Otto-von-Guericke-University Magdeburg

Department of Process Engineering

Chair of Mechanical Process Engineering

Practical course Air Classification

Content:

1. Introduction

2. Basics of air classification

3. Task formulation

4. Performing of the experiment

5. Evaluation of the experiment and discussion of the result

6. Notes for preparation

7. References

1
1. Introduction

The objective of a mechanical separation process of particulate materials is the classification

into two or more size classes. In the following figure 1 a scheme of classification process is
presented.

Feed material
mfe, q3(d)

Fine fraction
mfi, q3,fi(d) classifier Coarse fraction
mc, q3,co(d)

Fig. 1: Flow sheet of a classification device

The classification process is divided into three particulate steps:

- dispersion of the feed material in the gaseous phase and forward to the separation site
- separation at least into two fractions and
- separated deposition of the fine and coarse products from the gaseous phase

The eldest applications of air classification are known from cleaning procedures of corns.
Nowadays high-grade efficiency separators are used for separation of particulate materials
with very small particle sizes (approx. 1 m).
Air classifiers are distinguished according to the setup and their kind of phase flow and force
impact.
The most efficient process of separation is carried out by using centrifugal action principle.
Depending on number of revolutions larger particles settle more easily and hence are sepa-
rated.

2
2. Basics of air classification

A particulate material with a particle size distribution (dmin - dmax) will be separated by an
ideal classifier into a fine fraction (dmin dt) and a coarse fraction (dt dmax). The diameter dt
is called cut-diameter. This separation process is comparable with sieving whereby the dt-
diameter corresponds to sieve aperture.
Real classification is imperfect, as some particles with d0 > dt are found in the fine fraction
and some particles du < dt will be found in the coarse fraction. The cut size, by definition, is
the particle size which is found with the same amount in the fine and the coarse fraction. The
overlap range (du to d0) is characterized by the grade efficiency curve (Fig. 2). The efficiency
grade specifies that part of particles with the size class di in the feed material which is sepa-
rated into the coarse fraction.

Ti
1,0
ideal classifier

0,5 real classifier

du dt do d

Fig. 2: Grade efficiency curve of an ideal and a real classifier

The slope of the efficiency curve shows the classification effect. Thus a steep incline of the
curve means a sharp classification whereas a flat curve shape shows an inefficient classifica-
tion.

The cut size diameter represents a theoretical diameter which remains on the separation circle
on which the resistance force FR and the centrifugal force FC are in equilibrium (Fig: 3).
These forces affect the separation of the particulate material.

FR

FC

Fig.3: Separation circle for the cut size diameter

3
For an approximate dimensioning of a centrifugal wheel classifier the cut size diameter is the
most important parameter. A turbulence model for turbulent cross flow classification can be
used to determine the cut size diameter (Equ.1).

V
VF ln F
V
dC = k S G
( s g ) n ra l R (ra ri )
2
(1)

- dynamic viscosity of air [Pa*s]

S particle density [kg/m]
g - gas density [kg/m
VF fine particle flow [m/h]
VG coarse particle flow [m/h]
n - number of revolutions [m/h]

The apparatus related parameter kS has to be determined prior to experiments. The ratio of
volume flows (VF/VG) (Equ. 3) can be calculated by using the mean particle content s,g (Equ.
2) of the classifier input.

ms
s ,g =
(2)
mg

VF s
(3)
VG g R m ,g s ,g

With the assumption that the separation and the transport of fine particles is determined by air
rate, VG VF follows. Hence from Equ.1 following correlation exists:
- cut size diameter is reciprocal proportional to the wheel revolution,
- cut size diameter depends on air rate as well as wheel revolution in a direct
way,
- small cut size diameter needs high rpm as well as small air rates.

4
3. Task Formulation

Using the particulate system of limestone a separation procedure has to be done with the cen-
trifugal wheel separator HTS 63 (Firm MICROTEC) Fig. 4 (apparatus flow sheet).

material input

speed adjustment

HS
separater wheel

fine material dust filter

feed device

air separater

additional air

main air

coarse material

coarse material- fine material-

container container

Fig. 4: Flow sheet of the Air classifier

4. Performing of the experiment

Following steps for carrying out the task have to be done in sequence:
- putting the classifier into operation (Parameters for the wheel separator adjustment will be
determined by the adviser)
- feed input (measuring of input dosing time)
- determination of the amount of fine and coarse materials
- determination of the particle size distributions of fine and coarse materials.

5
5. Evaluation of the experiment and discussion of the results

By using the particle size distributions (fine and coarse materials) and mass balances
the grade efficiency curve has to be calculated for the separation process.
Taking the above mentioned model the cut size diameter has to be determined.
Compare the calculated cut size diameter with the experimental determined diameter and dis-
cuss the results.
The calculation of the grade efficiency curve can be performed by using following algorithm:

- evaluation of the mass balances

mfe = mfi + mc

- calculation the mass recovery

m
R rec,c = c
m fe

- measurement of the distribution function of fine- and coarse-product (measurement de-

vice: Mastersizer 2000)

