Improvement of the Separator to Reduce Fibre Loss

This research addresses fibre loss during raw material transport in pneumatic conveying systems in the cotton ginning industry, focusing on structural improvements to separator components. Despite extensive research on pneumatic conveying systems, a critical gap remains: no structural modification has been developed to effectively redirect cotton flow trajectories and minimise mechanical fibre damage during separation. The study is relevant because it aims to eliminate free fibre formation and prevent quality degradation caused by perpendicular air-cotton impacts against the mesh surface within the separator chamber. The objective is to optimise aerodynamic processes and reduce mechanical impacts by installing trapezoidal guides inside the working chamber. The research methodology includes aerodynamic modelling based on two-phase medium motion theory and experimental tests on the SS-15A model separator, where fibre quality parameters were analysed according to ASTM D4605 using the HVI system. The results show that the proposed structural solution shifts the cotton flow tangentially, allowing a 60% reduction in fibre loss for high-grade cotton and a 36% reduction for lower grades. These findings have practical applications in cotton ginneries’ pneumatic transport systems to reduce raw material waste and improve economic efficiency. The study concludes that controlling the flow trajectory within the separator reduces fibre damage by 34% and yields substantial economic benefits per unit per season.

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