Spiral classifier separator

Types of spiral classifier separators

The spiral classifier separator is a useful tool for separating fine ore, such as powder, from heavier particles. It is mainly used in the mining industry but can also be helpful in other industries, such as agriculture. The spiral classifier is usually made of steel and has a spiral blade that moves the settled materials back to the trough for further processing. The settled materials are then dried or worked on further by the production team. Classifiers are usually worked on in conjunction with a dewatering unit or a flotation machine.

The main types of spiral classifiers include:

• Single Spiral Classifier

  The single spiral classifier has the ability to separate ore and water. Once the water and ore are separated, the ore will be transported via the spiral back to the crusher for further processing. The water will be removed by a specific drainage system. This single classifier can be used independently to process certain types of materials or in conjunction with a ball mill to further classify materials that need to be separated further.

• Double Spiral Classifier

  The double spiral classifier carries out the same functions as the single one, but since it has two spirals, it is better able to cope with larger processing needs. The double spiral classifier separator is usually used with a rod or ball mill to help further process ore that needs to be worked on in greater quantities.

• Embedded Spiral Classifier

  This type of spiral classifier is submerged under the water level. It is generally used in the construction and mining industries where there is enough space to conveniently submerge the classifier in water.

• Floating Spiral Classifier

  The floating classifier works in a similar manner to the embedded one, but it is anchored to allow it to remain in position while it separates the ore from the water.

In addition to the above types, spiral classifiers may be further divided according to their specifications, such as spiral classifier for sale with various dimensions, capacities, and other specification requirements.

Specification and maintenance of spiral classifier separators

The specifications of a spiral classifier separator will vary depending on the different models available. However, some basic spiral classifier specifications are as follows.

• Size

  The overall size of the classifier will vary depending on the function it is performing and what type of classifier it is. The overall size of the classifier will determine how much slurry can be processed, the thickness of the settled material, and what particles can be separated.

• Capacity

  Whether it is a cement spiral classifier or any other separator, the classifier's capacity refers to the amount of material it can process in a specific timeframe. The capacity is mainly determined by the size of the equipment and the settling rate of the material in the slurry.

• Power

  The motor power determines the capacity at which the classifier can operate. Larger classifiers may require more power to move the settled material and operate efficiently.

• Materials

  The classifier's structure consists of materials capable of withstanding corrosive substances and abrasion. Depending on the type of separation that is to be carried out, chemicals may or may not be used in the classifier to aid in better separation.

• Spiral design

  All classifiers do not look the same. Some classifiers will have a single spiral or double spirals. The pitch, which is the distance between each turn of the spiral, is also different. Other designs include an arch-shaped transport spiral.

• Incline

  The angle at which the classifier is set up will determine how quickly the settled material is moved. A higher incline will result in a slower discharge rate but improved separation. On the other hand, a lower incline will facilitate a faster discharge but poorer separation.

It is important to carry out regular classifier maintenance procedures to ensure maximum uptime and efficiency and prevent any premature wear and tear. Some recommended maintenance practices are as follows.

• Routine checks:

  Regular visual inspections should be carried out to see if any abnormal signs indicate wear, strain, breakdown, or leakage. The foundation, connections, and fasteners should all be inspected to ensure they are secure and firmly attached. Routine lubrication is critical in the proper functioning of the separator and should be done as required by the manufacturer.

• Clean the equipment:

  Any spilled or excess slurry material should be cleaned up to prevent any material buildup that could lead to equipment breakdown. Aggressive solvents should not be used to clean the equipment as they may damage the classifier.

• Abnormal conditions:

  Any unusual sounds or operating conditions, vibrations, or change in the classifier’s separation efficiency should be investigated immediately. Prompt action should be taken in case of any signs of wear and tear or damage to avoid further breakdown of the spiral classifier and any related equipment.

Scenarios of the spiral classifier separator

Aspiral classifiers are widely used in several industries that mine minerals or treat water. The classifier operates in tandem with a ball mill or granulator to form a closed-circuit recycling system to handle waste water. The classifier can also work as an independent separator to treat waste and extract usable materials.

