OptSep™ – 4th Generation Dynamic Separators

CEMI developed and patented the OptSep™ system for optimization of the Dynamic Separator efficiency of any generation in dry grinding circuits.

The OptSep™ System implementation provides coarse reclassification through a mechanical device projected especially for recycling the fines. The result is final classification efficiency superior to the classification achieved by the original separator with considerable capacity gains for the entire grinding circuit.

This is possible because OptSep™ is a complete system with a secondary classifier which works in a close circuit jointly to the classification chamber of the original dynamic separator. A significant amount of air is injected with a suitable outflow inside the classification chamber to remove and reclassify the fines that usually return to the coarse product.

The main component of OptSep™ is a static classifier with regulating blades used for outflow air entrance. Also, it is necessary a complete exhaust system with fan and sometimes cyclone or filter to promote the additional outflow air. 

Exhaust System

For the process balance, an Air outflow gear is installed interconnected in circuit ventilation system which presents under several forms that change according to the circuit and type of existing dynamic separator. The ventilation system is constituted by a filter and a fan at least. But it can have a cyclone that makes the precipitation of pneumatically carried material in order to ease the solid amount on the filter (bag or electrostatic). The products of the filter and cyclone are added in the final product of dynamic separator.

How OptSep™ act in the dynamic separators?

OptSep™ installation and some small additional modifications in the circuit ensure a perfect functioning of the optimized equipment.

These modifications provide an excellent result, since the existing dynamic separators, even the third generation one, have deficiencies between the air outflow and the quantity of the material fed into the equipment.  

It is necessary to increase the outflow air through the Dynamic separator for its optimization. Thus the dispersion capacity to carry the finer material to the final product is enlarged.

OptSep™ improves dynamic separator performance because of decrease a number of fines that shouldn’t return to the mill. But, the return occurs due to classification inefficiency. 

So when the return of fines is decreased and dispersion capacity is increased, it is possible to enhance grinding productivity overall.

How do the additional modifications occur?

OptSep™ doesn’t change the balance point of the existing separator remaining the granulometry in the same original situation. However, in some cases, the process gets away from the balance point changing the specified granulometry.

If that happen, little additional adjustments can be made in the original separation chamber of the dynamic separator keeping the grinding product with the desirable granulometry and the circuit working on greater productivity. These adjustments could be a simple rotation regulation of the centrifugation device – second and third generation separators – or angle and number of the centrifugation fixed blades – first generation separators.

All this effort results in an optimized partition curve for the dynamic separator and a greater productivity of the dry grinding circuit.

Which are the advantages of the OptSep™ system implementation?

The outcomes reached with OptSep™ can change according to characteristics and performance of the pre-existing circuit. However, in general, the gains have been significant around and sometimes over 10% of productivity increase with the same product quality. The investment is paid between some weeks to few months in cement grinding.

OptSep™ represents a revolution in dynamic separators optimization providing significant capacity gains for the entire circuit. The investments are around 10% of the price to replace the dynamic separator for a new one.