exemplary coarse-produkt:
Size (m) Vol Under % Size (m) Vol Under % Size (m) Vol Under % Size (m) Vol Under % Size (m) Vol Under % Size (m) Vol Under %
0.020 0.00 0.142 0.00 1.002 0.00 7.096 1.38 50.238 72.58 355.656 99.42
0.022 0.00 0.159 0.00 1.125 0.00 7.962 2.71 56.368 75.14 399.052 99.74
0.025 0.00 0.178 0.00 1.262 0.00 8.934 4.65 63.246 77.41 447.744 99.90
0.028 0.00 0.200 0.00 1.416 0.00 10.024 7.25 70.963 79.49 502.377 99.99
0.032 0.00 0.224 0.00 1.589 0.00 11.247 10.56 79.621 81.46 563.677 100.00
0.036 0.00 0.252 0.00 1.783 0.00 12.619 14.57 89.337 83.36 632.456 100.00
0.040 0.00 0.283 0.00 2.000 0.00 14.159 19.22 100.237 85.25 709.627 100.00
0.045 0.00 0.317 0.00 2.244 0.00 15.887 24.42 112.468 87.11 796.214 100.00
0.050 0.00 0.356 0.00 2.518 0.00 17.825 30.01 126.191 88.94 893.367 100.00
0.056 0.00 0.399 0.00 2.825 0.00 20.000 35.83 141.589 90.70 1002.374 100.00
0.063 0.00 0.448 0.00 3.170 0.00 22.440 41.70 158.866 92.37 1124.683 100.00
0.071 0.00 0.502 0.00 3.557 0.00 25.179 47.42 178.250 93.90 1261.915 100.00
0.080 0.00 0.564 0.00 3.991 0.00 28.251 52.84 200.000 95.26 1415.892 100.00
0.089 0.00 0.632 0.00 4.477 0.00 31.698 57.83 224.404 96.45 1588.656 100.00
0.100 0.00 0.710 0.00 5.024 0.02 35.566 62.30 251.785 97.46 1782.502 100.00
0.112 0.00 0.796 0.00 5.637 0.11 39.905 66.23 282.508 98.28 2000.000 100.00
0.126 0.00 0.893 0.00 6.325 0.55 44.774 69.64 316.979 98.93

exemplary fine-produkt:
Size (m) Vol Under % Size (m) Vol Under % Size (m) Vol Under % Size (m) Vol Under % Size (m) Vol Under % Size (m) Vol Under %
0.020 0.00 0.142 0.00 1.002 0.00 7.096 48.08 50.238 100.00 355.656 100.00
0.022 0.00 0.159 0.00 1.125 0.00 7.962 57.90 56.368 100.00 399.052 100.00
0.025 0.00 0.178 0.00 1.262 0.00 8.934 67.40 63.246 100.00 447.744 100.00
0.028 0.00 0.200 0.00 1.416 0.00 10.024 76.09 70.963 100.00 502.377 100.00
0.032 0.00 0.224 0.00 1.589 0.00 11.247 83.56 79.621 100.00 563.677 100.00
0.036 0.00 0.252 0.00 1.783 0.00 12.619 89.58 89.337 100.00 632.456 100.00
0.040 0.00 0.283 0.00 2.000 0.02 14.159 94.06 100.237 100.00 709.627 100.00
0.045 0.00 0.317 0.00 2.244 0.10 15.887 97.11 112.468 100.00 796.214 100.00
0.050 0.00 0.356 0.00 2.518 0.50 17.825 98.96 126.191 100.00 893.367 100.00
0.056 0.00 0.399 0.00 2.825 1.40 20.000 99.86 141.589 100.00 1002.374 100.00
0.063 0.00 0.448 0.00 3.170 3.05 22.440 100.00 158.866 100.00 1124.683 100.00
0.071 0.00 0.502 0.00 3.557 5.72 25.179 100.00 178.250 100.00 1261.915 100.00
0.080 0.00 0.564 0.00 3.991 9.63 28.251 100.00 200.000 100.00 1415.892 100.00
0.089 0.00 0.632 0.00 4.477 14.90 31.698 100.00 224.404 100.00 1588.656 100.00
0.100 0.00 0.710 0.00 5.024 21.55 35.566 100.00 251.785 100.00 1782.502 100.00
0.112 0.00 0.796 0.00 5.637 29.48 39.905 100.00 282.508 100.00 2000.000 100.00
0.126 0.00 0.893 0.00 6.325 38.45 44.774 100.00 316.979 100.00

6
The calculation of the distribution of the feed product is exemplary pictured.

Such as particle class: 3.170 m to 3.557 m Q = 5.72 % - 3.02 % = 2.7 %

Mid class diameter: dm,k+1,k= (3.170+3.557)/2=3.36 m

Mass balance: m fe Q fe , k +1,k = m fi Q fi , k +1,k + m c Q c ,k +1, k (k-particle class)

Concerning definition of the grade efficiency function the curve can be calculated step by step
for each particle class.

m c,k m c Q c ,k +1,k Q c ,k +1,k

Tk (d k ) = = = R rec,c
m fe ,k m fe Q fe ,k +1,k Q fe , k +1,k

Note: the result of the function Tk(d)=f(dm,k+1,k), has to be plotted over the mid class diame-
ter

Evaluation of the following experimental parameters: dc (cut size diameter) and

(quality of separation)
from the grade efficiency curve.

6. Notes for preparation

The lecture in Mechanical Process Engineering (Introduction into Particle Technology) and
this Practical Manual are prerequisite for performing the practical course.

7. References

[1] Schubert, H. u.a.: Lehrwerk Mechanische Verfahrenstechnik, 3. Auflage, Deutscher

Verlag fr Grundstoffindustrie, Leipzig 1990, S. 177 - 182
[2] Schubert, H.: Aufbereitung fester mineralischer Rohstoffe, Bd. I, 4. Auflage, VEB Deut-
scher Verlag fr Grundstoffindustrie, Leipzig 1989, S. 293 - 303
[3] Tomas, J. : Vorlesung (Einfhrung in die ) MVT, IVT, 25.05.98
[4] Molerus, O.; Hoffmann, H.: Darstellung von Windsichtertrennkurven durch ein sto-
chastisches Modell, Sonderdruck aus der Zeitschrift "CIT", 41,(1969),5+6 S. 340-344,
Verlag Chemie, GmbH, Weinheim Bergstr.