O-Sepa® Separator n n n
Background shows O-Sepa separator rejects.
Low Maintenance High Efficiency Simple Layout
MILL SYSTEMS
Main Features
Proven Reliability n 25 years design and operating experience n Over 425 units worldwide Cost Savings Reduced specific power consumption n Increased grinding efficiency n Low maintenance n Integral cooling capability n
Low Maintenance Wear protection targets specific abrasion mechanisms for each separator component n Circulating oil lubrication system promotes exceptional bearing life n
The O-Sepa separator is the world standard in high-efficiency separation. F.L.Smidth has supplied O-Sepa separators since 1983. There are now over 425 units installed worldwide. The O-Sepa separator’s success, based on its innovative design, continues as a result of superior performance and optimization. There are numerous features that place the O-Sepa separator at the top of industry lists for both performance and mechanical integrity.
Reduced Capital Cost Compact design n Simple Layout n Bolt together construction for low installation time
INSTALLATION The O-Sepa separator has a compact design requiring minimal space for installation. Its simple circuit layout allows the highly flexible separator to be applied in a variety of systems and to fit any new process requirement or existing system. Installation time for the O-Sepa separator is minimized by its bolted-flange design.
n
Flexibility New and Retrofit installations n Raw and Cement Grinding n High Blaine operation n Standard and Mixed products n Compatible with Semi-finish Grinding n Full Gas recirculation optional n Full size range
Material Feed Entry
n
Air & Product To Dust Collector
Dispersion Plate No Trajectories No Dead Zones No Wall Effect
Stable operation Simple system control Precise, uniform separation n Less fine returns to the mill
Centripetal Force
Drag Force
n
Better product quality High separator efficiency n Improved product particle size distribution from first and second generation separators n Increased cement quality n Reduced coarse bypass in the product n
Air Entry
Vertical Flow Adjusting Blade
Gravitational Force
Vertical Guide Vane
Balance of Forces Classification Zone
The rotor’s speed directly affects the centripetal force. The amount of airflow directly affects the drag force.
Full Vent System
FLEXIBILITY
Separator Collector
Clinker
Separator I.D. Fan
Primary Air
Secondary Air O-Sepa Separator
Gypsum
To Product Storage
Mill Discharge El evator Mill Collector Collector I.D.Fa n
Finish Mill
Alternate Arrangement: The mill vent gases can be taken through the O-Sepa separator with either system design, thus eliminating one collector and fan.
Cyclone System
Cyclone Secondary Air Clinker
Gypsum
O-Sepa Separator
Primary Air
Separator I.D. Fan
Separator Collector Collector I.D. Fan
To Product Storage Mill Discharge Elevator Mill Collector Collector I.D. Fan
Finish Mill
The O-Sepa separator is installed for cement and non-cement applications. The O-Sepa separator can be retrofit into existing ball mill circuits or installed in new mill systems. A system with dedusting cyclones on the outlet (product) stream can be beneficial for retrofits to existing systems. In this arrangement there is less exhaust gas which can be an advantage in obtaining environmental permits. This compact system, which requires a smaller bag collector, is very flexible and can require less overall space than other system designs. For new installations where a simpler system containing less equipment and fewer drives is desired a full vent arrangement is possible. In this arrangement the separator fan handles clean gas which reduces maintenance and allows for a higher efficiency fan design. Any recycled air is therefore clean and does not limit the duct arrangement. The dust loading is higher, but of a coarser size, which reduces dust collection problems. This system gives the maximum air cooling or maximum system temperature for controlling product quality. In either arrangement it is possible for all of the classifying air to come from atmosphere. Because of this feature the O-Sepa has a superior cooling capability. The ability to control recirculating material temperatures reduces the chance of ball coating and pack set problems in silos. Further, in either system arrangement it is possible to take the mill vent gases through the separator eliminating the need for a separate dust collector and fan.
The O-Sepa separator properly classifies a higher proportion of feed materials.
100
The Tromp curve is a plot of the probability of a given size of particle in the separator feed that will be returned to the mill. Thus better separation is indicated by higher probabilities for coarse material, and lower probabilities for fine material.
80
90
70
Conventional Separator (Whizzer-Type)
60
50
The Tromp curve is an effective tool when evaluating separator performance. Calculations are based on separator feed, rejects, and product samples. The top side control, which can be determined from the curve, indicates if the seal is operating correctly. Also, the amount of bypass and the extent of the fines’ tail can be determined. These parameters along with the separator inlet loading give an accurate depiction of the separator’s performance in the circuit.
