From the desk of,

Consultant – Cement Sector

Study Rotor / Impeller of Separator type SF 600 / 140 – Supplier HCRDI – China
Location One of the Cement Pakistan Limited
Application Installed inside separator to produce air current for separation of fine & coarse material
Product Ground Cement by Ball mill
Reference Our visit at site on 18th. July 2020 to visualize the situation at present
Reported problems
 Wear of blade at outer ring due to abrasive clinker dust
 Rapid removal of material of top plate resulting of fell down of entire rotor because the
top plate is constructed in two pieces

Basic principal of equipment to search the cause of reported problems

Separation as performed by mechanical air separators is the division of a given material stream into two
separate streams, using air as the carrying medium. Hereby one stream should contain only fine particles, and
the other, as far as possible, only coarse particles. To perform this function, the separator feed must be evenly
distributed inside the separator, and subjected to classifying forces, which should be variable. The classifying
forces acting upon the various solid particles of different sizes are described down.
The dispersion separator, (also called the mechanical air separator) is the most representative air separator in
the cement industry. This kind of separator utilizes a distribution plate to disperse the feed material into the
separating space. There are various designs of feeding arrangements of the mechanical air separator. The
majority of the mechanical air separators generate the circulating air inside the separator itself; therefore they
are also called circulating air separators. Mechanical air separators can also be supplied with separating air
generated outside the separator.
The operation of the air separator is based on the following principle:
The action of an air current of a certain velocity upon a mass-particle is proportional to the surface presented
by this particle to the air current, thus to the square of the mean dimensions of the particle. The action of the
force of gravity upon a mass-particle is proportional to the volume, thus to the cube of the mean dimensions
of the particle. Therefore the effect of the force of gravity increases faster than that of an air current of
constant velocity. If these two forces are concurrent, i.e. when particles being in a state of free fall are exposed
to an ascending air current, the force of gravity will prevail over the effect of the air current as particle
dimensions increase. On the other hand a properly adjusted air current will oppose the force of gravity and lift
up the finest mass-particles.
From the desk of,

Consultant – Cement Sector

During rotation of rotor to produce air current with gravitational drop of ground material, friction forces
between metal & ground material multiplies resulting excessive wear of rotor’s blades.
Most important to understand that ground material falls on distribution plate and moves fastly in circular
direction increasing in diameter from small to large like waves. This action press to molecular structure of
contacted surface and push it towards outer ends.
Secondly, contact of abrasive material with rotor’s blade with higher circular speed makes tiny pitting impact
causing pre-mature removal of material from edges of rotor’s blade.

Our Opinion & Suggestions

A- Existing blade of Rotor

Blade of rotor 40
43

28
8
R6

Outer Inner
ring ring
73 73

 No need of any change because the profile is giving proper flow. No complain showed by client

B- Construction of Rotor

Dia 1030
Dia 1010
Suggested change in material by using standard materials
1. Hardox 500 because of diamond shaped molecular structure to
provide best resistance against circular wavy friction
Top plate
1 2. 1040 or compatible
Ring plate 3. 1040 or compatible
2
4. 1040 or compatible with hard facing at internal curve by applying
Rod dia 8 mm hard facing electrodes to achieve surface hardness HRc 45 ~ 50
5
5. Suggested to fully weld a solid rod of dia 8 mm at outer ring of
blade vertically with each blade. Material of rod will be just hard
Blade of rotor than the material of blade.
4
6. Keep in mind that profile of blades must be strictly same for a
uniform disbursement of air current.
7. Manufactured rotor must be balanced dynamically at 900 rpm

Shroud
3

Conclusion:-
Client may please be asked to confirm our suggestions / recommendations for financial estimation of
manufacturing.