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    Cyclone Separator

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    Rahul Narang
    This document describes the design and working of cyclones, which are commonly used to remove particles from gas streams. It discusses: - Cyclones use centrifugal force to separate particles from gas based on differences in specific gravity. Gas enters tangentially and follows a helical path, pushing particles outward where they fall to the bottom for collection. - There are different types of cyclones including vertical, horizontal, single, and multi-cyclone designs. Cyclone efficiency increases with particle size/density and depends on design parameters. - The document provides details on calculating cyclone size and efficiency using Stairmand's method, including equations for determining particle cutoff size and pressure drop based on design variables like

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    Cyclone Separator

    Uploaded by

    Rahul Narang
    920 views24 pages
    This document describes the design and working of cyclones, which are commonly used to remove particles from gas streams. It discusses: - Cyclones use centrifugal force to separate particles from gas based on differences in specific gravity. Gas enters tangentially and follows a helical path, pushing particles outward where they fall to the bottom for collection. - There are different types of cyclones including vertical, horizontal, single, and multi-cyclone designs. Cyclone efficiency increases with particle size/density and depends on design parameters. - The document provides details on calculating cyclone size and efficiency using Stairmand's method, including equations for determining particle cutoff size and pressure drop based on design variables like

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    Cyclone Separators

    Original Title

    Cyclone Separator (1)

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    This document describes the design and working of cyclones, which are commonly used to remove particles from gas streams. It discusses: - Cyclones use centrifugal force to separate particles from gas based on differences in specific gravity. Gas enters tangentially and follows a helical path, pushing particles outward where they fall to the bottom for collection. - There are different types of cyclones including vertical, horizontal, single, and multi-cyclone designs. Cyclone efficiency increases with particle size/density and depends on design parameters. - The document provides details on calculating cyclone size and efficiency using Stairmand's method, including equations for determining particle cutoff size and pressure drop based on design variables like

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    920 views24 pages

    Cyclone Separator

    Uploaded by

    Rahul Narang
    This document describes the design and working of cyclones, which are commonly used to remove particles from gas streams. It discusses: - Cyclones use centrifugal force to separate particles from gas based on differences in specific gravity. Gas enters tangentially and follows a helical path, pushing particles outward where they fall to the bottom for collection. - There are different types of cyclones including vertical, horizontal, single, and multi-cyclone designs. Cyclone efficiency increases with particle size/density and depends on design parameters. - The document provides details on calculating cyclone size and efficiency using Stairmand's method, including equations for determining particle cutoff size and pressure drop based on design variables like

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    © All Rights Reserved
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    Download as pptx, pdf, or txt
    of 24

    CYCLONE

    SEPARATOR
    Group 9
    Paras Sood
    Parth Anand
    Pawan Kumar
    Pooja Rathore
    Pranav Sharda
    Pushpendra Kumar
    Rahul Kumar
    Rahul Narang
    Introduction

    Cyclones are mostly used for removing


    industrials dust from air or process
    gases. They are the principal type of gas-
    solid separator
    Most common form of particulate removal
    gas is spun rapidly heavier particulate
    matter to collect on outside of separator
    by centrifugal force, where it is collected
    and removed.
    Working Principle
    As with centrifugation, the driving force behind cyclone
    separation is centrifugal force and the difference in
    specific gravity between the particle and the carrier gas.
    In a Cyclone, the air or vapor containing particulate
    material is forced into along the tangential axis. A helical
    flow pattern is set up within the chamber.
    The centrifugal force causes the particles to migrate to the
    outside of the chamber. Here they fall down to the bottom
    of the cyclone by gravity.
    The air moves up the center of the cyclone and reaches the
    top.
    Lets understand with a diagram
    Lets make it
    more clear
    Vortex
    Finder

    Tangential inlet duct

    Barrel

    Cone

    Dust Collector
    TYPES

    Vertical
    cyclone
    separator
    Horizontal
    cyclone
    separator

    Single
    cyclone
    separator
    Multiple
    cyclone
    separator
    Vertical Cyclone Separator

    Vertical cyclone separators are


    used to remove 99% of free liquids
    and solids 5 microns and larger.
    These separators are particularly
    effective for the removal of solids,
    such as iron sulphides. The high
    efficiency of these separators is
    due to the unique design which
    enables the separator to be
    approximately 1/3 the diameter of a
    conventional separator.
    Single-cyclone separators

