Field Operator Certification

Sturtevant Separator
Learner Guide
 Sturtevant Separator Learner Guide

Introduction
This lesson on Sturtevant Separators, as with your other lessons on Auxiliary Equipment, consists of
two main learning components a self-directed/in-class component and an on-the-job component.
You are expected to complete both components as part of your Certification Program.

Review the remaining information contained in the Introduction section of this document prior to
beginning the Content section. If you have any questions about this information, speak with your
Instructor.

Objectives
Your learning objectives are broken down into two categories learning objectives for the self-
directed/in-class portion of your learning; and, learning objectives for the on-the-job portion of your
learning. They are listed below for your information.

Self-Directed/In-Class Learning Objectives

State the purpose of Sturtevant Separators
Name the main components of Sturtevant Separators
Explain the principle of operation for Sturtevant Separators
State the applications for Sturtevant Separators in cement manufacturing
Describe the running and static inspections for Sturtevant Separators
State common problems and troubleshooting for Sturtevant Separators
State safety concerns related to Sturtevant Separators

On-the-job Learning Objectives

Perform a running inspection on Sturtevant Separators
Perform a static inspection on Sturtevant Separators

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Lesson Outline
The first portion of the lesson, the self-directed/in-class portion, involves reviewing the following
information:

The purpose and basic principle of operation of Sturtevant Separators

A listing and description of the various components of Sturtevant Separators
Various applications of Sturtevant Separators
Inspection points of Sturtevant Separators and basic troubleshooting
Safety concerns related to Sturtevant Separators
Pictures and graphics are included where appropriate to help you understand how Sturtevant
Separators function. At the end of this section, there are a series of questions that you will be
required to answer and review with your Instructor.

The second portion of the lesson, the on-the-job portion, primarily involves the completion of
several inspections on Sturtevant Separators, including both a running and static inspection. When
you are ready to perform these inspections, inform your Instructor.

If you are a new Field Operator, you will complete a series of steps in your OJT portion of this
lesson. These steps are listed below for your information.

Step One
Your Instructor will walk through an inspection procedure with you. At that time
you can ask questions and take down any notes required.
This walkthrough may be completed out in the field or during a meeting with your
Instructor.
Step Two
Your Instructor will demonstrate an inspection procedure in the field.
Step Three
You will conduct an inspection procedure in the field under the supervision of your
Instructor.
Your Instructor will provide you with feedback about your performance during the
inspection.
Step Four
You will complete a full inspection procedure without any assistance from your
Instructor.

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This inspection will be assessed against the inspection checklist contained in this
document. If you achieve 100% on the inspection, you will be certified on it. If you do
not achieve 100% your Instructor will provide you with further feedback and you will
have the opportunity to be re-assessed.
If you are an experienced Field Operator, you may already be quite familiar with inspection
procedures. Discuss this with your Instructor and you may only be required to actually complete
Step Four as discussed above.

Reference Material
NA

Pre-requisites
All auxiliary equipment should be completed prior to taking this lesson

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Sturtevant Separator Learning Content

Purpose
The purpose of the Sturtevant Separator is to divide a given material feed into two separate
streams using air as the carrying medium.
The two resulting material streams are referred to as:
1. Fines: Material that is fine enough to be considered finished product
2. Rejects: Material that will be returned to the process for further size reduction

S EPARATOR DIAGRAM

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Components

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Fines Chamber
Collection chamber for material separated as finished product.
Material from the fines chamber is directed to bulk storage

Tailings Cone
Collection cone for material separated as tailings or rejects
Material from the tailings cone is directed back to the mill for further size reduction

Ring Liner
Wear liner used to protect tailings cone from excessive wear
This unique step liner design promotes material retention within the tailings cone to reduce
wear on the cone structure

Air Vanes
Located below the separation zone and directly on top of the tailings cone
This air vane assembly allows for the circulation of air from the fines chamber back
into the separation zone as ascending air produced by the main fan blades
The air vanes are designed to produce an abrupt change in airflow direction
This abrupt change in direction reduces fines re-entrainment into the separation zone

Outside Casing
Outside support structure for the separators internal components
Is also the external wall for the fines chamber

Outside Casing Liner

Wear liner used to protect the outside casing from material abrasion

Inside Drum
Internal structure used to separate the fines and tailings chamber
The area of the inside drum also defines the separation zone

Inside Drum Liner

Wear liner used to protect the inside drum casing from material impact and abrasion

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Inside Drum Cover

Steel structure fastened to the top of the inside drum designed to support the fineness control
valve
These components define the cut-off point for material at the top of the separation zone