40
Perfect Separator
30
20
O-Sepa Separator 10
Bypass 0 0 5
10
20
30
40 50
100
200
Particle size (microns)
OPERATION Low Cost Operation Compared to other separator designs the O-Sepa separator offers improved efficiency. Higher separation efficiency results in less fine material returning to the mill, which in turn reduces the mill power consumption at a given product fineness. System capacity is maximized through the combination of superior grinding efficiency and better product size distribution. Stable operation is easily achieved through simple system control and precise, uniform separation. The results of superior efficiency and stable operation are evident through increased cement strength and a reduced amount of coarse material present in the product. Low Maintenance Maintenance in the O-Sepa is reduced by specifically addressing the cause and mechanism of wear in each area of the
separator with the most effective wear protection materials. Ceramic tiles lining the separator inlet and exit ducts and the rotor shaft protect against jet abrasion from any dust entrained in the gas streams. The rotor vanes are coated with a spray ceramic for the same reason. The guide vanes around the rotor are made from chromium carbide bulk-welded plate to resist the impact of oversized material rejected from the rotor. The feed chutes are made from abrasion-resistant plate. The air seal and material distribution plate are made from impact and abrasion resistant NiHard castings. The use of dedicated wear materials reduces the maintenance requirements of the separator and saves overall operating costs. To maximize the protection of the separator bearings the O-Sepa separator incorporates a standard circulating lubrication system. The use of circulating lubrication system ensures a long bearing life.
Fraction of separator feed entering reject stream at a given particle size (%).
Typical Separator Efficiency Curve (Tromp Curve)
Wear Protection Wear Protection Component s
Motor
Ceramic tile on inlet ducts, outlet ducts, and shaft assembly
Reducer Reducer Wear Protection Support Components
Spray ceramic coating on rotor
Low Speed Coupling
Ceramic tile on inlet ducts, outlet ducts, and shaft assembly Exit ceramic Spray coating Duct on rotor Assembly Chromium carbide bulk-welded plate for guide vanes
Drive Suppor t Shaft Assembly
Material Feed Chute
NiHard castings fo Dispersion Plate
Buffer Plate Air Seal
Primary Air Inlet
Secondar y Air Inlet Rotor Assembly
Vor tical Flow Adjusting Blade
GuideVane Partition Plate
Hopper
Tipping Valve Rejects Outlet
Chromium carbide bulk-welded plate for guide vanes NiHard castings for air seal, distribution plate, and buffer ring Abrasion-resistant plate in feed chutes Autogenous hopper lining
How to Size an O-Sepa Separator n Predict circulation factor. Circulation factor =
irculating Load (%) = _____________ feed [1 + C__________________ ] separator 100% production
n Determine expected system production and feed rate to separator. ( _____ mtph production x _____ Circulation factor = _____ mtph feed)
n Pick the separator size (from the chart below) that has rated feed and production which are greater than those expected. If separator will produce several types of cements, use maximum feed and production.
C
CL
4.5
350%
4.0
300%
3.5
250%
3.0
200%
2.5
150%
2.0
100% 3000
3400
3800
4200
4600
5000
Blaine cm2/gm
Sizing Chart Size
N-250 N-350 N-500 N-750 N-1000 N-1500 N-2000 N-2500 N-3000 N-3500 N-4000 N-4500 N-5000 N-5500 N-6000 N-7000
A (mm)
B (mm)
C (mm)
D E (mm) (mm)
1522 *2550 1757 1350 2109 1470 2517 1650 2714 1890 3294 2220 3804 2500 4194 2590 4689 2610 5154 2780 5459 2880 5750 2890 6074 2900 6300 3000 6613 3010 6991 3020
— 1190 1396 1676 1693 2281 2541 2894 3087 3408 3363 3744 3458 3454 3453 4736
673 798 956 1107 1387 1434 1643 1791 1933 2077 2515 2331 2806 3330 3607 3237
1604 1510 1993 2310 2505 2931 2878 3275 3616 3861 4118 4171 4596 4900 5100 5500
Typical Drive Type
Rotor Diameter (mm)
Rotor Height (mm)
Speed (rpm)
V-belt Vertical Vertical Vertical Vertical Vertical Vertical Vertical Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal
940 1040 1220 1460 1660 2000 2270 2530 2760 2970 3150 3330 3480 3640 3850 4159
550 518 580 730 850 1060 1240 1390 1530 1660 1780 1900 2000 2100 2200 2371
250-550 170-370 190-420 170-360 150-320 120-260 105-230 95-205 85-190 80-175 75-165 70-155 65-150 60-145 54-135 50-125
Motor Air (kW) (m3/min)
Feed (mtph)
25 35 55 75 90 110 150 185 225 260 300 335 375 410 450 525
37.5 52.5 75 112.5 150 225 300 375 450 525 600 675 750 825 900 1050
250 350 500 750 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 7000
Production (mtph) 13 18 26 38 51 77 102 128 153 179 204 230 255 281 306 357
DENMARK F.L.Smidth A/S Vigerslev Allé 77 DK-2500 Valby Copenhagen Denmark Tel: +45 36 18 10 00 Fax: +45 36 30 18 20 E-mail:
[email protected]
USA F.L.Smidth Inc. 2040 Avenue C Bethlehem, PA 18017-2188 United States Tel: +1 - 610-264-6011 Tel: +1 - 800-523-9482 Fax: +1 - 610-264-6170 E-mail:
[email protected]
INDIA F.L.Smidth Ltd. Capital Towers 180, Kodambakkam High Road Nungambakkam Chennai 600 034 India Tel: +91 - 44-52191234 Fax: +91 - 44-28279393 E-mail:
[email protected]
04-2004-OSEPA
* with V-belt drive, value is B+C