    They create a dual vortex to


    separate course from fine
    dust.
    The main vortex spirals
    downward and carries most
    of the coarser dust particles.
    The inner vortex created
    near the bottom of the
    cyclone, spirals upward and
    carries finer dust particles.
    Multi Cyclone separator
    It consist of a number of small-
    diameter cyclones, operating in
    parallel and having a common gas
    inlet and outlet, as shown in the
    figure.
    Multi-clones operate on the same
    principle as cyclones--creating a
    main downward vortex and an
    ascending inner vortex.
    Multi clones are more efficient than
    single cyclones because they are
    longer and smaller in diameter.
    The longer length provides longer
    residence time while the smaller
    diameter creates greater centrifugal
    force. These two factors result in
    better separation of dust
    particulates.
    Horizontal Cyclone Separator

    Low ceilings pose a challenge for high-efficiency


    cyclones due to their long tapered bodies.
    As the dirt-laden gas stream is drawn in to the
    collector, it passes through a stationary spinner
    which imparts a rotational flow and forces
    particulate toward the walls of the collector.
    Because this design does not rely on gravity to bring
    the dust to the hopper like conventional cyclones, its
    operational efficiency is not affected by horizontal
    installation.
    This type of dust collector may be suspended from a
    ceiling, conserving valuable space on the
    manufacturing floor.
    Cyclone Efficiency

    The efficiency of a cyclone has direct effect on the


    pressure drop.
    Higher efficiency cyclones have highest pressure
    drops.

    The collection efficiency of cyclones varies as a


    function of density,
    particle size and cyclone design. Cyclone efficiency
    will generally
    increase with increases in particle size and/or density;
    inlet duct
    velocity; cyclone body length; number of gas
    revolutions in the cyclone;
    ratio of cyclone body diameter to gas exit diameter;
    inlet dust loading;
    smoothness of the cyclone inner wall.
    Cont

    The efficiency of collection of various particles () can be determine


    form the
    empirical relation and graph developed by Lapple 1951.
    Industrial usage
    spray dryers
    power stations
    synthetic detergent production units
    food processing plants

    crushing, separation, grinding and calcining operations in the


    mineral and chemical
    industries
    fossil and wood-waste fired combustion units
    vacuum cleaning machines
    dust sampling equipment
    Advantages

    the collected product remains dry and, can be fabricated from plate metal or, in the
    normally useful. case of smaller
    units,
    low capital investment and maintenance
    costs in most
    applications. can, in some processes, handle sticky or
    tacky solids with
    proper liquid irrigation.
    very compact in most
    applications.
    can separate either solids or liquid
    particulates; sometimes
    can be used under extreme both.
    processing conditions

    no moving parts.

    very robust.
    Some disadvantages of cyclones are:

    low efficiency for particle sizes below their cut-off diameter when operated
    under low solids-
    loading conditions.
    usually higher pressure loss than other separator types, including bag filters
    and low pressure drop scrubbers.
    subject to erosive wear and fouling if solids being processed are abrasive or
    sticky.
    Case Study
    Abstract Air pollution is assuming alarming dimensions from industries, automobiles and
    house hold fuel burning. Cement industry can be classified as highly air polluting industry
    emitting PM (Particulate Matter) into the atmosphere. This pollutant is in the form of PM
    (Particulate Matter) is required to be control by installing air pollution control equipment like
    ESP (Electrostatic Precipitators), Bag houses, Wet scrubbers and cyclone. Cyclone is considered
    to be cheaper having low maintenance cost. The present paper aims at designing of high
    efficiency cyclone by using STAIRMAND METHOD for a tiny cement plant. The efficiency
    achieved with this design is of the order of 91.1 %. Index Terms Air pollution, cyclone, pm
    (particulate matter), tiny cement plant

    STANDARD CYCLONE DESIGN BY STAIRMAND METHOD


    Stairmand developed two standard design for gas-solid cyclones (1) High efficiency
    cyclone and (2) high gas rate cyclone.The performance curve for these design, obtained
    experimentally under standard test conditions, are shown in figure .This curve can be
    transformed to other cyclone sizes and operating conditions by use of the following
    equation, for a given separating efficiency.
    D2= [(DC2/DC1) 3 X Q1/Q2 X 1/2 X 2/1]
    (1) 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,200 C)


    =0.0018 mNs/m2

    2=viscosity of proposed fluid.


