PARTICLE CLASSIFIER

Abstract: A particle classifier includes a generally cylindrical, air and fine particles permeable cage having a closed top and open bottom mounted to a central drive shaft. A casing surrounds the cage and defines a volute air passage about the cage with an air separation zone between the volute and the cage. A generally tangential air inlet is provided in casing volute and a material inlet is provided in the upper end of the casing. A stationary chamber is positioned below the cage for the air and fine material which enter the cage. From the chamber, the air and fine material is directed to cyclone separators in which the air is separated from the particles. A hopper is positioned below the chamber for collecting coarser material which fails to enter the cage. The size of the volute can be adjusted by a vertical partition within the casing. The partition allows flexibility in setting the air velocity. Means are provided for steam-lining the air flow from the air inlet to the cage and retaining particles in the separation zone. In one case, louvers are provided for these two purposes, and in another case a screen is provided between the volute and particle separation zone.

Description: This invention relates to a particle classifier and in particular to a classifier in which particulate material is separated substantially into fine and coarse particles by means of cylindrical rejector means (DE-A-1607631) The present invention is applicable to the processing of any solids but is particularly useful in cement manufacturing plants. In such plants, it is important to separate fine particulate material from coarser material. In one form of particle classifier, a separation zone is provided between an inlet air passage and a rotating rejector cage. From the air passage air is directed through the separation zone into the rotating rejector cage. A mixture of fine and coarser material is fed into the separation zone by gravity. Coarser material drops through that separation zone and is collected through a hopper. Finer material is carried by the air flow into the cage and is subsequently drawn from the cage and separated from the air flow in a cyclone collector. In one form of classifier, the inlet air passage is in the form of a volute into which the air is introduced tangentially. The outer wall of the volute spirals inwards through a single circle about the rejector so that the cross sectional area of the volute across the air stream is reduced as the air flows about the rejector. The volute causes the air to curve inward through the separation zone into the rejector cage. The size of particles carried into the cage is a function of several forces on particles of different size, density or shape. Those forces include particularly gravity, the drag force of the air on the particles, the collision force of particles impacting the rotating rejector and centrifugal forces imparted on the particles either by the rotating air or by mechanical devices or both. Further, sharpness of classification and the efficiency of classification are dependent on the precision of control of those various forces. It is of course preferred that all particles smaller than a given size enter the rejector cage and all particles larger than that size pass through the hopper and that a minimum of power input be required. The disadvantage of the existing classifiers is that, in full-size industrial equipment, the volute is large and the air flow through it is difficult to control. Instead of moving laminarly, the air forms local currents and eddies that disrupt the required smooth radial flow into the rejector cage and interfere with the even distribution of air over the cylindrical rejector surface. Attempts have been made to correct this problem by providing vertical vanes in the volute and horizontal blades in the cage. However, the vanes are not effective if the air is brought to the volute by a duct with a horizontal bend close to the volute or pumped by a centrifugal fan close by, which is the case in the majority of plants. The duct bend or fan cause a vertically scewed velocity profile of the air in the duct that cannot be corrected by vertical vanes. The blades are not effective because they are downstream from the separation zone. Another disadvantage of the existing classifiers is that some of the particles descending through the separation zone around the rejector cage are always thrown outward beyond the separation zone either by a rotary distributor on top of the zone, or by local currents of the non-laminar air flow, or by collision with other particles, or by being bounced off too far by the rejector. Some of these particles deposit at the bottom of the volute close to the vertical outside wall where the tangential air velocity is small. Once the particles deposit the air cannot act on them to separate the fine particles from the coarse particles. While coarser particles settle down preferentially, they trap finer particles among them. The deposit continuously slides down to the hopper and is replenished by more particles settling down, thus contaminating the coarse product with fine particles and decreasing classification efficiency. Attempts have been made to prevent the particles from settling or to reduce the deposit by increasing the volumetric air flow rate. However, this requires more power to pump the air and increases carry-over of coarse particles in the fine product by raising the radial air velocity into the rejector cage. Yet another disadvantage of existing classifiers is that the rejector is an assembly of vertical and sometimes also additional horizontal blades. The purpose of the latter is to streamline the air while the number