• Mining and Minerals Processing: The mining industry is the largest user of spiral classifiers. It is used to segregate fine ore particles from coarse ore that needs further processing. Classifiers work well with ball mills to create a closed-loop system. Ground ore is separated into usable fine ore or coarse material that needs more grinding.
• Sand Washing and Aggregates Production: In the stone and construction aggregate industry, spiral classifiers separate sand from stone and dirt. The dirt or other impurities are removed from the sand before it is used in concrete and other construction projects.
• Water Treatment and Waste Management: The water treatment process also uses spiral classifiers to separate contaminants from clean water. Impurities like sand, silt, plastics, and organic matter are removed for further processing or disposal, while clean water continues through the treatment process.
• Soil and Organic Matter Separation: At composting facilities, spiral classifiers can segregate plastic material from compost. The plastics are sent for recycling, while the compost is used for agricultural or landscaping applications.
• Cement and Fine Material Production: Classifiers can combine several materials, including limestone, clay, and gypsum, to form cement. They can also produce other fine materials in several industries, such as the sugar and salt industries.
• Coal and Fly Ash Recovery: Coal power plants can use classifiers to separate fly ash from carbon dioxide during the cooling process. The fly ash is removed and can be sold to the cement industry or further processed for safe disposal.

How to choose a spiral classifier separator

Some important factors and tips are helpful for business buyers to consider when selecting spiral classifiers for their specific purposes:

• Identify specific needs:

  First of all, business buyers need to determine their specific applications and needs so as to select suitable spiral classifiers. They need to take the types of materials they want to deal with, the classifying accuracies they require, the throughputs they need to achieve, and available installation spaces into account.

• Choose proper working principles:

  Business buyers must choose suitable classifiers with appropriate working principles according to their material characteristics and processing needs. For example, if they want to classify materials according to their specific gravities, they can buy air classifiers; if they want to separate materials according to their particle sizes, they may choose screening classifiers.

• Consider classifier designs:

  Spiral classifiers’ designs will affect their operation efficiencies and maintenance conveniences. Business buyers can consider the quality and design of the spiral blades, the structure of the classifiers (e.g., the tank's shape and size), and the materials of the classifier's body.

• Check the parameters:

  Business buyers can evaluate spiral classifiers based on relevant parameters, such as the size range and separation accuracy of the classified particles, the processing capacity (throughput), the motor power, and the dimensions.

• Assess integration and automation:

  In some industrial production settings, integration and automation are important. Business buyers can choose those classifiers that can be easily integrated into existing production lines, and they also have automation functions to facilitate the automation and intelligence of the whole production process.

• Pay attention to energy efficiencies:

  Energy efficiencies of spiral classifiers directly affect enterprises' production costs and environmental responsibilities. Therefore, business buyers need to choose energy-efficient models to consume less power and water during the classifying process.

• Evaluate supplier's service:

  When buying spiral classifiers in bulk, business buyers also need to evaluate the suppliers' services. Apart from the products, the technical support, installation guidance, and after-sales services offered by the suppliers are also important considerations for buyers.

Spiral classifier separator faqs

Q1: What kind of material does the spiral classifier use?

A1: Cast iron is a common use material for spiral classifiers. Cast iron provides the support structure for the spiral shaft and flights because of its sturdy nature. This ensures that the classifier functions correctly and lasts for a long time.

Q2: What are the differences between spiral classifier and hydrocyclone?

A2: A spiral classifier is a separation device that relies on gravity while a hydro-cyclone uses centrifugal force to separate materials. The two devices have different separation size ranges. The spiral classifier can separate coarser particles, usually greater than 70 mesh, while hydro-cyclones are suitable for finer separations, typically up to 200 mesh or even finer.

Q3: Why is the spiral classifier important?

A3: The spiral classifier plays an essential role in water-saving separator sand classifying.

Q4: Does the spiral classifier have any disadvantages?

A4: This type of classifier is relatively slow. It can take a few hours to separate the particles correctly. Moreover, the spiral classifier base has a shallow water pool, which is not ideal if there are a lot of fine particles.