    The pressure drop in a cyclone will be due to the entry and
    exist losses along with friction and kinetic energy losses in the
    cyclone. The empirical equation given by Stairmand (1949)
    can be used to estimate the pressure drop:
    P=f/203 {u1^2 [1+22 (2r1/re-1)] +2u2^2 } (2)
    where, P= cyclone pressure drop, millibar,
    pf= gas density, kg/m3 ,
    u1= D inlet duct velocity, m/s,
    u2 =D exit duct velocity, m/s,
    rt= D radius of circle to which the centre line of the inlet is
    tangential, m,
    re =D radius of exit pipe, m,
    = factor ,
    = parameter in ,
    given by:
    =fc As/A1
    Fc= friction factor, taken as 0.005 for gases,
    As= surface area of cyclone exposed to the spinning fluid, m2
    A1= Area of inlet Duct .
    Design Parameter

    a = inlet height
    b = inlet width
    Dx = vortex finder
    diameter
    Ht = total height of
    cyclone
    h = cylinder height
    S = Vortex finder
    diameter
    Bc = cone tip
    diameter
    DESIGN OF HIGH EFFICIENCY CYCLONE BY STAIRMAND METHOD

    As 10 per cent of the particles are below 05m the high-efficiency design will be
    required to give the specified recovery.
    Flow-rate =4000/3600 = 1.11 m3 /s
    Area of inlet duct, at 15 m/s =1.11/15 = 0.07 m2
    Duct area = 0.5 Dc x 0.2 Dc=0.07
    So, Dc = 0.84 m
    This is clearly too large compared with the standard design diameter of 0.203 m.
    Flow-rate per cyclone = 4000/8=500 m3 /h=0.13m3 /s
    Here, area if inlet ducts =0.13/15=0.00925m2
    Now area of inlet duct =0.5Dc x 0.2 Dc=0.1Dc 2 =0.00925 Dc=0.30 meter, which is
    comparatively safe as it is close to standard size diameter of 0.203 meter.
    Density of nitrogen base gas at 150o c =Mol.
    Weight of nitrogen/mol.
    Weight of air xTo K of air at 00 C/To K of gases =28/22.4 x 273/ (273+150) =0.81 kg/m2
    Which is negligible compared with solid particle density.
    Viscosity of nitrogen at 1500 C =viscosity of standard air x 28/22.4 = 0.018x28/22.4 =
    0.023 mNs/m2
    From equation (1)
    D2= [(DC2/DC1) 3 X Q1/Q2 X 1/2 X 2/1] 1/2
    Scaling factor = [(0.30/0.203)3 x 223/500 x 2000/2500 x 0.023/0.018]1/2 =1.20
    The performance calculations, using this scaling factor in the table below:
    Over all collected efficiency =91.1%[6] Hence, the above design of cyclone is
    safe, as the designed efficiency is more than 90%.
    Thus, the dimension of the design cyclone is as under:
    Dc=diameter of cyclone=0.30 m
    Height of inlet duct=Hi=0.5 Dc=0.5x0.3=0.15m
    Width of inlet duct=wi=0.2 Dc =0.2x0.30=0.06 m
    Diameter of out let duct=D0=0.5 Dc =0.5x0.3=0.15m
    Diameter of dust outlet=Dd=0.375xDc =0.375x0.3=0.11m
    Length of cyclone main body = (1.5Dc) =1.5x0.3=L1=0.45m
    Length of cyclone hopper = 2.5Dc=2.5x0.3=L2=0.75m
    Total length of cyclone=L1+L2=1.2m
    A. Pressure Drop Calculation
    Area of inlet duct Ai= Hi xWi=0.15x0.06=0.009 m2
    Cyclone surface area As =xDcx (L1+L2)
    =3.14x0.30x1.35=1.272m2
    Fc taken as 0.005
    =fcxAs/Ai =0.005x1.272/0.009 =0.70
    Here, r1=Dc-Wi/2 = 0.30 -0.06/2 =0.27
    And re=Hi=0.15 Thus rt/re =0.27/0.15=1.8
    From, =0.9 U1 = inlet duct velocity =Flow of
    air/inlet duct area =0.13/0.009 =14.44 m/s
    Area of exit duct =D0 2 /4 =3.14x0.152 /4 =0.017
    m2
    U2=exit velocity =0.13/0.017 =7.64 m/s
    From equation 2
    P=f/203 {U1 2 [1+22 (2r1/re-1)] +2u2 2 }
    =0.81/203[14.442 [1+2x0.92 (2x0.27/0.15 1)]
    +2x7.642 ] =4.80 millibar =480 N/m2

    B. Power Requirement
    W=Q x P =1.11x4.80 =5.33

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