SEMINAR REPORT

ON
CYCLONE PRECIPITATOR: DESIGN
PARAMETERS
BY
NITIN PATEL
(M. TECH, 1ST YEAR, VJTI)

CYCLONE PRECIPITATOR: DESIGN

PARAMETERS
1. INTRODUCTION
Cyclones provide a relatively low-cost method of removing particulate matter from
exhaust gas streams. Cyclones are somewhat more complicated in design than simple
gravity settling systems, and their removal efficiency is accordingly much better than that
of settling chambers. However, cyclones are not as efficient as electrostatic precipitators,
baghouses, and venturi scrubbers but are often installed as pre-cleaners before these more
effective devices.
Cyclones come in many sizes and shapes and have no moving parts. From the small
1 and 2-cm diameter source sampling cyclones used for particle size analysis to the large
5 m diameter cyclone separators used after wet scrubbers, the basic separation principle
remains the same. Particles enter the device with the flowing gas (Figure 1); the gas
stream is forced to turn, but the larger particles have more momentum and cannot turn
with the gas. These larger particles impact and fall down the cyclone wall and are
collected in a hopper. The gas stream actually turns a number of times in a helical pattern,
much like the funnel of a tornado. The repeated turnings provide many opportunities for
particles to pass through the streamlines, thus hitting the cyclone wall.
The range of particle sizes collected in a cyclone is dependent upon the overall diameter
and relative dimensions of the device.

Figure 1 Particle collection process

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Various refinements such as the use of skimmers, turning vanes, and water sprays can in
some cases improve efficiency. Using cyclones in series or in parallel can provide further
alternatives for improving overall collection efficiency.
Three types of cyclones are shown in Figure 2. The first diagram, Figure 2a shows a
typical tangential entry cyclone arrangement. These cyclones have a distinctive and easily
recognized form and can be found in almost any industrial area of a town or a cityat
lumber companies, feed mills, cement plants, power plants, smelters, and at many other
process industrial sites. Since top inlet-type cyclones are so widely used, most of this
chapter will be devoted to their operational characteristics.

Figure 2 Types of cyclones: (a) top inlet; (b) axial inlet; (c) bottom inlet.

In axial entry cyclones, Figure 2b, the gas inlet is parallel to the axis of the cyclone body.
Here, the exhaust process gases enter from the top and are directed into a vortex pattern
by the vanes attached to the central tube. Axial entry cyclones are commonly used in
multi cyclone configurations; these units generally provide higher efficiencies.
The larger cyclonic-type separator shown in Figure 2c is often used after wet scrubbers to
collect particulate matter entrained in water droplets. The gas enters tangentially at the
bottom of the unit, forming a vortex. The large water droplets are forced against the walls
and are removed from the gas stream.
There are other variations in the design of cyclones. They are usually characterized by
where the gas enters and exits the cyclone body (tangentially, axially, or peripherally).
There are four major parts to a cyclone. These are also shown in Figure 2. The inlet, the
cyclone body, the dust discharge system, and the outlet all affect the overall efficiency of
the cyclone. Gas is directed into the cyclone by the inlet, which is instrumental in the
formation of the vortex. In the cyclone body the particulate matter is forced to the wall.
The gas continues down the cyclone body to the cone, which gives the gas enough
rotational velocity to keep the particulates against the wall. At the bottom of the cone, the
gas changes direction from downward to upward. The ascending vortex enters a tube
extension that is sometimes called a vortex finder and exits the cyclone. Meanwhile, the
collected particulate matter drops into a hopper, where it is periodically or continuously
removed.

Figure 3 Nomenclature for a tangential entry cyclone.

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The removal efficiency of a cyclone for a given size particle is very dependent on the
cyclone dimensions. The efficiency at a given volumetric flow rate is most affected by
the diameter. The overall length determines the number of turns of the vortex. The greater
the number of turns, the greater the efficiency. The length and width of the inlet are also
important, since the smaller the inlet, the greater the inlet velocity becomes. A greater
inlet velocity gives greater efficiency but also increases the pressure drop.
Consider the dimensions shown in Figure 3. Many different types of cyclones have been
designed by merely varying the dimensions highlighted in Figure 3. Table 1 gives
dimensional characteristics of a number of designs reported in the literature. Dimensions
are given relative to the body diameter Dc.
High-efficiency cyclones generally have smaller inlet and exit areas with a smaller body
diameter and possibly longer overall length. A conventional cyclone will be412 ft (1.2
3.6 m) in diameter, with a pressure drop of 25 inches (513 cm) of water. A highefficiency cyclone will be less than 3 ft (0.9 m) in diameter with a pressure drop of 26
inches (515 cm) of water.
TABLE 1 Dimensionless Design Ratios for Tangential Entry Cyclones

Figure 4 Cyclones in series.

