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    Cyclone Fundamentals

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    jayaram432
    Cyclones use centrifugal force to remove particulate matter from gas streams. They are commonly used as precleaners before other air pollution control devices to remove larger particles. Cyclones can be arranged in parallel or series configurations depending on the application and required performance. Key considerations for cyclone design include gas flow rate, particulate size distribution, required collection efficiency, and available space. Cyclones are often an economical option but their performance depends on factors like residence time and pressure drop.

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    Cyclone Fundamentals

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    jayaram432
    72 views61 pages
    Cyclones use centrifugal force to remove particulate matter from gas streams. They are commonly used as precleaners before other air pollution control devices to remove larger particles. Cyclones can be arranged in parallel or series configurations depending on the application and required performance. Key considerations for cyclone design include gas flow rate, particulate size distribution, required collection efficiency, and available space. Cyclones are often an economical option but their performance depends on factors like residence time and pressure drop.

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    Cyclones use centrifugal force to remove particulate matter from gas streams. They are commonly used as precleaners before other air pollution control devices to remove larger particles. Cyclones can be arranged in parallel or series configurations depending on the application and required performance. Key considerations for cyclone design include gas flow rate, particulate size distribution, required collection efficiency, and available space. Cyclones are often an economical option but their performance depends on factors like residence time and pressure drop.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    72 views61 pages

    Cyclone Fundamentals

    Uploaded by

    jayaram432
    Cyclones use centrifugal force to remove particulate matter from gas streams. They are commonly used as precleaners before other air pollution control devices to remove larger particles. Cyclones can be arranged in parallel or series configurations depending on the application and required performance. Key considerations for cyclone design include gas flow rate, particulate size distribution, required collection efficiency, and available space. Cyclones are often an economical option but their performance depends on factors like residence time and pressure drop.

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    Cyclone Fundamentals

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    • Use link from email
    Platform

    Test Here! Track Here!


    PDH Overview
    • Today’s Webinar Value = 1 PDH/CH.
    • Must Be Present for at least 50 Minutes.
    • Must Complete and Pass Test (8 out of 10).
    • Please Print Certificate. (Certification Widget)
    • Keep a Record Log.
    • CECO will Keep Records for Six Years.
    • Contact Mary Rusnak – [email protected]
    with Questions.
    Cyclone Fundamentals Outline
    • Definition and Basic Overview
    • Selection. Wet or Dry?
    • Anatomy and Performance
    • Arrangements
    • Design Considerations
    • Process Design Range
    • NFPA Requirements
    • Troubleshooting
    • Examples
    Poll Question

    How much experience do you have with Cyclones?

    A. I’m an expert
    B. I have some experience
    C. I have a little experience
    D. What is a cyclone?
    Cyclone Definition
    1.As precleaner before scrubber or oxidizer.

    • Cyclone separators are separation devices that use the principle of inertia and
    centrifugal force to remove particulate matter from gas streams.
    • Cyclone separators are one of many air pollution control devices available.
    • Often used as precleaners to remove larger pieces of particulate matter prior
    to another control device. (This prevents finer filtration methods from having
    to deal with larger, more abrasive particles, and reduces the dust loading on
    downstream equipment.)
    • Operation in parallel or series configurations depending on the application.
    • Multi-cyclone Arrangements – many cyclones in parallel.
    • Cyclones can vary drastically in their size depending on gas volume being
    handled and removal efficiency required.
    Example Industries and Processes
    Industries Processes
    • Food & Beverage • Dryers
    • Paper & Pulp • Kilns
    • Chemical • Roasters
    • Petrochemical
    • Nuisance Dust Collection
    • Automotive
    • Shredders
    • Oil & Gas
    • Metals & Mining • Wood Planers / Saws
    • Wood Processing • Fluid Bed Dryers
    • Building Products • Spray Dryers
    1.Cocobean dryer
    2.Shredders in metal and mining:Capture larger pieces of metals.
    3.Chemical:capture of powders of mail process stream
    4.Petrochemica:Fluidbed downstream.Capture excess catalyst in gas
    5.Wood:Recycle material
    Engineering and Design

    • ASME Section VIII, Divisions I & 2


    • ASME Section I
    • ASME STS-1
    • ASME B31.1
    • ASME B31.3
    • AWS D1.1
    • AWS D1.6
    • AISC
    • ASCE 7, IBC
    • GB Code, PED >15 psi os AMSE
    Customized Application
    Custom Materials Custom Design – Interior Custom Design –Exterior

