Design of Separation Equipments for

Heterogeneous Mixture

Er. RAHUL CHAUDHARI

Assistant Professor

Department of Chemical Engineering

Jaypee University of Engineering and Technology,
Guna, M.P.
Design of Separation Equipments for Heterogeneous Mixture:

Components of heterogeneous mixture can be separated using one or more

appropriate techniques.

These separation processes includes,

Gas-Liquid (vapor-liquid) separation,

Gas-Solid separation (vapor-solid),

Liquid-Liquid separation (immiscible),

Liquid-Solid, and

Solid-Solid separation etc.

These separation can be done by exploiting the differences in density between the
phases.

Gravitational force or centrifugal force can be used to enhance the separation.

The principle methods for the separation of heterogeneous mixtures could be classified as:

1. Cyclone separator

2. Gas-Liquid separator

3. Liquid-Liquid separator

4. Gravity separator

5. Centrifugal separator

6. High speed tubular centrifuge

7. Scrubbers

8. Electrostatic precipitator

9. Hydro cyclone

Table given in next slide shows the general field of application of each type in terms of the particle
size separated, the expected separation efficiency, and the throughput.

It can be used to make a preliminary selection of the type of equipment likely to be suitable for a
particular application.
CYCOLNE SEPARATOR :

Cyclone separators provide a method of removing particulate matter from air or other gas
streams at low cost and low maintenance.

Cyclones are basically centrifugal separators, consists of an upper cylindrical part referred
to as the barrel and a lower conical part referred to as cone.

They simply transform the inertia force of gas particle flows to a centrifugal force by means
of a vortex generated in the cyclone body.

Fig. 1 Fig. 2
The collection efficiency of cyclones varies as a function of density, particle size and
cyclone design.

Cyclone efficiency will generally increase with increases in

1. particle size and/or density

2. inlet duct velocity

3. cyclone body length

4. number of gas revolutions in the cyclone

5. ratio of cyclone body diameter to gas exit diameter

6. inlet dust loading

7. smoothness of the cyclone inner wall

Similarly, cyclone efficiency will decrease with increases in the parameters such as

1. gas viscosity

2. cyclone body diameter

3. gas exit diameter

4. gas inlet duct area

5. gas density

6. leakage of air into the dust outlet.

The efficiency of a cyclone collector is related to the pressure drop across the collector.

This is an indirect measure of the energy required to move the gas through the system.

The pressure drop is a function of the inlet velocity and cyclone diameter.
Fig. 3
Cyclone performance :
Particles are driven to the walls by centrifugal forces (an expression for this force is given
below), losing its momentum and falling down to the cyclone leg.

In the lower section, the gas begins to flow radially inwards to the axis and spins upwards to
the gas outlet duct.

(1)

The main variables describing the cyclone performance are pressure drop, efficiency
and cut diameter.
Cut diameter:

The cut diameter of the cyclone is defined as the size of the particles collected with
50% collection efficiency.

It is an indicator of the size range of particles that can be collected.

1
9 B 2

2Nv
c
d pc (2)

i p
 1 Lc
N Lb
H 2

Where,
N = number of turns inside the device (no units)
H = height of inlet duct (m or ft)
Lb = length of cyclone body (m or ft)
Lc = length (vertical) of cyclone cone (m or ft).
Collection efficiency:

The collection or separation efficiency is most properly defined for a given particle
size.

As mentioned, fractional efficiency is defined as the fraction of particles of a given

size collected in the cyclone.

The fractional efficiency equation of Leith and Licht (1973) is given as:

2 C
1
2 n 2
(3)
Ei 1 e

p d p2 vi
n 1 (4)
18Dc
In previous expression, C is a factor that is a function only of the cyclones dimensions. The
symbol expresses characteristics of the particles and gas and is known as inertia or impaction
parameter.

The value of n is dependent on the cyclone diameter and temperature of the gas stream.

And p times vi expresses the particles initial momentum.

A more popular and an older method of calculating cyclone fractional efficiency and overall
efficiency was developed by Lappel (1951).

He first computed the ratios dp/[dp]cut .

And it is observed that cyclone efficiency correlates in a general way with this ratio.

For a typical cyclone, efficiency will increase as the ratio increases.

1
E 2
d (5)
1 pc
dp
Pressure drop:
Pressure drop across the cyclone is of much importance in a cyclone separator.

The pressure drop significantly affects the performance parameters of a cyclone.

