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Culture Documents
Kurt Leschonski
Technical University Clausthal*
Abstract
It is the aim of this paper to show that it is possible in principle to obtain submicron cut sizes
with a counterflow centrifugal classifier, provided that a forced vortex is used in the classification
chamber and the circumferential velocities are greater than 100 m/s. These findings can be
generalized and are not limited to the geometrical dimensions of the classifier used in the
experiments. With a new impeller or deflector wheel classifier, cut sizes as small as 0.3 pm
have been obtained with feed mass flow rates of 5 kg/h and higher.
1 Introduction
the flow. If the removal of the coarse particles takes
The production of particle size distributions with top place against the flow, the classifier uses the counter-
sizes of 1 11m or even less is one of the most difficult flow principle. If the coarse particles travel perpendi-
tasks in the mechanical processing of powders. With cular to the flow, the classifier is called a cross-flow
comminution and classification in this size range, the classifier [2].
separation of the particles from the flow and even
the measurement of the size distributions produced
demand principles and designs which have to be 2 The Counterflow Principle
operated near or at their limits [1]. A gravity counterflow classifier [3] consists of a
It appears that with minerals a natural size limit of vertical tube of, for example, cylindrical cross-section.
approximately one micrometer seems to be stipu- The air rises in the tube. On each individual flow
lated by the physical laws which govern the above line, a particle is taken to the top of the tube that
processes. Problems arising in the classification of is removed with the flow if its stationary settling rate,
fine particles are mainly due to the fact that gravity Wg, is smaller than the air velocity, v 3 . It settles in
forces become negligible and stochastic particle move- the rising flow if its settling rate is greater. The
ment caused by diffusion or Brownian motion and so-called cut size is defined by:
turbulence of the flow may become predominant.
Qpgx2
Fine particles follow the drag forces exerted by the Va = Wgc = c
(1)
flow more readily and it becomes more and more 18ry
difficult to move the particles in directions which The cut size, at least theoretically, does not leave
deviate from the direction of the flow. The choice the classification zone, because its exit velocity equals
of a size limit of approximately one micrometer is zero. In actual operation, cut size particles are distri-
not arbitrary, although depending on the material, buted evenly to the fine and the coarse fraction, and
the size limit varies. The systematic movement of are therefore sometimes called the equiprobable par-
a particle in a flow, described by its trajectory, is ticles. Due to their small settling rates, gravity counter-
governed by its stationary settling rate, Wg, in the flow systems are unsuitable for small cut sizes. These
gravity field. The most important forces controlling demand a counterflow centrifugal system, the basic
the systematic particle movement are, for example, principle of which is shown in Figure 1 [4]. It con-
drag force, gravity force, dynamic lift, inertia and sists of a flat cylindrical classification zone of height
electrical forces. The different classifier principles H. Air is introduced at the periphery under a certain
are defined by the main forces used and the principal angle, thus inducing a free vortex sink flow passing
movement of the coarse particles with respect to through the classification zone on a spiral path (flow
line). The feed particles enter the classification zone
* Institut fur :'vlechanische Verfahrenstechnik, Leibnizstr, 19
D- 38678 Clausthal-Zellerfeld. Germany
near the outer periphery. Fine particles follow the
t Received: 4 July, 1996 flow towards the centre while coarse particles remain
kT
(3)
t
with respect to their numerical constants:
Wac = Vr = Wgc -
g
a
=
rw 2
Wgc - -
g
=
of the air, Vr, equals the settling rate of the particles Introducing Eqn. 4 into Eqn. 5 yields Eqn. 6, where
in the centrifugal field, Wac· The latter exceeds the
stationary gravity settling rate by the acceleration
ratio, a/g. If the particle travels on a radius of r =
0.1 m with a circumferential velocity of v10 = 100 m/s,
the ratio of centrifugal acceleration, a, to gravity
4
Cu - 1 + : ;T 1.257 + 0.4exp t
T has to be introduced inK, p in Pa and x in ILm:
! 0.024229 i)]
(6)
constant, g, becomes ten thousand, thus increasing It is convenient to plot Cu as a function of the
the stationary settling rate considerably. product xp in JLmPa, with the temperature, T, as the
It is a well-known fact that counterflow centrifugal parameter. Figure 2 shows that the Cunningham
classifiers operated under the above or similar con- correction starts to rise as soon as the product xp
ditions have a lower cut size limit of approximately becomes smaller than xp = 105 JLmPa, or if the
