Deflector wheel classifiers are widespread in industry for the separation of powders into fine and coarse powders. Even though this separation process has been known for quite some time, it is not yet fully understood, and existing models fail to precisely predict the separation characteristics. Due to the high throughput of deflector wheel classifiers, it is greatly beneficial to estimate the separation characteristics before the experiment. Here, the developed model critically examines the usual assumptions, such as ideal airflow, neglection of particle–wall and particle–particle interactions, or spherically-shaped particles. First, the investigation of the air flow using a Particle Image Velocimetry (PIV) system showed significant differences to the assumed ideal flow field, then particle sphericity and its influence on the interaction between the particles and the paddles of the deflector wheel was investigated and compared with particle rebound behavior on a static wall. Surprisingly, comminuted glass behaves similarly to comminuted limestone in multiple aspects and not like glass beads. To determine the number of particle–particle collisions, Discrete Element Method (DEM) simulations were performed. The aforementioned aspects found application in the model and the separation behavior was well-estimated.

Triboelectric separation as an inexpensive and environmentally friendly technique could contribute to material-specific sorting. However, the application as a widespread method is limited due to the complexity of the process. In particle wall collisions, various parameters like collision energy and angle, work function of the contact partners, humidity, surface roughness, etc. influence the particle charging in a hardly predictable way. This study investigates the possibilities of forced triboelectric particle charging by applying an electrical potential to the metal contact partner (copper/steel pipe). The variations included different pipe lengths (0.5 m–3 m), particle materials, and particle sizes for limestone. A distinction is made between the net charge of the particles and the positive, negative, and neutral mass fractions. The work functions of the investigated materials vary from about 3.2 eV to >8.5 eV for glass, limestone, artificial slag, and lithium aluminate particles. With the applied high-voltage potential, the particle net charge can be shifted linearly. For limestone, it is shown that the neutral fraction is highest at the Point of Zero Net Charge (PZNC). This observation may identify an approach for the material selective separation of one target component from a multi-material mixture.