and size of the vertical blades control the amount of remaining coarse particles in the fine product. However, changing the number of, or replacing, the vertical blades is difficult because there is no easy way of pulling out or reinstalling the blades without at least partially disassembling the classifier. Furthermore, rotating blades, more so than stationary vanes, are subject to fast erosion due to their large area to thickness ratio when an abrasive material is classified. The streamlining effect of the horizontal blades is not very effective because the air turbulence that interferes with classification is caused upstream from the separation zone while the blades are downstream. An object of this invention is to provide a sharper and more efficient classification in a particle classifier and better control of solids processing. According to this invention there is provided a particle classifier comprising a rotating classifying assembly coupled to rotary drive means above the rotating assembly and having a disc-shaped top and an open bottom, feed material inlet means for directing feed material to the top of the rotating assembly for centrifugal dispersion, means defining an annular separation zone immediately surrounding the rotating assembly, air passage means for directing air around and radially inward through the separation zone towards the rotating assembly, coarse hopper means coaxially disposed below the separation zone for receiving coarse material, and outlet means for removing fine particles, wherein the rotating assembly is a cylindrical rejector cage mounted for rotation about its cylindrical axis, the air passage means being arranged to blow feed material against the cage, characterised in that coaxially disposed immediately below the cage there is a cylindrical stationary fines chamber which is surrounded by the coarse hopper means and which has an open top, a side wall, and a closed bottom, the outlet means extending laterally from the fines chamber to remove fine particles from the interior of the chamber, the cylindrical stationary fines chamber has a substantially flat closed bottom and the outlet means comprise a plurality of outlet ducts raised above the closed bottom of the chamber. The cage may include a vertical coaxial drive shaft coupled to the drive means and having a free lower end which extends in the direction of the fines chamber, a horizontal disc coaxially mounted to the shaft, and a plurality of elongated vertically disposed spaced elements suspended from the circumference of the disc, the lower ends of the elements being connected to a ring-like member juxtaposed with the upper portion of the side wall of the fines chamber. The cage may further include support means extending diagonally outward and upward from the lower portion of the shaft to a radially intermediate point on the disc. Such support means may be a conical wall having its apex connected to the lower portion of the shaft. Preferably, the outlet means comprises a plurality of outlet ports defined in the side wall of the fines chamber, and a plurality of outlet ducts connected to the fines chamber side wall at the outlet ports and extending sealingly through corresponding openings in the coarse hopper means, the fines chamber being supported primarily by the ducts so as to be suspended in the coarse hopper means coaxially below the cage. A plurality of cyclone means may be connected to respective ones of the ducts for evacuating fine particles from the fines chamber. The vertically disposed spaced elements may be individually removable from the cage through the disc, and may have wear resistant sleeves. The invention will now be described with reference to the accompanying drawings in which:- Figure 1 is a perspective view, partially broken away, of a particle classifier in accordance with the invention; Figure 2 is a vertical cross section of the embodiment of Figure 1 taken along lines 2-2; Figure 3 is a horizontal cross section of the embodiment of Figure 1 taken along lines 3-3; Figure 4 is a vertical cross section of an alternative embodiment of the invention; and Figure 5 is a horizontal cross section of the embodiment of Figure 4. Figure 1 illustrates the primary elements of a system embodying this invention. At the heart of this system is a classifier 12 which will be described below. Particulate material, including fine and coarse material which are to be separated, are delivered to the classifier 12 through an inlet conduit 14. Air is forced into a tangential inlet 16 by a blower 18. By action of the air flow and rotation of a rejector cage 20 within the classifier, fine material is carried into the cage and coarser material or tails drop alongside the cage into a discharge hopper 22. The fine particles are carried into a stationary fines chamber 24 below the cage 10 and are carried with the air flow through a plurality of outlet conduits 26 to several cyclone collectors 28. The number of cyclones depends on the capacity of the system. In the cyclones, the fine material is separated from the air flow and the fine product drops into discharge hoppers 30. The particle free air is returned through upward extending conduits 32 into a manifold 34 which returns the air from the several cyclones to the blower 18 for reuse in separating fine material from coarser material. Details of the classifier 12 can be best seen in the cross sectional views of Figs. 2 and 3. The outer casing of the classifier includes the hopper 22, a cylindrical section 36 above the hopper which directs separated coarser material to the hopper, a volute casing 38 and an upper cover 40. The stationary chamber 24 is suspended within the cylindrical section 36 by the outlet