1 ILm to 2 !Lm for mineral particles. The production particle size drops to 1 JLm at 1 bar air pressure.
of even finer cut sizes demands: If the product of particle size and pressure drops
higher circumferential velocities, v10 , of the air and by a factor of 100, the Cunnningham correction rises
of the particles, respectively, than those used up from Cu = 1.167 at xp = 105 JLmPa to Cu = 22.62 at
until today, xp = 103 JLmPa.
a reduction of the volume flow rate of air, or the Y. Yamada, S. Doi and K. Iinoya [7] have described
size of the classifier, experiments performed with a counterflow centrifugal
operating the classifier at reduced air pressures air classifier at a reduced pressure. The classifier
using the so-called slip between the particles and was installed together with its ancillary equipment,
the gas molecules. for example, its feeder, etc. in a special tank and
~
4 1
gc -
20oc
[ern Pal
Cu 1.167
10
2.905 22.62
10 ·I
into this equation one obtains:
~
x"~· ~ =V:; ,""v;r 1[; ~
5
2.5
~t'--- (8)
zrn· ~
1----- r----- One realizes from Eqn. 8 that for a given flow rate
of air and a given classifier size, the product of the cut
x.p (I'm P a l - size and circumferential speed, XcV'I', remains con-
Fig. 2 Cunningham-correction : Cu = f (xp) stant. With limestone particles of Qp = 2710 kgfm3
and air of 20°C, the product XcV'I' equals:
4.0
XcV~ = 3.4673 • 10·4 .JV;i (9)
3,0
I
Figure 4 shows the dependence represented by
<==
v 50m/s
O,Sm/s Eqn. 9. The lower curve shows the range of cut sizes
2.0
v-- ~ obtainable if the product vrr = 0.1 m2/s, the second
if Vrr = 0.01 m2/s.
( L
v; == O,Sm/s
\' lOOmis
Cut sizes below 1 11m demand high circumferential
velocities of the air and small products of vrr, i.e.
small classifiers and low radial velocities. With vrr =
0.01 m2 /s, a cut size of 1 ~-tm demands a circum-
1.0
0.8
vo - - ...-
~
~ ~ - - (
ferential air velocity of 110 m/s. Halving the cut size
to 0.5 ~-tm doubles the circumferential air velocity.
Therefore, depending on the conditions chosen,
0,6
!/
f:Y
/
...-
extremely high circumferential velocities may be
necessary to obtain small cut sizes.
0.5 5
0.4
(/ I--
"
- Legenhausen I'
(~ calculated (9]
""'
0.3
0 Yamada et al
measured [7]
I--
""' ~
0.2
0 0,2 0.4 0.6 0.8 "'-..
r-.
0. 1
p [10 5 Pal ----+- 10 100 250
v, [m/s]
Fig. 3 Cut size = f (pressure)
V = 2 JTrHvr (10)
~
I \ ~
I \
v \' v
._; = 0,67 " = 1 ---"-- = 1,34
~·
s
vs vs
If, on the other hand, as observed in the inner periphery and a bladeless inner zone, this condition
bladeless zone of the rotor, the flow in circumferential cannot be met, as can be seen from Figure 7. The
direction follows a free vortex flow, one obtains Eqn. cut size rises, as intended, within the zone with blades
15, because of: but drops again in the bladeless zone. Particles which
passed the outer periphery of the rotor may therefore
v,r = constant (free vortex) (14)
find a new equilibrium radius at smaller radii. These
particles cannot, at least theoretically, be removed
r (15) 10,---------------------,-------~
8
In a free vortex spiral flow, the cut size rises r
linearly with radius, r.
One therefore obtains the situation as shown in 6
3 Description of the Clausthal High-Speed Fig. 8 Sectional view of the Clausthal Impeller Wheel Classifier
Classifier
Based on the flow field measurements and earlier
classification experiments, a high speed impeller
wheel classifier was developed by the author and ].
