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Classifying Complexes KCM

High-performance dynamic air classifier for powders of -500… -40 μm classes, equipped with a patented two-phase flow system without the use of any screen sizing systems.

General information

Micropowder production classifying complex KCM is a new unique equipment unit manufactured by Ural-Omega CJSC, which has embodied the Company’s long-term experience in production and introduction of dynamic air classifying complexes KC.

KCM complex ensures the high quality ultra-fine micropowders production due to its ability to separate particles of the fine classes according to their density. Such complexes have been successfully applied in the processes of ore and materials beneficiation and roughing by dry method.

KCM complexes are applicable in different branches of industry, which traditionally require the use of carbonate fillers in the production process: dry building mixes, all kinds of paintwork materials, production of insulating materials, rubber technical goods, pastes and scouring powders, mud-flush agents, paper, etc.

KCM classifying complex’s operating principle is based upon the dry separation of the uniform-sized micropowder and material particles according to their density or fineness. KCM complexes make it possible to produce two narrow classes of micropowders with the fineness of 5 – 50 μm with the function of operational control of the fineness degree in the course of operation.

Pilot-scale research confirmed the possibility of 8-15 μm D98 class powders production.

KCM micropowder classifying complexes give the possibility of efficient material separation with the production capacity of up to 10 t/h.

KCM complexes are not equipped with any screen sizing systems. Dynamic air classification of materials is the basis of the complex operating principle, which is carried out entirely due to air flows and particle acceleration. Segregation of particles takes place on the basis of their ability to reduce the set speed on interaction with the aerodynamic flow. KCM complexes do not require routine service maintenance.

Technological classification system of KCM micropowder production complexes includes modular units that are easy to operate, require little space, and are notable for high performance and low power consumption. Actual complex use factor reaches the value of 0.9.

Fields of application

KCM classifying complexes can be used in any branches of industry, where the narrow class products output (separation) is required. They enable separation of fine class particles according to their density. These units are successfully applied in the processes of ore and materials beneficiation / roughing by dry method.

KCM micropowder classification complex is the most efficient when used for the production of: 


  • micro talc – fraction of less than 10 μm. Micro talc is frequently used in the production of paintwork materials, glues, adhesives, mastics, ceramics, sealants, rubber, and plastics.
  • micro calcite – fraction of less than 5 μm. Micro calcite is used in the production of paper, paintwork materials of all types, plastics, linoleum, rubber technical goods, scouring powders, sealing materials, dry tender and other construction mixes, mud-flush agents, oil-well cements, foam concrete blocks, slag blocks, other types of blocks, concretes.
  • fine microgrits – fraction of 2-10 μm. Efficiently used in the surface treatment of precision bearing parts and critical parts of the automated component units in complex technical systems.

KCM micropowder classification complex is highly efficient in the production of paintwork material fillers, plastics, composite materials, rubber technical goods, etc.

 

Advantages

KCM classification complex is a complete complex solution that requires no additional systems.

Operation:

  • contains no wear parts;
  • low metal and power consumption;
  • contains no mechanical impact mechanisms, produces no vibration when operating;
  • low maintenance time, long servicing intervals;
  • low noise characteristics;
  • lubrication-free;
  • low dust emission level.

Technological advantages:

  • efficient separation of the materials rich in ultra-fine dust fractions content;
  • high accuracy of separation (90-95%);
  • wide cut-point range;
  • smooth stepless cut-point adjustment;
  • possibility of cut-point adjustment in the course of operation.

Operating principle

KCM complex air classification flow chart

1- bin feeder; 2- KC dynamic air classifier; 3- multicyclone arrangement; 4- filter; 5- transportation fan; 6- aspiration fan; 7- control box / panel

 

Transportation fan (5) produces rarefaction in all units of the line (classifier, cyclones) with the air inleakage (reversal cyclone) to the large product chute of the complex. Source material is moved to the classifier (2) by the feeder through the inlet chute.

KCM classifier separates the product into two classes on the basis of the set fineness cut point. Large product is discharged into the classifier, and the underflow is directed to the multicyclone arrangement (3, 4) for separation and further discharge.

Air flow returns to the classifier from the multicyclone arrangement. A part of the air flow (30%) is discharged into the atmosphere via the exhaust pipe following its final purification in the filter (5). Final products may be discharged into plastic big bags, pneumatic chamber pumps for silo supply, etc.


KCM classifying complex operating principle

Two-phase air stream is created inside the classifier volute (3) with the help of rotation of the acceleration rotor (5) and two inlet air flows. Source material is fed to the classifier along with the main air stream in the form of a dust air mixture through the inlet chute (1).

In a dynamic flow created by the rotor, large particles are centrifugally driven to the periphery. Having reached the internal surface of the volute (3), the particles are slowed down and lowered into the cylindrical body part circular cavity (6) under the action of gravity, and then to the large product collector (7). After that the particles are discharged by the lock feeder.

Particles smaller than the limit fineness value in size are carried by the air flow into the rotor. The secondary air flow that enters the classifier through the joining pipe (4) prevents small particles from sticking to the walls of the volute (3) and contributes to their carry-over into the rotor.

Small particles are carried over from the classifier through the outlet connection (2) located at the top of the rotor, and then they are directed for cycloning for deposition and discharge purposes. 

 

Product separation limit fineness is controlled via the acceleration rotor rotational rate and the adjustment of primary and secondary flow values.



Classification characteristics

High-performance dynamic air classifiers with the patented two-phase air flow system make it possible to provide high rates of efficiency and product classification frequency on an industrial scale, which cannot be reached when using other dry classifying systems.

Materials classification fineness range in KCM classifying complexes is [-5 … -50] μm with the possibility of separation of the raw product into 2 classes according to an arbitrary fineness cut point [-1 … -30] μm.

Product classification performed by KCM classifying complexes is characterized by high efficiency and final products homogeneity.

Raw product fineness:

-500 μm

Raw product permissible humidity:

<0,5%

Number of cut points:

1 (classifier) + 1 (when cycloning)

Cut point:

1-30 μm with the possibility of adjustment in the course of operation

Productivity:

up to 10 t/h

Classification efficiency:

95-98%

 

KCM complex operating range

Specifications

KCM classifying complexes are the sequential technological classification system based on the modular units that are notable for high performance, good operability, low power consumption, and low spatial requirements.

Classifying complexes virtually do not require routine service maintenance, and the actual equipment use factor may reach the value of 0.9.

Power consumption, kW/h 12-42
Replacement parts Not required
Wear parts Not required
Use factor >0.9
Equipment routine inspection (with partial disassembly) 1 per month
Standard maintenance time No servicing idle periods
Maintenance personnel, number of persons  1
Product quality Content of impurities from adjacent classes: 2-5 %
Exhaust air dust content  0.1-0.5 g/m3

 

1.Model 2.Productivity, t/h 3.Number of separation products 4.Installed capacity, kW 5.Dimensions, mm 6.Weight, t
L B H
 

KCM


1-10

2

125

9900

5100

7600

14,5

Note:
(2) – Productivity depends on the source material fineness and target final products classes
(4) – Power consumption accounts for 60-80% of the installed capacity and depends on the equipment operating modes.
(5),(6) – Weight and dimensions of the complex are given for reference only, the actual values may vary depending on the optional features and design variant or modification.

Implemented projects
More than 267 mplemented projects for more than 200 clients
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