conduits 26. A number of vertical ring liners 41 are fixed to the hopper 22 to collect material. That collected material isolates the hopper 22 surface from the falling material and thus minimizes wear. A motor 42 and gear reducer 43 are mounted above the cover 40. The reducer is driven by a belt 45. A shaft 44 driven by that motor extends into the volute casing concentric with the cylindrical section 36 and the hopper 22. The rejector cage 20 is mounted to the shaft for rotation by the motor. The cage includes a plurality of pins 46 extending vertically between an upper distribution plate 48 and a lower ring 50. The lower ring 50 is suspended above a flange 52 on the stationary chamber 24. Two guide rings 54 and 56 extend downward from the ring 50 to assure that the rotating cage remains concentric with the collection chamber. A conical section 58 provides structural support of the cage on the drive shaft 44. It also serves as a directional element to deflect air flow and the fine material carried by the air flow downward through the ring 50 into the stationary chamber 24. The size and number of pins control the amount of coarse particles remaining in the fine product. The lower part of each pin rests in a blind tapped hole 78 located on the bottom ring 50 of the rejector cage. The upper part of the pin extends through a hole drilled in the distributor plate 48. The top of the pin is flush with the upper surface of the distributor so as not to interfere with the feed distribution. A pin can be easily removed manually or with a set of special tools through a port 75 in the top cover 40 of the classifier. This is done by grabbing the pin in the middle, lifting it, grabbing the top and pulling the entire pin out. The cage is then turned until the next pin to be removed is under the port, and the pulling process is repeated. For inserting pins, the process is reversed. A minority of pins, typically eight out of 48 for a two-foot diameter rejector cage, are used to hold spacers 76 that establish a constant distance between the distributor plate and the bottom ring. The spacer is a piece of tubing through which the spacer pin is slipped during insertion. The spacer pins 77 have a threaded bottom that fits into a threaded blind tapped hole. The top of the pin extends above the distributor and is also threaded. A nut 79 screwed tightly on the top of the pin holds the spacer in position. Size of the regular, non-spacer pins can be increased by "loose" spacers, that is pieces of tubing not individually held in position by a top bolt. They are, of course, fixed by tightening the bolts on the spacer pins. The size of any pin can be varied by using bigger or smaller spacers. For classification of abrasive materials, all pins may be protected by abrasion resistant spacers or bigger pins may be provided that resist wear longer. Particulate feed material introduced into the system through the conduit 14 is divided into two or more conduits 60 and 62, and from those conduits the material is dropped onto the rotating distribution plate 48. Centrifugal force imparts radial motion to the material so that it slides off the periphery of the distribution plate. The material is then deflected downward by a frustoconical deflector 64 to create a curtain of particulate material which descends around the cage through the separation zone. In this embodiment, a cylindrical screen 66 is stretched between the deflector 64 and the cylindrical casing section 36 to surround the cage 20. The screen may be a mesh or a perforated sheet. The screen 66 defines a separation zone 68 between an outer volute air passage 70 and the cage 20. Air, which initially enters the volute air passage 70 tangentially, curves in through the screen and then through the rotating cage 20. In the separation zone 68, the air flow has both tangential and radial components. Within the separation zone, the particles of material are subjected to a number of countering forces which affect the heavier and lighter materials differently. Initially, as the material is thrown from the distribution plate 48, the coarser particles have greater inertia and thus tend to be thrown further from the distribution plate. Below the deflection plate 64, the particles are subjected to a drag force from the air flow which entrains the particles in the air flow. As noted above, a component of that air flow is tangential and the larger centrifugal force of the coarser particles again pulls them to a wider radius than the finer particles. The particles are also pulled down by gravity. Coarser particles are held away from the cage 20 by their inertia as they drop the full distance through the separation zone 68 and enter the cylindrical casing 36. From the casing 36 those coarser particles enter the hopper 22. Fine and medium particles, on the other hand, are pulled into the cage 20 by the air flow before they drop to the bottom of the separation zone. Some of those particles, particularly the medium sized particles, are rejected by the rotating pins back into the separation zone where they are again entrained in the air flow and continue to drop towards the cylindrical casing 36. Coarse particles may carry smaller particles with them into the hopper 22. If the coarse particles are retained in the separation zone 68 throughout their fall to the cylindrical section 36, there is a greater chance that those smaller particles will be separated from the coarse particles and be carried into the rejector cage. The screen 66 retains the particles within the separation zone for better separation. The solid portions of the screen deflect material back into the separation zone. The screen also locally increases the velocity of the air flow at the