The total pressure drop in a cyclone will be due to the entry and exit losses, and friction
and kinetic energy losses in the cyclone.

Normally most significant pressure drop occurs in the body due to swirl and energy
dissipation.

The idea is that having such an equation, one could work back and optimize the design of
new cyclones.

The empirical equation given by Stairmand (1949) can be used to estimate the pressure
drop.

g 2 2rt 2

P u1 1 2 1 2u2
2

203
re

(6)
P = cyclone pressure drop

g = gas density

u1 = inlet duct velocity

u2 = exit duct velocity

rt = radius of circle to which the centre line of the inlet is tangent

re = radius of exit pipe

= cyclone pressure drop factor is function of radius and

= fc (As/A1) fc= friction factor, taken as 0.005 for gases

As = surface area of cyclone exposed to the spinning fluid For design purposes
this can be taken as equal to the surface area of a cylinder with the
same diameter as the cyclone and length equal to the total height of
the cyclone.
A1 = area of inlet duct
Blue arrow indicates the radius rt

Fig. 4
Fig. 5
Previous equation is for the gas flowing alone, containing no solids. The presence of solid
will increase the pressure drop over that calculated using following equation ,depending on
the solids loading.

(7)

In this equation kc is a dimensionless factor express of cyclone inlet vanes.

kc = 0.5 for cyclones without vanes

kc = 1.0 for cyclone vanes that do not expand the entering gas or touch the outer wall

However,
kc = 2.0 for cyclone vanes that expand and touch the outlet all.
Design of Cyclone Separator:
Design procedures for cyclone separators are given by Stairmand (1951),
Stairmand developed two standard designs for gas-solid cyclones:

A High-Efficiency Cyclone Design A High Throughput Cyclone Design

Fig. 6
Fig. 6
Standard cyclone dimensions:
The performance curves for these designs, obtained experimentally under standard test
conditions are,

Fig. 7
Fig. 7
Scaling equation, for a given separating efficiency,

1
D Q
3 2

d 2 d1 c 2 1 1 2
Dc1 Q2 2 1 (8)

Where,

d1 = mean diameter of particle separated at the standard conditions, at the chosen

separating efficiency,
d2 = mean diameter of the particle separated in the proposed design, at the same
separating efficiency,
DC1 = diameter of the standard cyclone = 8 inches (203 mm),
DC2 = diameter of proposed cyclone, mm,
Q1 = standard flow rate: for high efficiency design = 223 m3/h,
for high throughput design = 669 m3/h,
Q2 = proposed flow rate, m3/h,
1 = solid-fluid density difference in standard conditions = 2000 kg/m3,
2 = density difference, proposed design,
1 = test fluid viscosity (air at 1 atm, 20C) = 0.018 mN s/m2,
2 = viscosity, proposed fluid.
General design procedure:

1. Select either the high-efficiency or high-throughput design, depending on the

performance required.

2. Obtain an estimate of the particle size distribution of the solids in the stream to be
treated.

3. Estimate the number of cyclones needed in parallel.

4. Calculate the cyclone diameter for an inlet velocity of 15 m/s (50 ft/s). Scale the other
cyclone dimensions from Figures

5. Calculate the scale-up factor for the transposition of Figures 10.45a or 1Q.45&.

6. Calculate the cyclone performance and overall efficiency (recovery of solids). If

unsatisfactory try a smaller diameter.

7. Calculate the cyclone pressure drop and if required, select a suitable blower.

8. Cost the system and optimize to make the best use of the pressure drop available, or, if a
blower is required, to give the lowest operating cost.
Design a cyclone to recover solids from a process gas stream. The anticipated particle size
distribution in the inlet gas is given below. The density of the particles is 2500 kg/m3, and
the gas is essentially nitrogen at 150C. The stream volumetric flow-rate is 4000 m3/h, and
the operation is at atmospheric pressure. An 80 per cent recovery of the solids is required.
The performance calculations, using this scaling factor and Figure 7 a, are set out in the
table given next slide.
The collection efficiencies shown in column 4 of the table were read from Figure at the scaled
particle size, column 3. The overall collection efficiency satisfies the specified solids recovery.
The proposed design with dimension in the proportions given in Figure 6a is shown in Figure 8
Fig. 8
5