Effects of Flow Baffles on Flow Profile, Pressure Drop and Classification Performance in Classifiers

This paper presents a study of the use of flow baffles inside a centrifugal air classifier. An air classifier belongs to the most widely used classification devices in mills in the mineral industry, which is why there is a great interest in optimizing the process flow and pressure loss. Using Computational Fluid Dynamics (CFD), the flow profile in a classifier without and with flow baffles is systematically compared. In the simulations, turbulence effects are modeled with the realizable k-epsilon model, and the Multiple Reference Frame approach (MRF) is used to represent the rotation of the classifier wheel. The discrete phase model is used to predict the collection efficiency. The effects on the pressure loss and the classification efficiency of the classifier are considered for two operating conditions. In addition, a comparison with experimental data is performed. Firstly, the simulations and experiments show good agreement. Furthermore, the investigations show that the use of flow baffles is suitable for optimizing the flow behavior in the classifier, especially in reducing the pressure loss and therefore energy costs. Moreover, the flow baffles have an impact on the classification performance. The impact depends on the operation conditions, especially the classifier speed. At low classifier speeds, the classifier without flow baffles separates more efficiently; as the speed increases, the classification performance of the classifier with flow baffles improves.