outer perimeter of the separation zone 68. That local increased air velocity at the screen perforations also helps direct material back into the separation zone 68. It can be recognized that turbulence in the air flow within the volute air passage 70 and the separation zone 68, including local currents and eddies, adversely affects the precision and efficiency of the system. The screen 66 serves the further function of streamlining the air flow into the separation zone 68 by breaking the air flow into a sheet of minute jets through the perforations in the screen. By breaking the air flow into the minute jets, turbulence is broken up and the overall air flow is made more uniform about the entire periphery of the separation zone 68. It is important, however, that the screen not significantly interfere with the tangential component of the air flow introduced by the volute air passage 70. Therefore, it is important that the screen be at least 50 percent open to the air flow, that is, at least 50 percent of the cylindrical surface defined by the screen should be open to air flow. Preferably, greater than 70 percent of the screen surface area is open. The overall result of the countering forces in the separation zone is that fine material is carried by the air flow between pins 46 into the cage and is then deflected downward by the conical directional element 58. The air and fine material enter the stationary chamber 24 and are divided into several conduits 26 which lead to the cyclone separators 28. As previously stated, the air is there separated from the fine material, and the air is returned to the blower 18 for recirculation through the classifier. It can be recognized that the sharpness of classification, that is the degree to which one can expect only material less than a given size to pass into the cage 20 and only material greater than that size to drop into the hopper 22, the efficiency of the system and the capacity of the system are dependent on a number of variables. Those variables include the size, shape and density of material entering the system, the rotational speed of the cage 20, the volumetric flow rate of air entering the system, the tangential and radial components of air velocity throughout the separation zone 68 and the number and size of the pins 46. In conventional systems, many of those parameters can be controlled by controlling the speed of the rejector 42 and the flow of air delivered by blower 18. One aspect of the present system is that the tangential velocity of air in the volute 70 and thus in the separation zone 68 can be controlled independently of the air flow set by the blower 18. By controlling the tangential air velocity, one can control the size of particles that are thrown outside of the separation zone. With a higher air velocity, less particles escape the separation zone to slide down to the cylindrical casing 36. The air velocity also controls the time that particles are entrained by the air flow in the separation zone. To that end, a partition 72 is mounted in the volute casing 38 to define a smaller volute air passage about the separation zone 68. By moving that partition inward, the cross sectional area of the volute air passage is decreased and the air velocity is increased. Moving the partition 72 outward decreases the air velocity where other parameters are held constant. The partition 72 allows for construction of the basic classifier with an outer casing wall 38 defining the largest volute that would be required for any expected application. For example, the outer volute would allow for a given classification size from a given size range of particles entering the system at a given density. The partition 72 can then be set in the volute at an optimum position for any other particular application. Partition 72 may be welded into position where the application is to remain constant. Where the application is to vary, the partition 72 can be collapsible within the volute casing in order that the volute passage 70 can be varied for the varying applications. In either case, the partition 72 introduces one more design parameter which can be controlled to optimize operation of the classifier. An alternative embodiment of the invention is shown in Figs. 4 and 5. This embodiment is much the same as that of Figs. 1 through 3 except that a different means is used to eliminate turbulence in the air flow. In this embodiment, the screen 66 is eliminated and louvers 74 are mounted within the volute air passage. Those louvers can be seen to extend inward, generally parallel to the air flow in the volute air passage. They thus break the air flow into several streams and thereby minimize turbulence in the overall stream and equalize the air velocity throughout a cross section of the volute air passage. For ease in manufacturing, the louvers are regular cones which touch the outer volute wall only at the narrowest section of the volute. The inner edges of the louvers are at about the outer radius of the separation zone. The louvers 74 can be horizontal, but by angling them downward somewhat as shown in Fig. 4, they can also serve the function of directing any material which passes beyond the separation zone back into the separation zone. In this case, the louvers may be angled 45° from the vertical. While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the scope of the invention as defined by the appended claims. For example, the streamlining screen 66 and louvers 74 have been shown in conjuction with the volute partition 72. However, each of those features of the system could be used advantageously in a system which does not include the partition 72, and the partition can be used without either the screen or louvers.