    • Carbon Steel • Polished Ss – Super Mirror • Insulation And Cladding


    • Cr-mo Steels / Electropolish • Steam And Electrical
    • Hsla(high Strength Low • Hex Steel Refractory Tracing
    Alloy) Steels • Dual Layer Insulating • Tube Wrapping And Half-
    • Abrasion Resistant Steels Refractory pipe
    • 300 Series, AL6XN, Duplex • Engineered Alumina Tile • Double Wall, Steam Jacket,
    Stainless Steels • Chrome Carbide Overlay Cooling, Lethal Service,
    • Inconel, Incoloy, And • Rubber Lined Dimple Jacket
    Hastelloy • FRP Lined • Paint And Coatings
    • Aluminum • Ceramic Insert
    • GB Code • Coatings
    90% in Carbon steel (CECO experiance)
    Polished SS : Food industry
    Particulate

    • The typical unit for particle size is the micron (µm) which is 1.0 x 10-6 meters or 1
    millionth of a meter.
    • Solid particles between 1 and 100 μm (microns) in diameter are called dust
    particles (mechanical generation) while solid particles less than 1 μm in diameter
    are called fumes, or smoke (chemical or thermal generation).
    • Particles less than 10 μm (microns) in diameter are of biggest concern to human
    and animal health as they can be easily inhaled and get trapped in the respiratory
    system.
    Particulate Size
    Particulate Size
    Wet or Dry Collections? Why? When?

    Consider Wet Collection when: Consider Dry Collection when:


    • Sticky particulate or humid gas • Water availability/disposal is an issue
    stream • Collected dust must remain dry
    • Explosive/Combustible dust • Contaminant has low moisture
    • Slurry can be reprocessed • Plenty of space available
    • Fumes or acid gases are to be • Simplify system controls
    removed
    • Water is readily available and liquid
    discharge is not a problem
    a)Scrubber :Wet Particles

    Selecting the Correct Solution


    b)Bag house:Fine particle
    c)Cyclone:

    Cyclone Baghouse Scrubber


    Advantages of a Cyclone
    • Often the most economical form of gas/particle separation
    • Simple to operate and maintain
    • No moving parts
    • Severe Service Design:
    • High pressure/vacuum, High Temperature, Erosion,
    Corrosion, Explosive Dusts, etc.…
    • No product contamination
    Cyclone Anatomy
    Cyclone Performance
     Two main factors determine cyclone efficiency
    – How quickly the particle moves towards the wall or
    collection area of the cyclone where it is
    theoretically collected
    – The length of time available for collection: Residence
    Time
     Two main factors describe cyclone performance
    – Pressure drop
    – Fractional efficiency curve (FEC)
    Centrifugal force is proportional to gas speed
    inversally propr to dia of body
    residence time:High efficieny (important for small particle
    size)
    Lager particle:moreeff if cyclones used
    Small partice:Less eff if cyclones used
    Data Required for Cyclone Design
    Mechanical
    Temperature, pressure, corrosion allowance, MOC, paint
    requirement, etc.
    Process
    Gas flow, temperature, pressure, gas density, viscosity,
    particle specific gravity, particle loading, efficiency

    Importance of Aerodynamic Particle size distribution


    (BAHCO micro classifier, liquid sedimentation, cascade
    impaction)
    Design Data and
    Sieve Analysis
    Design Data

    Particle Testing
    • Empirical Testing
    • Aerodynamic Particle Sizing – Liquid
    Sedimentation
    • Why Not Use A Sieve Analysis?
    • Why Use Stokes Diameters?

    FEC is done based on Stokes diamaeter using imperical tests


    Liquid sedementation to form diameter to find stoke dia
    Cyclone Families
    • Multiple Families/Models
    • Multiple Arrangements
    • Optimization For Performance & DP
    Limitations
    • Customization
    Higher residence time ==> Higher efficiency
    Arrangements

    Parallel:Pressure drop is of individual cuclone


    Series:Adds pressure drop
    Parallel Cyclone Arrangements

    Advantages: Disadvantages:
    • Higher collection efficiency • Higher cyclone cost vs a single cyclone
    • Lower energy consumption vs series • Larger footprint
    arrangement • Multiple dust outlets for material
    • Parallel arrangements may provide the handling
    best solution when headroom is
    limited
    Dual Cyclone

    Wood planar mill plant.


    Eliminated need for bag house in downstream
    Large air head with explosion pannels
    Triple Cyclone Arrangements
    Quad Cyclone Arrangement

    Baby powder.
    Six Pack Cyclone
    Eight Pack Cyclone

    Plywood industry
    Downstram of wood drier
    Conveying exhaust to Wet Electro Static Precipitator
    Poll Question

    What are some advantages of Parallel Cyclone Arrangements?

