Classifying Complexes KG

Complexes for dry air classification of granular materials of -10 mm fractions with the productivity of up to 60 t/h and effective separation of up to four finished product classes.

General description
Application
Advantages
Operation principle
Description of classification
Technical characteristics

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General information

Task of KG classifying complexes is the separation of granular and powder uniform-sized particles according to their density or fineness.

KG screening complexes are efficient in producing fine fraction crushed stone, building sand, and mineral fillers from the grinding screened material, which is accumulated as crushing and screening production wastes.

KG classifying (screening) complexes include the sequential technological classification system based on the modular units that are notable for:

low power consumption,
ease of operation,
low spatial requirements,
high performance.

Accuracy of separation at Ural-Omega screening complexes reaches 95%.

In the course of KG classifying (screening) complex work it is possible to produce 2-3 classes of the narrow fraction finished products with the fineness of 0-5(10) mm. Complex productivity is 1 – 60 t/h.

KG screening complexes’ operation is based on the cascade-gravity material classification principle, which consists in the particle segregation by an air flow according to their density or fineness.

Freedom from mechanical screen sizing systems and sieves is an important feature of KG classifying (screening) complexes. Material screening is carried out entirely due to air flows and multiple duplication of sections and chambers of the classifier.

Classifying complexes do not require service maintenance. All units are free from lubrication systems and wear parts, due to which the complex use factor reaches the value of 0.95.

Currently there are more than 25 KG classifying (screening) complexes operating on the territory of the Russian Federation and CIS countries, which are allocated to different tasks, such as: production of fine aggregates, building sand, mineral fillers, ore and non-ore materials roughing, as well as sand fractionating and screening, crushed stone dedusting, removal of powdery wastes from the abrasive materials, elements extraction of useful from the industrial wastes.

KG classifying complexes are the fully automated up-to-date equipment. Standard equipment set includes frequency converters that control safe units operation.

Operation of the complexes is equipped with a feedback system for finished product preset quality parameters, which enables the immediate ACS (automated) response for changes in the initial parameters of the material.

Fields of application

Use of KG classifying complexes for reprocessing of the granulation screenings of crushing and screening industries helps to produce graded building sands, fine crushed stones, mineral fillers, etc.

These complexes are efficiently used in the branches of construction mixes production, materials utilization and beneficiation, etc.

Integration of a KG classifying complex into the screening and crushing plant route sheet allows establishing a non-waste production of sands of classes 1 and 2 according to GOST (Russian National Standard) with the fineness modulus of 2-2.5 from the granulation screenings.

Granulation screenings reprocessing.

Efficiently used for reprocessing of the granulation screenings of crushing and screening industries (mainly that of impact crushing). Granulation screenings reprocessing carried out with the help of the KG classifying complex allows producing the following materials:
- fine size fillers / crushed stones of 3-5 (10) mm classes, used as an upper layer of the road bed;
- building sands (of the class 1) 0.16-3mm;
- mineral filler / dust 0-0.16 mm.
Various ore and non-ore materials roughing.
Fractionation:
- production of dedusted fillers and aggregates of the required fineness;
- sand fractionation;
- crushed stone fractionation.
Utilization / recycling:
- regeneration of the used shot blast and abrasive materials through the removal of unconditioned grains and other dust wastes from them;
- secondary resources utilization (extraction of the useful elements from the electronic waste, cable industry wastes, etc.).

Currently the complexes are applied in classification and production of the following materials:

Fractionation, sands, granulation screenings			Beneficiation	Utilization
Hornblendite	Sand and gravel mix	Chicken grit	Kimberlite	Concrete goods reprocessing
Granite	Bank gravel	Dolomite	Gold bearing ores
Porphyrite

Интеграция комплекса классификации КГ в схему дробильно-сортировочного завода, позволяет организовать безотходное производство с получением из отсева дробления песков 1 и 2 класса по ГОСТ с модулем крупности 2-2,5.

Advantages

Operation:

contains no wear and replaceable parts;
low metal and power consumption;
contains no mechanical impact mechanisms, produces no vibration when operating;
requires virtually no technical maintenance during the whole operating life;
low noise characteristics;
lubrication-free;
low dust emission level.

Technological advantages:

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

Comparative characteristics of a screen and the KG classifying complex
(productivity: 30 t/h)

Operating principle

KG classifying complex standard flow chart

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 / conveyor through the inlet chute. KG classifier separates the product into three classes on the basis of the set fineness cut point. Large and medium-sized product is discharged into the classifier, and the underflow (dust product) is directed to the multicyclone arrangement (3) for deposition. 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 passage through the aspiration cyclone (5). Final products are discharged onto the conveyor belts. Dust products may be discharged into plastic big bags / bulk cement truck / pneumatic chamber pumps for silo supply.

