Air separator

Types of Air Separators

An air separator is a piece of equipment used to classify and separate materials based on their density by utilizing air or wind as a separating agent. The air separator is an essential component in various industries like chemical, mining, construction, feeding, recycling, etc. The air separator can be classified into the following based on their mechanism of operation:

• Based on Mechanism of Operation

  An air separator works by utilizing air currents or wind in different forms to provide separation between materials of different densities as they pass through the machine. The following air separators use the same principle but with different mechanisms of separation.

  Trommel Separator: It is a rotating cylindrical drum with holes of different sizes. The material is fed into the drum, where it is allowed to roll and tumble. During this, the trommel uses size distinction to separate air (smaller particles) from its larger counterparts. Because of its simple design and effectiveness, trommel separators are commonly used in recycling and mining industries.

  Vibrating Separator: This separator operates by vibrating. The separator options fish meal plants and animal experiments. The separator adopts a triple vibrating screen model. The incoming material moves through the feeders and then is separated. As the feed material moves, large particles are separated in the first section, medium ones in the second, and fine ones in the third.

  Liquid Air Separator: The liquid separator operates by allowing air bubbles in a liquid stream to rise to the surface. Lighter solids and materials float are skimmed off, while heavier ones sink.

  Drum Air Separator: It works by using a revolving belt. The heavier particles fall off the conveyor belt. The feeder material is first treated with magnets to eliminate magnetic impurities. Then non-magnetic material is fed inside the conveyor belt. The non-magnetic and nonferrous impurities will fall into the drum base.

  Screen Air Separator: This works by screening incoming materials through a screen mesh. Depending on the size holes of used screen, materials are separated by their sizes and fall into different chutes.

• Based on Pressure

  An air separator works by producing nitrogen in blood plasma for diverse purposes. This separator produces nitrogen gas using electrical energy. The nitrogen is then used for industrial air separation. They are used for storing carbon dioxide and liquid gases under high pressure.

  Low-Pressure Air Separator: This separator ensures that the materials pass through at a lower pressure. The machine provides a pressure range of about 300 to 1000 Pascals by using an axial fan or blower.

  High-Pressure Air Separator: This works by employing a centrifugal compressor to produce a high pressure of about 2000–3000 kPa. They are suitable for heavy-load work for minerals like bauxite, iron, and copper.

Specifications and maintenance of air separators

Specifications

• Air separator dimensions: The overall dimensions of the air separator. For example, the length, width, and height dimensions of 6-inch air separators are 152.4 x 152.4 x 304.8 mm.
• Inlet and outlet size: The sizes of the inlets and outlets of air separators are compatible with pipeline systems. For 6-inch air separators, the inlet and outlet sizes are 152.4 mm.
• Material: The materials used to manufacture an air separator, such as carbon steel, stainless steel, etc. For example, the body material of the air separator is mild steel, and the connection type is a welded type.
• Pressure rating: It indicates the applicable pressure grade of the air separator. An air separator with a higher pressure rating can adapt to a system of high pressure.
• Separator efficiency: This is the performance of an air separator in removing air. Efficiency may be evaluated based on factors like removal rates and separation factors.
• Working temperature: The working temperature of the air separator determines the types of materials and structures that can withstand them. For example, the working temperature of the air separator is less than 120 °C. High or low temperatures may affect the performance of the separator.

Maintenance tips

• Inspection: Inspect the air separator regularly to monitor the working status of it. Check whether the air outlet is unblocked, whether there is air leakage or water leakage, and whether the fasteners are loose or not, etc.
• Cleaning: In order to keep the functionality of the air separator, the separators should be cleaned and maintained. Remove the dirt and debris on it so that the air inlets and outlets remain unblocked. Use clean water to flush the interior of the separator to avoid the accumulation of impurities.
• Anti-rust treatment: The air separator should be prevented from getting rusty, which may damage its equipment quality and working performance. Apply anti-rust paint or coatings on the air separator and anti-rust treatment for the exposed metal parts or carry out regular anti-rust treatments.
• Fastener checking: Regularly check fasteners, such as bolts and nuts, in the air separators. Make sure they are fastened tightly and eliminated safety hazards. If they become loose, they should be fastened in time.
• Pay attention to the temperature and pressure: Maintain air separators' working temperature and pressure within the scope of specification requirements. Avoid operating at excessively high temperatures or pressures, which may damage the separator and system.

