Separation and classification processes

The second group of papers deals with particle separation and classification. These paper can be
further split into three subgroups, liquid-solid separation, gas-solid separation and particle
classification.

3.1 Liquid -solid separation

The two papers by Ward and Poh (13) and Grecol and Davis (14) are concerned with flow in inclined
parallel walled settlers.The aim was to verify the theoretical analyses of Acrivos and Herboltzheimer
and Nakamura and Kuroda. A ciné camera was used to measure the temporaldevelopment of the
clear liquid layer formed along the length of the separator. Experimental results compared
reasonably well with those predicted theorically and it was concluded that the analyses provide
satisfactory guidelines for design purposes.

Grecol and Davis (14) consider the more general problem of classification of particle of different
sizes and densities at concentrations such that hindered settling effects are significant. The analysis
of Davis, Herboltzheimer and Acrivos for classification of dilute suspentions was extended to higher
concentrations by accounting for hindered settling effects. Experiments were performed with
mixtures of 267 µm spherrical glass particles and 83 µm acrylic beads in a Newtonian liquid (Union
Carbide UCON 50 HB-280X). It was noted that the efficiency of classification by inclined settling
increased with increasing concentration.

The scale-upof conical hydrocyclones at high feed concentrations such that the slurry behavior is
non-Newtonian was investigated by Ortega-Rivas and Svarovsky (15). Selection and operation of
hrdrocyclones is based on relationship between pressure drop and flow rate, and the relationship
between separation efficiency and flow rate. Relevant dimensionless groups for hydrocyclones were
enumerated and discussed. These are the Euler number, a Stokes number associated with the size
of the particles likely to be separated, an appropiate Reynolds number for non-Newtonian
behavior,the ratio of undeflow (that leaves through the apex of the conc) to throughput, and the
feed concentration. Experiments were performed with suspensions of dolomitic limestone, with
feed concentrationsranging from 5 to 25 vol.%. By using a multiple regression analysis the authors
obtained correlations relating these dimensionless groups appropiate for high feed concentrations.
The correlations can be used for performance prediction as well as for the design and selection of
small diameter hydrocyclones.

3.2 GAS-SOLID SEPARATION

To separate effectively fine particles in the size range below 1. The existing devices have to be
improved or to be operated under changed conditions. Separators used today in industrial
application differ not only in their performance but also in their investment and operating costs are
high in most cases.

Reccently, a new separator, named multiwir, was developed by Fischer and leschonski. The new
separator consists of a structured packing wich subdivides the incoming gas into a great number of
narrow streams which cross each other. As a results of transfer of momentum between these gas
streams, they keep rotating. Due to the centrifugal forces, originating from the rotation, the
particles entrained in the gas streams are separated and deposite don the Wall of the packing.
Multiwir separates 1 particles at efficiencies as high as 54-75% whereas conventional dust collectors
base don gravity, inertial or centrifugal forces generally show less tan 10% efficiency for such fine
particles their results also shows that there exists an optimum velocity of about 9.3 m/s, below
which increasing gas velocities and after which the efficiencies cecrease with increasing gas velocity,
due to particle bouncing and particle reentrainment.

The separation of particles directly from high temperature gas streams is becoming increasingly
important in many industrial processes. This topic is addressed by Stefan and Loffler (19). In their
experiments, the hot exhaust gas produced by a natural gas burner is mixed with dust from a
continuousdust feeder and enters the filter housing within which a filter element is hung. The pulse
jet regeneration of the rigid ceramic surface filter was investigated under the influence of high
temperatures 600 and 850 °C for three different dusts (quartz, brown coal and hard coal fly ashes).
If the influence of the temperature dependent gas viscosity upon the pressure drop at the filter is
eliminated, an improved dedusting of the filter element is achivied at higher temperatures for all
three dusts investigated. This can be explained by a higher maximum pressure built up inside the
filter element during the pulse jet regeneration. Increased maximum pressures prevail during the
dedusting causing stronger separating forces and improved jetting of the filter cake. Their results
demostrated that a prolongation of the valve opening time, an increase of the pressures in the jet
gas reservoir and the filtration of thicker dust layers also improve the regeneration of the filter
element.