Inside Drum Cover Liner

Replaceable wear liner used to protect the inside drum casing from material abrasion

Valve & Valve Rod

A steel plate and adjustment assembly that rests on top of the inside drum cover
The valve and valve rod assemblies are used to provide online fineness adjustment by
controlling the amount and the direction of the ascending air

Gear Reducer
Used transmit the power from the Separator drive to the main shaft at design speed

Main Shaft
Support and drive element for the main fan blades, upper distribution plate, distributing hub,
and lower distribution plate
The main shaft is protected from material abrasion within the feed cone by a replaceable
shaft liner

Distributing Hub
Support element for the lower distribution plate sections

Distributing Hub Liner

Wear liners used to protect the distributing hub from material impact and abrasion

Lower Distribution Plate

A circular steel disk assembly located below the upper distribution plate
The Lower distribution plate rotates with the main shaft and is designed to disperse the fresh
feed evenly into the Separator

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Intake Cone
The intake cone is the internal structure below the feed chute that is designed to direct the
material to the lower distributing plate

Intake Cone Liner

The intake cone liner is a replaceable wear liner designed to protect the intake cone from
impact and abrasion

Fan Cone
Steel hub assembly used to support the main fan blades and the upper distribution plate

Packing Ring
A labyrinth seal assembly that is designed to seal the annular gap between the dynamic fan
cone and the static feed cone

Upper Distribution Plate

A circular steel disk assembly located between the main fan blades and the lower distribution
plate
The Upper distribution plate rotates with the main shaft and is designed to support the
selector blades

Upper Distribution Plate Liner

A replaceable wear resistant liner designed to protect the underside of the upper distribution
plate from material abrasion

Selector Blade
Steel blades mounted at the outer edge of the upper distribution plate used to control material
fineness

Main Fan Blade

Steel blades that are mounted to the fan cone assembly
These blades rotate with the main shaft and are designed to produce the ascending airflow
within the separation zone

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Principle of Operation
The main fan blades, upper distribution plate and lower distribution plate all rotate at the
same speed on a common shaft
This common shaft is the main gear reducers output shaft
F AN S ELECTOR AND D ISTRIBUTION T ABLE R EDUCER AND M AIN S HAFT

S EPARATOR Z ONES
Fresh feed enters through an inlet chute
located at the top of the Separator
The feed material is directed downward
through a cone surrounding the main shaft
The feed cone directs the material onto a
rotating distribution table located at the
bottom end of the main shaft
The material is thrown off the lower
distribution plate towards the inside drum
It is important that the distribution plate impart enough centrifugal force to the material to
ensure that it enters the separation zone faster than new material is received

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S TURTEVANT F ORCES
The material in the separation zone is
immediately acted upon by three forces :
Centrifugal force imparted by the
rotating distribution plate
The force of gravity
Ascending air flow created by the
main fan blades
Heavier particles immediately fall out of
suspension within the separation zone due to
the force of gravity and are collected in the
tailings cone, and returned to the mill for further size reduction
The ascending air that is created by the main fan blades entrains the finer particles
These particles are further segregated by the selector blades on the upper distribution table
that impart additional centrifugal forces to the material
This material is thrown against the inside drum and returned to the tailings cone
M ATERIAL F LOW
Particles that are fine enough to pass the
selector blades and the change in direction
caused by the control valves are carried
through to the fines chamber
In this respect, the ascending air in the
separation zone now becomes a descending
airflow in the fines chamber
The descending airflow in the fines chamber
returns to the separation zone by the air vanes
located above the top of the tailings cone
The air vanes are designed to create an abrupt change in the direction of the airflow
This change in direction ensures the fines remain in the fines chamber and exit the Separator
This process is also enhanced by reduced air velocity at the location of the air vanes
The air velocity is reduced in this area by an increase in volume in the fines chamber due to
the cone located below the inside drum
Super fine material will pass with the airflow back to the separation zone creating a small
recirculating load within the Separator
Fineness in the Sturtevant Separator can be controlled in one of three ways:

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Main fan blade size and mounting location.(coarse adjustment)

Number of selector blades.(coarse adjustment)
Diaphragm Valve adjustment.(fine adjustment)
An increase in the size of the main fan blades or the positioning of the blades further out on
the support arm will increase the airflow and enable the entrainment of coarser material
through the separation zone and into the fines chamber
The result is a coarser finished product
The opposite adjustment with smaller blades or positioning the blades closer to the main
shaft will decrease the air flow generation and result in a finer finished product
An increase in the number of selector blades will increase the centrifugal force imparted to
the material at the upper distribution plate and as a result send more material back to the
tailings cone
The impact will be a finer finished product
A decrease in the number of selector blades will have the opposite affect and make the
finished product coarser

