any classifiers are (i) a partially drained
fraction containing the coarse particles, and (ii) a fine fraction of particles. Usually, the
principle of the classification is based upon the various densities, specific gravity,
terminal falling velocities of particles in liquid and in air. Classifiers help to achieve
optimum size control, improved product quality, enhanced efficiency and increased
throughput. An important industrial application of classifiers is to reduce overgrinding in
a mill by separating the grinding zone output into fine and coarse fractions.
Air classifiers eliminate the blinding and breakage issues associated with screens.
They work by balancing the physical principles of centrifugal force, drag force, collision
and gravity to generate a high-precision method of classifying particles according to size
and density. Air classifiers can only be used for dry processing. In order to effectively
remove fine powders, the surface moisture of the feed must be very low.
One of the most significant advantages of a classifier is its dry process. For
dedusting aggregates, dry processing eliminates the need for water or settling ponds,
saving money and land, and benefiting the environment. Mechanical centrifugal air
classifiers are useful in many applications, including the following:
• Reducing the fines load on a water flotation system for extracting precious metals from
many types of minerals, including iron, gold, phosphate or ilmenite ores.
• Upgrading the fineness of milled limestone, silica, feldspar, refractory slag, fused
glass, kyanite, zirconia, alumina, lithium carbonate, copper oxide and others.
PRATER
Prater Air Classifiers are designed to provide ultra-fine separation and narrow
particle distributions for dry bulk materials. Their air classifiers offer size separations in
the range of 3 to 150 microns. They are ideal as a stand-alone process that includes a
feeder and dedicated dust collection system. They are equally suited to “closed-circuit”
grinding when coupled to a conventional milling system.
STURTEVANT
a. WHIRLWIND
i. The Whirlwind Air Classifier is used to separate powders in the range of
100 to 400 mesh (150-38 microns).
b. MOBILE AC
i. Mobile Air Classifier is the world’s first and only 100% mobile air
classifying plant with integral collapsible conveyors
c. SIDE DRAFT AC
i. The Side Draft High Efficiency Ai Classifier is used to separate powders in
the range of 100 to 400 mesh (150-38 microns).
d. SUPERFINE AC
i. Superfine Air Classifier is used to separate powders in the range of 5 to 44
microns.
HOSOKAWA ALPINE
The ACM classifier mill was the first classifier mill on the market in 1962. Since
then, the ACM has been continuously developed and adapted to the changing needs of
the market. With over 1000 references worldwide, it is used in every industry. At beater
tip speeds of up to 140 m/s, fineness values of d97 = 10 µm are achieved. The product
becomes entrained in the cooling, conveying and classifying air drawn through the mill
by the downstream fan and is routed along the guide vanes of the vane ring.
a. ACM CX
i. The coaxial bearing arrangement of both classifier and grinding
disc shafts makes a vertical product discharge possible, which
in turn prevents product deposits.
b. ACM CL
i. with direct classifier drive is ideal for all those applications
where the preferred configuration is a horizontal product
discharge duct that has the shortest possible connection to
downstream system components.
c. ACM EC (Easy Clean)
i. was developed to meet the demands for quick and easy
cleaning. This is especially important for those branches of
industry where the product is changed frequently or for batch
production.
d. ACM EC-CL
i. combines the advantages of the CL model, namely compact
configuration with short connections to downstream system
sections, with those of the EC model, with the main focus laid
on short cleaning times.
e. ACM 2 and 5
i. for laboratory and small-batch production. With the newly
developed easy-clean concept, the Mikro ACM machine sizes 2
and 5 offer a high degree of user-friendliness and a minimum of
cleaning effort when changing products. A space requirement of
just 15 m², a mains power socket and a compressed air
connection is all this mill needs for operation.
CLASSIFICATION TECHNIQUES
Mechanical classifiers
o incorporate moving parts which influences the motion of particles.
Non mechanical classifiers
o use fluid drag only to separate particles.
In terms of the forces exerted to particles, classifiers can be categorized into two
major types: gravitational and centrifugal classifiers.
Gravitational classifiers
o are generally used to separate very large particles and are mostly seen as
a pre-treatment stage. This is because gravity itself does not provide
sufficient partition power in classifying small particles.
o The gravitational classifiers are designed for coarser separations in the
range of 12 mesh size (1.4 mm) to 100 mesh size (150 micrometers).
o Gravitational classifiers are suitable for close grinding circuits, de-dusting
of coarser feeds, reducing a high feed loading rate to a finer classifier and
it can also be used as a density separator if the specific gravity difference
of the product to waste.
o MANUFACTURERS:
METSO: OUTOTEC
VAN TONGEREN
Works by using the centrifugal force on the larger particles to
make them flow along the baffles in the classifier. Transport
air then passes through a curtain of the circulating particles
as they sweep off the baffles edge. A secondary air stream
is introduced lower in the classifier to sweep any uncollected
fines out of the coarser material
Used for separating material from 100 microns to 15 microns
from more coarse material
o Product dedusting
o Fly ash
o Mineral’s processing
o Fertilizer
DRY CLASSIFICATION
WET CLASSIFICATION
The applications of wet classifiers were found in the treatment of raw materials
for example effecting a simple sand-slime separation resulting in two products. In
general, wet classifier types fall into two categories: gravitational and centrifugal
classifiers.
Gravitational classifiers
o can be subdivided into sedimentation and hydraulic classifiers.
Depending on the operation manner, each type can be further divided
into mechanical and non-mechanical classifiers.
Sedimentation classifier.
Spiral classifiers and rake classifiers are two types of
sedimentation classifiers and are mostly used in
separating coarse particles from a mixture. A typical
spiral classifier consists of a sloping elongated round
bottom tank and a sand-raking spiral. The raw materials
are fed to the central section of the pool and flow to the
weir while the suspended particles settle down. Four
zones can be identified in the poor, which are stationary
zone, moving zone, hindered settling and free settling
zone. The cut size depends on a number of parameters
including the height of the weir, angle of tank slope,
viscosity of the mixture, and so on. Secondary fresh
water may be supplemented to clean the coarse fraction
before discharging. Spiral classifiers produce coarse
particles in good quality while they are generally not used
in separating fine particles. The rake classifiers have
almost similar configurations with spiral classifiers. The
only difference is that the rakes move following a
rectangular direction in rake classifiers.
Hydraulic classifiers
differ from sedimentation classifiers in that particle
settling directions are in opposite to fluid movement. It is
a mechanical cone classifier consisting of a cylinder and
a conical tank. The materials are fed from top to
a slowly rotating disk. A vane is placed above the disk to
generate upward water current. The coarse particles
escape from the upward stream and go to the lower part
of the classifier where being washed by water jet. The
device has around 50%
of overflow capacity for 74 µm particles but the overflow
drops dramatically for finer particles. Therefore, it has
been used to treat low quality classifier sands.
Hydro cyclones
consist of a top cylindrical section and a lower conical
section. The raw materials were fed into the body
tangentially through the inlet on the top sidewall. The
solid-liquid mixture followed a downwards helical
pathway.
The centrifugal effects pushed coarse particles away
from the fluid stream to the wall where the coarse
particles felled and were collected below. The fine
particles remained in the fluid stream and discharged
above.
SUMMARY
REFERENCES
Yang, W. Particle separation and classification. www.researchgate.net
Ahmed, W. Separation, screening and classification. www.slideshare.net
Solid-solid separation. en.wikipedia.org
https://www.praterindustries.com/products/air-classifiers/
https://sturtevantinc.com/air-classifiers/
https://www.hosokawa-alpine.com/powder-particle-processing/machines/classifier-
mills/acm/