sepax seperator

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SEPAX Separator ■ High efficiency ■ Low initial and maintenance costs ■ Highly adaptable and versatile

01-02-251 Gramstrup Design ApS

■ Feed system extracts nibs and reduces wear

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MILL SYSTEMS

Main features

Low initial cost • Self-supporting shell structure • Standard range drive parts • One support for the complete separator • One feed point in low position • Most of the ducting integrated Low operating costs • High-efficiency separation • Highly effective nibs extraction minimises clogging of mill grates, thus enabling longlasting full mill capacity Low maintenance costs • Wear protection selected for cost efficiency and based on experience • Automatic grease lubrication with enclosed refill system • Practically eliminated nibs recirculation reduces maintenance work and downtime caused by clogged mill grates. • Designed to enable easy access for inspection and replacement of components Highly flexible and versatile. Adaptable to a wide range of grinding and drying systems such as • All cement grinding ball mill systems • Fully or semi air-swept raw grinding ball mills • Flash driers

F.L.Smidth is the leading supplier of separators to the world’s cement industry, providing various types of high-efficiency separators for a wide range of applications. Decades of know-how in high-efficiency separation enables F.L.Smidth to supply the most suitable separator for almost any application. The SEPAX concept – introduced with the original SEPAX separator and later adopted for separators of derived design - has proved highly successful in the cement industry.

Low initial costs The simple and space-saving design of the SEPAX makes it an economical investment. The separator is fitted within a self-supporting shell structure, and the entire separator unit with cyclones is supported by one ringshaped support only. Reducer and motor are placed in line with the bearing housing, forming a compact and rigid drive-line unit. Finally, the SEPAX has one feed point placed at a low level, minimising the height of the separator feed elevator and simplifying the layout.

Parallel flow through rotor for maximum equality, i.e.: sharpest possible separation Guide vane with wear plate Wear plate: chromium carbide

v - particle, relative to rotor

v - particle, relative to stator v - rotor SEPAX rotor and guide vane detail

7 4 6

6

Rotor top principle 3

5 2

2

1

The SEPAX top seal principle: The air flow across the rotor seal area (1) is limited by narrow gaps (2) Reduced air flow across the rotor top, fitted with deflector wings (3), practically eliminates passage of coarse material to the fines outlet (4) Coarse material that is inclined to pass in a ballistic curve (5) across the rotor is intercepted by the chromium carbide protected seal ring (6)

6

Low initial cost • Self-supporting shell structure • Standard range drive parts • One support for the complete separator • One feed point in low position • Most of the ducting integrated Low operating costs • High-efficiency separation • Highly effective nibs extraction minimises clogging of mill grates, thus enabling longlasting full mill capacity Low maintenance costs • Wear protection selected for cost efficiency and based on experience • Automatic grease lubrication with enclosed refill system • Practically eliminated nibs recirculation reduces maintenance work and downtime caused by clogged mill grates. • Designed to enable easy access for inspection and replacement of components Highly flexible and versatile. Adaptable to a wide range of grinding and drying systems such as • All cement grinding ball mill systems • Fully or semi air-swept raw grinding ball mills • Flash driers

F.L.Smidth is the leading supplier of separators to the world’s cement industry, providing various types of high-efficiency separators for a wide range of applications. Decades of know-how in high-efficiency separation enables F.L.Smidth to supply the most suitable separator for almost any application. The SEPAX concept – introduced with the original SEPAX separator and later adopted for separators of derived design - has proved highly successful in the cement industry.

Low initial costs

Flexible and versatile

The simple and space-saving design of the SEPAX makes it an economical investment. The separator is fitted within a self-supporting shell structure, and the entire separator unit with cyclones is supported by one ringshaped support only. Reducer and motor are placed in line with the bearing housing, forming a compact and rigid drive-line unit. Finally, the SEPAX has one feed point placed at a low level, minimising the height of the separator feed elevator and simplifying the layout.

The SEPAX is designed to be equipped with drives ranging from low power drives for raw grinding to powerful drives for the finest grinding while still utilising the full design air flow. This ensures maximum efficiency regardless of the end product quality specified. The SEPAX can be equipped with separator-supported cyclones or stand-alone cyclones for the collection of fines. The feed concept is based on the material being suspended in the vertical air flow through the riser duct. This makes the SEPAX highly adaptable to various raw grinding applications. Consequently, the separator can be integrated into the mill venting system, in the case of fully or semi air-swept mills, or installed on top of a flash dryer that forms the riser duct leading up to the SEPAX.

Finished product

Reject flow New feed

Nibs disposal Mill product

SEPAX system with bag filter for collection of fines: This system ensures maximum product cooling.

Parallel flow through rotor for maximum equality, i.e.: sharpest possible separation Guide vane with wear plate Finished product

Wear plate: chromium carbide

v - particle, relative to rotor

Reject flow

v - particle, relative to stator v - rotor 7 Mill product

4

SEPAX system for raw grinding installation suitably integrated into the mill vent line

6

6

Rotor top principle

The SEPAX is very efficient in operation and cuts specific energy consumption to a minimum, while maintaining maximum output. A highly effective system for removal of worn grinding media from the mill discharge material means less clogging of diaphragms. This optimises mill performance and enables long-term continuous operation.