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D IAPHRAGM V ALVE
The diaphragm valve position is used for
online fineness adjustment within a small
range
The control valves acts like a flow damper on a
centrifugal fan regulating the airflow from the
main fan
Positioning the control valve in towards the
center of the Separator restricts the airflow
from the main fan and through a constant
volume within the Separator, reduces the air
velocity
The reduced velocity allows only finer material to be entrained to the fines chamber and the
result is a finer finished product
D IAPHRAGM V ALVES WITH MT
S EPARATOR
By positioning the control valves out away
from center of the Separator the airflow is
increased and coarser material is entrained to
the fines chamber
The result is coarser finished product
The control valves also create an abrupt
change in direction of the airflow at the top of
the separation zone as it is forced around the
control valves
This change in direction also enhances
separation

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F LASH D RYING (#4)

The Sturtevant Separator is typically
connected to a Dust Collector that vents off of
the fines chamber just below the air vanes
Two inlet ducts are routed through the outer
casing into the tailings cone to provide an air
inlet
These ducts are used for the following
purposes:
Ensures that the Separator operates under
slightly negative pressure
Provide ambient air for material cooling
Provide hot air from an external source in order to flash dry the material, reducing
material moisture content
Generally, the circulation of ambient or hot air through the Separator for drying or cooling
does not modify air velocities within the separation zone and therefore will not impact the
operation of the Separator
Excessive venting beyond the capacity of the Separator will however increase the coarse
fraction in the finished product
In order to achieve the highest separation efficiency:
S TURTEVANT D IAPHRAGM
Provide the highest airflow within the
separator by maximizing fan blade size
and position within the limits of the
Separators drive motor.
Position the diaphragm valves as open
as possible while maintaining enough
control for small fineness adjustments
Add or subtract selector blades to
allow for recommended position of the
diaphragm valve as indicated above

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S TURTEVANT F INENESS C ONTROL

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Applications
Raw Grinding
Finish Grinding

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Inspection Points

Sturtevant Separator Running Inspection

Check For OK

Inspect the condition and support integrity of all safety guards

Inspect the drive motor for material build up on cooling fins and cooling fan inlet screen. Remove build-
up
Palm test the motor casing temperature. If too hot to touch, record temperature with hand pyrometer or
contact thermometer
Inspect drive motor electrical connections for damage or strain
Listen for abnormal noise or vibration in the separator and the separators drive system
Inspect the drives mounting base for damage, cracks, loose bolts,
Inspect the condition of drive components (motor to reducer). V-belt condition and tensioning, sheaves,
direct coupling condition, fluid coupling, intermediate shafts and bearings
Check separator reducer for signs of leaks, verify oil reservoir level and drops of oil to lower bearing
Inspect separator Feed / Fines / Rejects chutes for material leaks
Inspect separator for signs of improper venting or positive pressure
Inspect the position and operation of all control valves. Should be positioned evenly around
circumference and operate freely
Inspect the position of venting control damper. Record static pressure if applicable
Inspect field control station for damage or cable strain. Remove any obstructions for access
Inspect the equipment for general condition cleanliness, damage
Check that all access doors and inspection ports are closed and properly sealed

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Sturtevant Separator Static Inspection - External

Check For OK

Inspect the condition and support integrity of all safety guards

Inspect the drive motor for material build up on cooling fins and cooling fan inlet screen. Remove build-
up
Inspect drive motor electrical connections for damage or strain
Inspect the drives mounting base for damage, cracks, loose bolts
Inspect the condition of drive components (motor to reducer). V-belt condition and tensioning, sheaves,
direct coupling condition, fluid coupling, intermediate shafts and bearings
Check separator reducer for signs of leaks, verify oil reservoir level and drops of oil to lower bearing
Inspect separator Feed / Fines / Rejects chutes for holes or wear
Inspect the position and operation of all control valves. Should be positioned evenly around
circumference and operate freely
Inspect the position and condition of venting control damper
Inspect the condition of separator vent ducts inlet and outlet for wear damage and support integrity
Inspect field control station for damage or cable strain. Remove any obstructions for access
Inspect the equipment for general condition cleanliness, damage
Check that all access doors and inspection ports are closed and properly sealed