Applications of air separators

Industrial air separators are important for businesses in a variety of industries. Here are a few of the businesses that use air separators:

• Mining companies

  The mining industry utilizes air separators to separate minerals from their ores. This is most prevalent in the separation of gold from ore using cyanide solutions, where an air separator is utilized in the agitation leaching tanks to ensure efficient gold extraction. Some separators also separate tailings from valuable minerals, thereby preventing environmental pollution.

• Cement manufacturers

  Cement manufacturers utilize air separators to efficiently separate fine cement particles from larger ones. The air separators help to recycle coarser particles back into the grinding mill, thus improving the mill's productivity, cement quality, and energy consumption.

• Food and beverage producers

  Food and beverage producers, like breweries, use air separators during fermentation to separate carbon dioxide from the air, which is important for beer quality. Additionally, some dairy processors use air separators to separate cream from milk and process emulsions.

• Recycling facilities

  Recycling facilities employ air separators to separate valuable recyclable materials from waste streams. For example, heavy plastics and non-organic matter can be separated from organic materials like leaves and papers using air separators.

• Textile manufacturers

  Textile manufacturers often face the problem of separating air from fibers, such as cotton, wool, or synthetic fibers. Air separators do this by removing excess air trapped within fiber lumps, which increases the subsequent processing efficiency.

• Pharmaceutical companies

  Pharmaceutical companies use air separators to separate target compounds from different reaction mixtures or to separate unwanted by-products. Air separation promotes purification and concentration in drug development and production.

How to Choose Air Separators

• Understand Requirements:

  It is essential to determine the specific needs before selecting an air separator. Consider factors such as the application, system design, and flow rate. Take note of the requirements, including the temperature range, pressure fluctuations, and particle sizes.

• Separator Types:

  Understand the different types of air separators. An air cyclone separator uses centrifugal forces to separate air from liquids. A hydrophobic filter can separate gases from liquids using filter membranes. Working knowledge of these two types of air separators can guide individuals toward separators that will work efficiently with their systems.

• Compatibility:

  Choose an air separator that is compatible with the system components. Ensure proper fit and functionality to prevent leaks and maintain system integrity. To maximize the performance and efficiency of their air separators, consider air separators with automatic venting capabilities. Automatic venting systems use sensors and microprocessors to detect and eliminate air.

• Quality and Reliability:

  Select air separators from reputable manufacturers with a track record of producing quality and reliable products. Research supplier ratings and customer feedback to make an informed decision. Choose air separators made from durable materials that withstand system conditions and provide long-term performance.

• Ease of Maintenance:

  Consider the maintenance requirements of the air separator. Choose separators that are easy to clean, inspect, and maintain, reducing downtime and maintenance costs. Opt for air separators with clear maintenance instructions and readily accessible components.

FAQ

Q1: What are the differences between an air separator and an air vent in a hydronic system?

A1: Both devices aim to release air from the system but follow different methodologies. An air separator utilizes centrifugal force to segregate air bubbles from the water. Once the air bubbles are separated, they rise to a specific head and get trapped in the expansion tank or a dedicated air separation vessel. The water, free of air, then returns to the hydronic loop. On the other hand, an air vent is a small floating device in a valve that permits air to exit the system while water is unable to enter.

Q2: How often should a separator be checked for performance and potential clogging?

A2: It is generally recommended to inspect the separator at least once a year. However, the frequency of inspection may vary depending on the size and complexity of the hydronic system and the separator's capacity. If the separator is found to be clogged during an inspection, it should be cleaned or replaced immediately to maintain the hydronic system's performance and efficiency.

Q3: Can air separators be installed in existing hydraulic systems, or are they only for new installations?

A3: Air separators can be added to existing hydronic systems provided that the air separator's size and specifications match the existing system's requirements. However, determining the correct size and location of the air separator in an existing system can be more difficult than in a new installation. It may be necessary to evaluate the performance of the existing system and air separators' potential benefits before deciding to add one.