Claims: A particle classifier, said particle classifier comprising: a rotating classifying assembly coupled to rotary drive means (42,43) and having a disc-shaped top and an open bottom, feed material inlet means (60,62) for directing feed material to the top (48) of the rotating assembly for centrifugal dispersion, means defining an annular separation zone (68) immediately surrounding the rotating assembly, air passage means (38) for directing air around and radially inward through the separation zone (68) towards the rotating assembly, coarse hopper means (22) coaxially disposed below the separation zone (68) for receiving coarse material, and outlet means (26) for removing fine particles, wherein the rotating assembly is a cylindrical rejector cage (20) mounted for rotation about its cylindrical axis, and the air passage means (38) are arranged to blow feed material against the cage, characterised in that, (a) coaxially disposed immediately below the cage there is a cylindrical stationary fines chamber (24) which is surrounded by the coarse hopper means (22) and which has an open top and a sidewall, the outlet means (26) extending laterally from the fines chamber (24) to remove fine particles form the interior of the chamber (24), (b) the rotary drive means (42,43) are located above the rotating assembly, (c) the cylindrical stationary fine chamber (24) has a substantially flat closed bottom, and (d) the outlet means (26) comprise a plurality of outlet ducts raised above the closed bottom of the chamber (24). A classifier according to claim 1, characterised in that the rejector cage (20) includes a vertical coaxial drive shaft (44) drivingly connected to the drive means (42, 43) having a free lower end extending in the direction of the fines chamber (24), a horizontal disc (48) coaxially mounted to the shaft (44), and a plurality of elongated vertically disposed spaced elements (46) suspended from the circumference of the disc (48), the lower ends of the elements (46), being connected to the ring-like member (50) juxtaposed with the upper portion of the side wall of the fines chamber (24). A classifier according to claim 2, wherein the rejector cage (20) further includes support means (58) extending diagonally outward and upward from the lower portion of the shaft (44) to a radially intermediate point on the disc (48). A classifier according to claim 3, wherein the support means (58) is a coned-shaped wall with its apex connected to the lower portion of the shaft (44). A classifier according to any preceding claim, characterised in that the outlet means comprises a plurality of outlet ports defined in the side wall of the fines chamber (24), and a plurality of outlet ducts (26) connected to the fines chamber (24) side wall at the outlet ports and extending sealingly through corresponding openings in the coarse hopper means (22), the fines chamber (24) being supported primarily by the ducts (26) so as to be suspended in the coarse hopper means (22) coaxially below the cage (20). A classifier according to claim 5, further comprising a plurality of cyclone means (28) connected to respective ones of the ducts (26) for evacuating fines particles from the fines chamber (24). A classifier according to claim 2, characterised in that the vertically disposed elements (46) are individually removable from the cage (20) through the disc (48). A classifier according to claim 7, characterised by wear resistant sleeves about the said elements (46).

Inventors: JONES, HAROLD T., SAVERSE, RONALD R.
Applicants: STURTEVANT, INC.
Application year: 1985
Main classification: B07B9
IPC codes: B07B11, B07B7, B07B4, B07B9