Sturtevant Separator Structure Static Inspection Internal

Check For OK

Inspect the condition and support integrity of all main fan blades
Inspect the fan blade support arms for signs of wear, damage, missing bolts
Inspect the condition of all diaphragm control valves / rods, check for freedom of operation and even
positioning around circumference
Inspect inside drum liners for signs of wear or missing bolts
Inspect clearance between selector blades and inside drum cover 3/8 to inch maximum
Inspect the condition and support integrity of all selector blades look for missing bolts, bent blades
Inspect the condition of the upper distribution plate. Inspect top and underside of table
Inspect the condition of the lower distribution plate and liner Inspect top and underside of table
Inspect the condition of the tailings or rejects cone. Position a light inside the fines chamber to identify
holes in the cone
Inspect the condition of the venting ducts both inside the fines chamber and tailings cone

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Sturtevant Separator Structure Static Inspection Internal

Check For OK

Inspect the air vane assembly for damaged or missing vanes, orientation and wear

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Troubleshooting
The following troubleshooting information has been prepared to help you resolve material flow
problems associated with Sturtevant Separator.

T ROUBLESHOOTING L OSS OF M ATERIAL F LOW

Problem Possible Reasons Actions Taken
Grindability of material Investigate material grindability
Loss of fineness
has changed
control Check inside Separator for holes in feed chute or
Control valves are at their tailings cone
maximum Check for physical damage to fan and/or selector blades
All the way
Add or take away selector blades as required. (Used for
in or out
coarse adjustment)
Used for
fine adjustment Inspect diaphragm control valves for freedom of
operation and equal positioning around circumference

Vent lines blocked Visually check vent lines from Dust Collector to
Separator is
separator
positive Dust Collector not
working properly Inspect flow control dampers for damage or wear
Check operation of Dust Collector. Take measurements
in vent lines at Separator
Holes in feed chute or Shut down and check feed chute and tailings cone for
Coarse material
tailings cone holes and wear
(chips) in the
sample Position and/or wear on Inspect drum cover and liners for wear, holes or missing
selector blades bolts
Excessive venting from Dust Collector
Selector blade pattern not Check pattern of selector blades for balance
Separator
balanced
vibrating Check inside Separator for build-up
Build-up
Check for wear on table as it may be flexing
Excessive wear on
Check ports at entry to distribution table for blockage
moving parts causing
flexing
Internal damage
Main fan blade wear Check inside Separator for build-up
Low
performance Aux. blade wear Check for wear on moving parts
Improperly set clearance Check clearance of selector blades to inside drum cover
between aux. blades and Max 3/8 to inch
drum cover liner Check vent lines to Dust Collector
Check Dust Collector operation

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Problem Possible Reasons Actions Taken

Coarse material Check mill ball charge

Excessive wear
Velocities in the Separator Check mill internals for signs of grate damage
indicating fine media in the circulating load
Check flash drying operation. Is Separator seeing all
material or just fines?
Check Separator speed
Wear causing parts to Check inside Separator for missing parts that might
Internal damage
come off have caused damage
Coarse material or mill Check mill discharge grates for a broken grate allowing
balls getting into the balls through
Separator Check inside Separator for excessive wear that allows
rotating table to flex

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Safety Work Page

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Safety
Follow confined space entry procedures when entering a Separator for inspection
Be aware that material and casing temperatures and internal gases may be extremely hot
Be aware that Separator casings may be oxygen deficient due to process gases
Be aware that Separators are controlled automatically and can start and stop at any time
Keep the work area clear of grease, oil, water, and other objects that could cause a slip or a
fall
Keep clothing, fingers, hair, and other parts of the body away from drive components
Inspect all guards for damage and support integrity regularly
Know the location and function of all control stations
Keep all control stations free from obstructions to ensure access at all times
Keep area around Separator clear of obstructions and debris
Report all unsafe conditions or practices immediately

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Review Exercise
Complete each of these questions and review your answers with your Instructor.

1. What is the purpose of the Sturtevant Separator?

2. What 3 main Separator components are fixed to the reducers output shaft and rotate at the
same speed?

3. What three forces are acting on the material within the separation zone?

4. What are the 3 means by which fineness can be controlled in the Sturtevant Separator?

5. Describe the applications for Sturtevant Separators in cement manufacturing?

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6. Describe 5 running inspection points for Sturtevant Separators.

7. Describe 5 static internal inspection points for Sturtevant Separators.

8. Describe 3 reasons that would explain a loss of fineness control in a Sturtevant Separator.

9. List 5 safety hazards associated with the Sturtevant Separator.

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