Electrostatic precipators (ESPs) are widelyused in many industries as efficient dust collectors.
However, it is necessary to be abble to design ESPs for different applications. The Deuts-Anderson
equation has been used as the basis for the engineering design of ESPs. However, in this equation
the so-called effective migration velocity of particles is an empirical parameter. This quantity is taken
to represent the collection behavior of an entire dust of a certain kind and under a certain set of
separating conditions. It is determined by back calculation using the Deutsch-Anderson equation
from experimental data (mostly proprieraty) and therefore really is a measure of the performance
of the ESPs. Thus, in actual use, the Deutsch-Anderson formula is a purely empirical tool.

3.3 PARTICLES CLASSIFICATION

The main object of classification of powders is to define the behavior of the powders into definite
specific regimes of class patterns. There are three main types of classification of powders relating
to their handling properties. They refer to handling and storage of deaerated powders; handling of
aerated powders, such as fluidized beds; and handling of suspensión of powders, such as pneumatic
conveying of powders or separation of particles from gases.

For aerated powders, such as in fluidized beds, particle density and size are the two most important
parameters governing the behavior of powders as was originally shown by Geldart. A vibrating reed
technology for the classification of powders aerated state was developed by khoory and
Mahgerefteh. This technology is based on relating the amplitude of transverse vibration of a reed
at resonance to the average particle size. The device used for vibrating classification basically
consists of a centrally driven reed made os spring Steel which is secured at both ends within a Steel
cylindrical chamber. The test poder with a constant mass is placed in a glass container mounted at
the center of the reed. A cover is used to prevent the escape of powder during vibration. The system
is sinusoidally vibrated using an electromagnet. The frequency and amplitude of the tranverse
vibration os the reed are measured by monitoring the induced voltaje signal from an optical detector
consisting of the reed.

The powder groups classified by the device closely correlatewith those show non Gerald’s
classification chart which plots the density diference between the powder ans the fluidizing médium
against mean particle size so that powders fall into four groups A, B, C and D. powders
corresponding to group C (fine particles <30) produce large displacements because they stick
together,behaving like a compacted solid mass, whereas powders corresponding to group A
(médium sizeparticles 30-300) circulate from the Wall towards the center of the bed, except for a
narrow región along the surface where particles return towards the Wall of the cavity. For powders
corresponding to group B (large particles 300-500) a shallow heap is formed in the center of the
cavity with the particles rolling down the top surface of the bed towards the Wall and then
circulating down the Wall and emerge rapidly through the center; particles in group D (very large
particles) move coherently with random spouting and modest mixing with the container.

Counter-flows separation technology is very useful for the classification of particles suspended in
gas os liquid streams. Based on this principle, an alpine zig-zag classifer can divide particles sizes as
described by ortega-rivas and svarovsky.

The momentum Exchange in the classifier can be improved by replacing the free vortex. A forced
vortex may be produced using a rotor with radial blades at its outer periphery. In this classifier, the
air and the well-dispersed feed material anter the classification zone near the outer periphery of
the rotor. The feed particles, being accelerated in circumferential and radial direction are classified
at this point into coarse and a fine fraction. The coarse particles are driven to the outer periphery
of the casing and they are continuosly removed from there. The fine particles follow moving towards
the center and leave the classifier together with the air.

Inertial classifiers are devices in which particles are anertially separated according to their size and
where they do not impacto n solid surfaces. As counter-flow classifiers mentioned previously,
inertial classifiers are also used for the classification of particles suspended in gas or liquid streams.
The size-dependent classification for two inertial classifiers, one consisting of two plates with two
centered orífices, and the other having and orifice in the top place and a smaller disc in the bottom
plate.