Принцип классификации материалов в комплексе КГ

1- bin feeder; 2- KG classifier; 3- multicyclone arrangement; 4- aspiration cyclone; 5- transportation fan; 6- aspiration fan; 7- control box / panel.

The chart shows several operational modes of the classifying complex, which do not reflect the full potential of different product classes’ production. To complete each particular task, find out the optimal scheme and equipment set, ask our experts.

KG cascade-gravity classifier

Классификатор каскадно-гравитационный КГ

KG cascade-gravity classifier’s operating principle is based upon the air flow separation of the uniform-sized bulk material particles according to their density or fineness with the possibility of a stepless cut-point adjustment.

Raw product enters the feed hopper of the classifier and then passes to the shaft I, where its air flow primary classification occurs: large (heavy) particles are separated – they are deposited and then discharged via the shutter located at the bottom of the shaft. More fine fractions are lifted and directed to the shaft II, where the process of particle separation according to the preset fineness (density) ranges occurs once again: medium product is lowered to the bottom of the shaft II and then discharged via the shutter, and the underflow is directed through the upper joining pipe of the classifier along with air into the deposition and aspiration system.

KG air cascade-gravity classifiers operate in the closed air circuit: the air from the deposition system is returned into the classifier and after its purification in the aspiration system it is partially exhausted into the atmosphere.

Multicyclone arrangement

Multicyclone arrangement is used to deposit and discharge the underflow. The classifying complex is equipped with the high performance cyclones, which makes it possible to separate up to 100% of the product with the fineness of more than 5 microns from the dust air mixture. Air from the multicyclone arrangement is returned into the classifying complex for next classification cycle.

Filtration unit

Filtration unit of the complex is used to purify the used air before its discharge. Technological air discharge accounts for no more than 25-30% of the whole required volume. Depending on the operational requirements and conditions, the filtration unit may be either an additional highly efficient multicyclone arrangement for deposition of the residual dust component or a group of bag-type purification filters.

Classification characteristics

Materials classification fineness range in KG classifying complexes is [-10 +0 … -0.8 +0] mm with the possibility of separation of the raw product into 2-3 classes. Fractional makeup of the final products is characterized by low content / inclusion of particles of plus and minus classes.

Standard configuration of the complex provides for rubber coating of the major wear areas. For the purposes of high abrasive materials reprocessing a special series of classifiers with polyurethane coating of the working surfaces is offered.

These solutions help to achieve:

high wear resistance,
long-term reliable operation,
no carry-over of metals into the finished product on its reprocessing.

Raw product fineness:	0-5(10) mm
Raw product permissible humidity:	0-7%
Number of cut points:	1/2/3
Base cut points:	2.5 мм / 0.16 mm or other ones – according to the requirements with the possibility of adjustment in the course of operation within the range of 20% of the base cut points
Productivity:	non-hazardous (=feeding fineness)
Classification efficiency:	by operator, ACS
Adjustment after the servicing idle period	not required

Classifying complex operating range	Typical classification characteristics

Specifications

Currently there are more than 25 KG classifying (screening) complexes operating on the territory of the Russian Federation, Kazakhstan, Ukraine, Belarus, and other CIS countries, which are allocated to different tasks.

1.Model	2.Productivity, t/h	3.Feeding fineness, mm	4.Ground product fineness, mm *	5.Installed capacity, kW	6.Dimensions, mm			7.Weight, t
1.Model	2.Productivity, t/h	3.Feeding fineness, mm	4.Ground product fineness, mm *	5.Installed capacity, kW	L	B	H	7.Weight, t
KG-60-3/2	60	3 / 2	130	23	16900	12100	11000	23
KG-40-3/2	40	3 / 2	95	155	18000	5810	10200	18
KG-30-3/2	30	3 / 2	95	209	14650	5080	9600	16
KG-20-3/2	20	3 / 2	60	315	12100	4950	8200	12
KG-10-3/2	10	3 / 2	60	375	7460	3800	7120	10
KG-5-3/2	5	3 / 2	35	375	6100	3800	6200	8
KG-1-3/2	1	3 / 2	15	375	3200	2100	3150	5

Note:

(4) – Installed capacity index. Power consumption accounts for 60-80% of it 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.

Power consumption, kW/h	0,85-1,5
Replacement parts	Not required
Wear parts	Not required
Use factor	>0,9
Equipment routine inspection (with partial disassembly)	1 per 3 months
Standard maintenance time	No servicing idle periods
Maintenance personnel, number of persons	1
Product quality	Content of impurities from adjacent classes: 5-7%* Classification efficiency: 93-95%* * - under the corresponding moisture and shape