The deflector wheel classifier is a widely used device for the separation of fine powders in different industrial applications. The primary objective of the separation process is to achieve high-quality separation of fine powders characterized by a narrow particle size distribution and high separation sharpness. Theoretically, the reduction in the cut size is accomplished by decreasing the gas flow rate or increasing the rotational speed of the classifier, which amplifies the centrifugal forces compared to the drag forces exerted on the particles. This behavior is, indeed, observed in many cases, but it cannot be extrapolated arbitrarily. At their performance limit, classifiers may, against expectation, show an increase in cut size and, in addition, a reduction in the sharpness of the separation process. The limitation in the reduction in the cut size and in the improvement in the separation sharpness arises due to an imbalance between the operating rotational speed and flow rate, which results in a non-uniform flow field in the classifier. If the balance conditions are fulfilled, an optimum separation with a high separation sharpness can be achieved. In this work, CFD simulations validated by some experimental results are employed to represent this limitation, which is obtained by varying the operating parameters using different material densities with particles ranging from one to ten microns.

The increasing use of lithium-containing materials highlights the urgent need for their recycling to preserve resources and protect the environment. Lithium-containing slags, produced during the pyrometallurgical process in lithium-ion battery recycling, represent an essential resource for lithium recovery efforts. While multiple methods for lithium recycling exist, it is crucial to emphasize environmentally sustainable approaches. This study employs dry forced triboelectrification (FTC) to recover valuable components from slag powder, commonly known as engineered artificial minerals (EnAMs). The FTC method is used to change the charge of the target material and achieve a neutral state while other materials remain charged. The downstream electrostatic separator enables the charged particles to be separated from the target material, which in this study is lithium aluminate. The results show that the method is effective, and lithium aluminate can be successfully enriched.

In this study, a two-dimensional separation of microparticles based on their settling velocity and triboelectric charge ability is achieved using an air classifier for size fractionation and simultaneous charging, followed by an electrostatic separator. In the first part, considerations for enhancing particle classification with high sharpness and low-pressure drops are discussed through improvements in blade design investigated with CFD simulations and validated experimentally. Blades with extended lengths towards the center of the classifier prevent the formation of high-velocity vortices, thereby minimizing the back-mixing of particles and enhancing separation sharpness. This approach also reduces pressure drops associated with these flow vortices. In the second part of the study, the modified blades within the classifier are utilized for two-dimensional separation. Powders from two different materials are fed into the classification system, where particles become triboelectrically charged, mainly through collisions with the walls of the classification system components. Coarse particles are rejected at the wheel and exit the classifier, while differently charged fine particles of the two materials are directed into an electrostatic separator for material sorting. An enrichment of approximately 25–35% for both materials has been achieved on the electrodes of the separator.

Lithium‐containing components in batteries, electronics, and renewable energy pose material and waste challenges. Ongoing research focuses on eco‐friendly recycling, emphasizing electrostatic separation as a method to recover, for instance, lithium, especially in battery recycling. This study investigates forced dry triboelectric charging and electrostatic separation of powdered materials, with a focus on the charging behavior of lithium aluminate and talcum. The electrostatic separation efficiency for a blend of powders is also evaluated. Collected samples are analyzed via inductively coupled plasma‐mass spectrometry testing to assess component enrichment. Results show successful lithium enrichment from a talcum‐lithium aluminate mixture, highlighting significant separation success.