Galk and investigated in]. Galk's thesis [12]. Figures
8 and 9 show sectional views of the classifier.
The high-speed rotor (Figure 8) consists of two
circular discs, made from a special aluminium alloy.
To lower the eigenstresses caused by high speeds of
rotation, carbon-fibre-reinforced plastic rings are
mounted at the outer periphery of the discs. The
maximum speed of the rotor is 250 m/s [12].
The radial rotor blades are mounted in radial
grooves cut into the plane surfaces of the discs.
As shown in the cross-sectional view of Figure 9,
only 16 long blades extend to the centre, i.e. the
outer radius of the outlet. An additional 80 short
blades, five of which are arranged between two long Fig. 9 Top view of the Clausthal Impeller Wheel Classifier
blades, guarantee the desired flow field, described
in the centre of Figure 6. m the coarse fraction be small or even negligible
The classifier air is fed into the classification zone and a high fine particle yield be obtained. Secondly,
at its outer periphery through three small rectangular as the sharpness of cut and the cut size of an air
channels, arranged tangentially. At least one of these classifier depend on the solids loading of the air,
channels is also used for the introduction of the feed the mass flow rate of the feed material should vary
particles with a special feeding and dispersion unit. as little as possible [14].
Fine particles leave the central outlet together with For the dispersion of the feed material in the air
the air. The coarse ones are collected at the inner used for the classification process and the accelera-
periphery of the housing (Figure 8) and are removed tion of both particles and air up to the circumferential
from there through tangential outlets (Figure 9). speed of the rotor, a combination of a newly deve-
loped brush feeder and an injector is used [14,15].
The unit is shown in Figure 10. It consists of the
4 The Feeding and Dispersion Unit
feeding unit on the right and the dispersion unit on
In order to achieve cut sizes in air classifiers in the left-hand side. Air is passing through both units
the submicron range, a number of further prerequisites from right to left. The rotating brush (1) receives
have to be fulfilled. Firstly, the feed material has the feed material from a small hopper (2). The feed
to be dispersed in an air flow with the largest material enters the voids between the bristles, is
agglomerates presented to the classification zone transported to the feeding point (3) and is then
being smaller than the desired cut size. Only then released into the incoming air travelling past the
will the amount of particles smaller than the cut size feeding point. The brush acts similarly to a rotary
vane feeder, controlling the throughput of particles velocity. The grade efficiency curves were obtained
by means of its speed of rotation, while producing at a feed mass flow rate of approximately 5 kg/h.
a constant mass flow rate with little fluctuation. The These experiments show that it is possible to obtain
brush also acts, depending on its speed of rotation, submicron cut sizes with a counterflow centrifugal
as a pre-dispersing unit.
The pre-dispersed feed material then enters the
dispersing and accelerating zone of a special injector. 0.9
1
I
I} I~ r?
' i
1/( 1/) I
The dispersion of agglomerates in the turbulent 0.8
0.4
v ~v
dispersion unit of Figure 8 is suitable for dispersing
0.3 ~ l;: vq>,O
o 200 m/s
feed materials with particles smaller than 1 1-lm. B,_, A 175 m/s
0.2 o 150 m/s
D 100 m/s
0.1 v 10 =1 m/s
5 Experimental Data as Obtained with the I
I ~ =0.05
0
Classifier 0.1 10
X[IJm]
The development and the theoretical and experi- Fig. 11 Grade efficiency curYes. Yariation of circumferential rotor
mental investigation of the Clausthal impeller or Yelocity
0.6
I
I I/ I I : !
The feed material was limestone with a median
particle size of xso.3 = 1.2 {till and a maximum 0.5
v J
particle size of approximately 4.2 {till. The grade 0.4 1/ f I
vq>O= 150m/s
efficiency curves given in Figure 11 were obtained "/ lf vro = 1 m/s
with a radial velocity of the air of vr0 = 1 m/s and
0.3
d /
v
0.2 ~ [-]: 0 0.15
circumferential rotor velocity of v¥" 0 = 100, 150, 0,1-' A 0.09
0.1 0 0.03
175 and 200 m/s, respectively, at the outer rotor D 0.01
0
periphery. The cut size that is the median of the 0.1 10