Evaluation of the performance of the cross-flow air classifier in manufactured sand processing via CFD–DEM simulations

Abstract

Manufactured sands are particulate materials obtained as by product of rock crushing. Particle sizes in the sand can be as high as 6 mm and as low as a few microns. The concrete industry has been increasingly using these sands as fine aggregates to replace natural sands. The main shortcoming is the excess of particles smaller than < 0.075 mm (Dust). This problem has been traditionally solved by a washing process. Air classification is being studied to replace the washing process and avoid the use of water. The complex classification process can only been understood with the aid of CFD–DEM simulations. This paper evaluates the applicability of a cross-flow air classifier to reduce the amount of dust in manufactured sands. Computational fluid dynamics (CFD) and discrete element modelling (DEM) were used for the assessment. Results show that the correct classification set up improves the size distribution of the raw materials. The cross-flow air classification is found to be influenced by the particle size distribution and the turbulence inside the chamber. The classifier can be re-designed to work at low inlet velocities to produce manufactured sand for the concrete industry.