    A. Higher collection efficiency


    B. Lower energy consumption
    C. Multiple dust outlets for material handling
    D. A & B
    E. All of the above
    D
    Series Cyclone Arrangements
    Advantages: Disadvantages:
    • Increased efficiency vs. a single • Increased cost vs a single cyclone
    cyclone • Increased energy usage vs a single or
    • Adds redundancy to the system parallel arrangement – pressure drop
    • First stage can be used to remove adds
    most loading, and second stage can
    be designed for removal of remaining
    fines
    Series:1st:Coarse material :Take bulk of loading:Higher abrasion rate
    2nd:Fine material :Can be designed for lower load
    Velocity vs abrasion?Later
    Series Cyclones
    Dust Receivers

    • Allows material to disengage from


    spinning vortex
    • Reduces abrasion in the cyclone and
    seal device below
    • Proper dimensions are recommended
    to realize full benefit
    • Pyramid or Conical:
    • Pyramid is less expensive
    • Conical for sticky materials and
    higher pressure design
    Different Inlet Types

    CECO:Involute or Wrap around


    Tangential:Standard eff and some high eff
    Axial:multiple cyclones in one:Cast mostly
    Process Design Range of Cyclones: Inlet Velocity

    • Below a certain velocity, solids will not be pneumatically


    conveyed in the cyclone inlet
    • With most materials and processes the inlet velocity should not
    be below 45 ft/s
    • Pressure drop, erosion, and particle attrition are exponential
    functions dependent on inlet velocity.
    • Generally inlet velocity is kept below 80 ft/s although values of up
    to 200 ft/s may be used in certain processes
    45 ft/s : 13.716 m/s
    80 : 25 m/s
    200 : 60.96 m/s
    Process Design Range of Cyclones: Pressure Drop

    • Purely an economic consideration when evaluated


    independently from inlet velocity
    • Normal industrial cyclones are typically between 3” w.c. – 8” w.c.
    • Pressure drops of several PSIG are common with high density
    gasses, series cyclone systems, or special applications

    76.2 mm WC to 203.2 mm WC :Varies


    depends on density
    For ASME cyclones:high PSI
    Process Design Range of Cyclones: Particle Size

    • Real limits are economical: cyclones can be built to provide +50%


    collection at .3 microns, they just aren’t economical
    • Cyclones are currently providing +90% collection on applications with
    average particle sizes of 1.4 microns
    • Cyclones are commonly providing +99% collection on applications
    with average particle sizes in the 5 - 10 micron range
    Difference By Design
    0.05 1.5 % FINES
    OUTLET LOADING, GR/ACF 5% FINES
    0.04 10% FINES

    0.03

    0.02

    0.01 *gr-acf = grains per actual cubic


    foot

    0.00
    XQ465-56 XQ340-40-2 XQ240-28-4 XQ170-28-4 XQ120-28-4
    CYCLONE MODEL AND SIZE
    Length (L/D Ratio) vs. Efficiency
    NFPA DESIGN

    • Cyclones Are Different From


    Baghouses
    • Finite Vent Area
    • Flame Length, L/D Ratio,
    Vessel Volume
    • Higher Pred (Pdes)
    • Dust Receiver Venting
    • Chemical Suppression

    Venting is cyclones?different from baghouses


    Cannot put vent on body or roof.effects design pressure.
    NFPA Design

    Steel Mill – DRI Dust


    • QUAD Cyclone
    • Tile Lining
    • Explosion Vents
    • Chemical Isolation
    NFPA Design

    Metal Dust
    • XQ340
    • Custom Dust Receiver
    • Explosion Vents
    • CO2 Nozzles
    High Efficiency

    Planer Mill
    • NFPA Vented
    • 99.99%+ Eff.
    • Meets EPA Emissions
    • 60,000 ACFM
    • 75 TPH

    Red:Explosion vents
    Common Causes of Performance Problems

    • Improperly Designed
    • Incorrect or Inaccurate Design Data
    • Leakage into the Cyclone
    • Material Buildup Inside Cyclone
    • Wear and Abrasion
    Common Design Problems

    • Short outlet pipes


    • Dished heads
    • Poor or non existent airlocks
    • Instruments or access ports installed into cyclonic flow streams
    • Inlet elbows, transitions, or other obstructions
    Short outlet pipes:Recirculation of dust
    Outlet Pipe Length
    Roof Design

    Flat roof:req for emission test passing.


    Look for Common Design Flaws

    • No Dust Receiver
    • No Airlock
    • Outlet Pipe Design
    • Shallow Cone Angle
    Design Data

    • Measure cyclone pressure


    drop
    • Confirm correct application
    data

    Check pressure drop and gas flow data while trouble shooting
    Check Rotary Airlock for Leakage

    15 rpm??
    Buildup And Dents

    Dents and buildup causes reentrainment and reduces efficieny


    Solutions for Material Buildup

    • Impact vibrator
    • Polishing
    • Coatings
    • Cyclone outlet sizing
    • Discharge device sizing
    • Insulation/Tracing
    Cyclone Erosion
    Cyclone Erosion
    Cyclone Corrosion and Erosion
    High Pressure Designs – Code Vessels

    Fertilizer Industry

    Polypropylene
    Exhaust Plenum
    w/ CIP System
    Platform

    Print Here!

    Test Here! Track Here!


    QUESTIONS?
    THANK YOU FOR ATTENDING!
    Exhaust Plenum
    Body Sections
    w/ CIP System

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