3

5 2

2

Low maintenance costs

1

The SEPAX top seal principle: The air flow across rotor (1) is limited by narrow gaps (2) Reduced air flow across the rotor top, fitted with deflector wings (3), practically eliminates passage of coarse material to the fines outlet (4) Coarse material that is inclined to pass in a ballistic curve (5) across the rotor is intercepted by the chromium carbide protected seal ring (6)

1 Air outlet 2 Flexible coupling

7

3 Motor 4 Reducer 5 Rotor 6 Reject collecting guide vanes 7 Planetary separator supported cyclone 8 Ring shaped support

8 9

9 Fine material outlet

11

10 Reject outlet cone valve 11 Feed point

10

12 Pneumatic unloading valve 13 Nibs disposal container 3

2

1

Low operating costs

New feed

SEPAX rotor and guide vane detail

5

Finished product Reject flow New feed

Nibs disposal Mill product

SEPAX system with cyclones for collection of fines: Lowest initial and operating costs. Recuperation of heat enhances drying of wet slag, puzzolana or other additives.

The SEPAX is designed to be easily serviceable. Worn and broken grinding media are not recycled, which helps to save maintenance work on the mill grate plates. The removal of nibs from the separator feed reduces the wear on critical separator parts. Easily accessible and serviceable wear protection is fitted where appropriate and the bearing unit can easily be replaced.

12

13

Tromp curve

100%

Percentage of feed rejected

MILL SYSTEMS

Main features

90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 1

10

d25 d75 x50

Particle size, micron

100

The tromp curve indicating the percentage of feed rejected in relation to particle size has the following characteristics: The cut size, x50, expresses the exact particle size at which the quantities of fine and coarse material are equal. The by-pass value, , expresses the proportion of separator feed that passes through the separator unprocessed and leaves it as coarse material. The sharpness factor, = d25/d75, expresses the inclination of the Tromp curve and thus the sharpness of the separation.

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Side 3

6 5

1 Air outlet 2 Flexible coupling

7

3 Motor 4 Reducer 5 Rotor 6 Reject collecting guide vanes 7 Planetary separator supported cyclone 8 Ring shaped support

8 9

9 Fine material outlet

11

10 Reject outlet cone valve 11 Feed point

10

12 Pneumatic unloading valve 13 Nibs disposal container 3 4 2

1

12

13

Tromp curve

Percentage of feed rejected

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 1

10

d25 d75 x50

Particle size, micron

100

The tromp curve indicating the percentage of feed rejected in relation to particle size has the following characteristics: The cut size, x50, expresses the exact particle size at which the quantities of fine and coarse material are equal. The by-pass value, , expresses the proportion of separator feed that passes through the separator unprocessed and leaves it as coarse material. The sharpness factor, = d25/d75, expresses the inclination of the Tromp curve and thus the sharpness of the separation.

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Side 4

Wear Protection

Densit Wearcast 2000 The material is a 30 mm thick cement bound composition containing 55% hard (9 Mohs) grains of corundum (Al2O3). Densit Wearcast is easy to install and repair. It has been tested to outlast basalt by a factor of 1.3 when exposed to sandblasting at various inclinations.

Hardox 400 This is a world-known, abrasion resistant, weldable steel plate, which is throughhardened to more than 360 HB and is recognised for its superior abrasion resistance properties.

Chromium compound wear plate This material is a mild steel plate with a thickness of 4 to 8 mm on to which a 4 - 5 mm layer of hardfacing is welded. The hardfacing consists of primary chromium carbides in a eutectic matrix with eutectic chromium carbides. The hardness of the matrix reaches 600-750 HV, the grains 1400 HV. The temperature limit is 400 deg C.

High carbon steel This is a low cost and highly versatile material which is used in places where moderate wear occurs.

Mild Steel

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Side 5

A2

C

A1

C

E

B

B

D

Dimensions and characteristics Size

Air flow m3/s

A1 mm

A2 mm

B mm

C mm

D mm

E mm

190

7.3

3108

N.A.

5704

N.A.

1900

N.A.

212 236

10.0 13.5

3500 3933

N.A. N.A.

6467 7296

N.A. N.A.

2120 2360

N.A. N.A.

250

15.7

4189

3754

7772

3040

2500

840

265 280

18.3 21.1

4460 4736

4004 4262

8285 8792

3258 3492

2650 2800

900 965

300 315 335

25.1 28.3 32.8

5102 5376 5746

4608 4862 5213

9468 9975 10647

3800 4036 4344

3000 3150 3350

1050 1115 1200

355

37.7

6115

5558

11319

4668

3550

1290

375 400

42.9 49.9

6485 6947

5907 6342

11989 12822

4976 5374

3750 4000

1375 1485

425

57.4

7412

6781

13656

5772

4250

1595

450 475

65.4 73.9

7876 8341

7217 7652

14488 15321

6154 6552

4500 4750

1700 1810

500

83.0

8807

8088

16152

6932

5000

1915

530 560

94.5 106.8

9365 9923

8611 9130

17148 18145

7402 7872

5300 5600

2045 2175

www.flsmidth.com Up-to-date addresses of worldwide subsidiaries and sales offices are available from our website

USA

INDIA

DENMARK

F.L.Smidth Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Tel: +1 610-264-6011 Tel: +1 800-523-9482 Fax: +1 610-264-6170 E-mail: [email protected]

Fuller India Limited Capital Towers 180, Kodambakkam High Road Nungambakkam Chennai 600 034 Tel: +91 44-827-6030/8228623 Fax: +91 44-827-9393 E-mail: [email protected]

F.L.Smidth A/S Vigerslev Allé 77 DK-2500 Valby Copenhagen Tel: +45 36 18 10 00 Fax: +45 36 30 18 20 E-mail: [email protected]

01-02-251 Gramstrup Design ApS

Data in this brochure is intended for preliminary project planning only. Manufacturer reserves the right to modify equipment details and/or specifications without notice.