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It should be apparent from the discussion above that small cyclones are more efficient
than large cyclones. Small cyclones, however, have a higher pressure drop and are limited
with respect to volumetric flow rates. Smaller cyclones can be arranged either in series or
in parallel to substantially increase efficiency at lower pressure drops.
These gains are somewhat offset, however, by increased cost and maintenance problems.
Multi-cyclone arrangements also tend to plug more easily. When common hoppers are
used in such arrangements, different flows through cyclones can lead to re-entrainment
problems.
A typical series arrangement is shown in Figure 4. Larger particles can be collected in the
first cyclone and a smaller, more efficient cyclone can collect smaller particles. Such an
arrangement can reduce dust loading in the second cyclone and avoid problems of
abrasion and plugging. Also, if the first cyclone should plug, there still will be some
collection occurring in the second cyclone. The additional pressure drop produced by the
second cyclone adds to the overall pressure drop of the system. The higher pressure drop
can be a disadvantage in such a series system design.
Many types of parallel arrangements have been designed for cyclones. An example of a
parallel arrangement using tangential entry cyclones is shown in Figure 5. With batteries
of cyclones using a common inlet plenum, higher volumes of gas can be treated at
reasonable pressure drops. In configurations where a common hopper is used, each
cyclone should have the same pressure drop or the gas will preferentially channel through
one cyclone or several cyclones.

Figure 5 Battery of four involute cyclones in parallel

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Another type of parallel arrangement uses the axial entry cyclone. Arrangements of highefficiency, small-diameter axial cyclones can provide increases in collection efficiency
with corresponding reductions in pressure drop, space, and cost. Such a multi-clone
arrangement is shown in Figure 6. Pressure drops commonly range from 4 to 6 inches
(from 10 to 15 cm) of water.
The axial entry minimizes the eddy formation that is common in tangential entry
cyclones. Here, the inlet guide vanes create the vortex. Care must be taken in designing
the inlet plenum for the multi-clone since the inlet exhaust gas should have an even
distribution to each individual cyclone. Sticky materials should not be collected using
multi-clones since the vanes and smaller outlet tubes are prone to plugging.

Figure 6 Battery of vane axial cyclones.

Reentrainment can be minimized by making the cyclone hopper large in volume and deep
enough so that the collected dust level will lie below the point where the vortex ends. The
addition of a mechanical valve that can periodically or continually remove the dust from
the cyclone can effectively reduce inflow from the hopper. A number of designs are
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shown in Figures 710. These designs are often employed with electrostatic precipitators
and baghouses.
A valve between the cyclone and the bin can be a simple manual device as shown in
Figure 7, or can provide a continuous discharge as with the rotary valve and screw feeder
shown in Figures 8 and 9. Automatic flap valves shown in Figure 10 can periodically
swing to discharge accumulated dust in a double-valve arrangement.
Cyclone efficiency can also be improved if a portion of the flue gas is drawn through the
hopper. An additional vane or lower pressure duct can provide this flow. However, it may
then become necessary to recirculate or otherwise treat this purge exhaust to remove
uncollected particulate matter.

Figure 7 simple manual slide gates

Figure 8 Rotary valve

Figure 9 Discharge screw feeder

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Figure 10 automatic flap valves

2. DESIGN AND PERFORMANCE EQUATIONS

2.1 DESIGN
The design of cyclones is usually based on seven geometrical relations of the below
mentioned dimensions. These dimensions, when expressed as fractions of the body
diameter Dc, are fixed for a given cyclone family that can also be subdivided, according
to their use (high efficiency, high flow rate, general purpose). Table 2 from lists the
dimensional relations for the classical Lapple, Stairmand, and Swift cyclone families and
includes a criterion for the adoption of Dc based on the gas volumetric flow rate (in m3/h).
TABLE 2 Dimensions for the Design of Standard Cyclones

2.2 FORCE EXERTED ON PARTICLES

Objects moving in circular paths tend to move away from the center of their motion. The
object moves outward as if a force is pushing it out. This force is known as centrifugal
force. The whirling motion of the gas in a cyclone causes particulate matter in the gas to
sense this force and move out to the walls. An expression for this force is as follows:

(1)

The term F is the force that the particulate matter experiences in a cyclone. The larger the
mass, the greater the force. The tendency to move toward the walls is consequently
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increased and larger particles are more easily collected. The reason why all of the
particles do not move to the wall is because of the drag resistance of the air. The buffeting
molecules in the gas resist the outward motion and act like an opposing force. Particles
move to the wall when the centrifugal force is greater than the opposing drag force.
Note also from Equation (1) that as r (the radius of the circular path) decreases, the force
increases. This is why smaller cyclones are more efficient for the collection of smallersized particles than are large cyclones.
These types of considerations, in conjunction with considerations of cyclone geometry
and vortex formation, have led to the development of numerous performance equations.
These equations attempt to characterize the behavior of cyclones. Some work well, and
some do not. None adequately describe performance under all operating conditions such
as at high pressure and high temperatures.
Three important parameters can be used to characterize cyclone performance:

2.3 CUT DIAMETER

The cut diameter is defined as the size (diameter) of particles collected with 50%
efficiency.
It is a convenient way of defining efficiency for a control device since it provides
information on the effectiveness for a particle size range. A frequently used expression
for cut diameter is

.. (2)

The cut diameter is a characteristic of the control device and should not be confused with
the geometric mean particle diameter of the size distribution.
Figure 11 shows a size efficiency curve and points out the cut diameter and the critical
diameter, [dp]crit, the particle size collected at 100% efficiency. Values of
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[dp]crit are difficult to obtain from such curves so the cut size is often determined
instead.

Figure 11 Typical size efficiency curve.

The expression for the cut diameter Equation (2) has been found to agree with some
experimental data. However, other experimental work has shown limitations to its
application. A high-efficiency cyclone can have a cut diameter of typically 510 mm.
Equation (2) is typical of most of those devised for determining the cut or critical
diameter. Note that an increase in the number of turns, inlet velocity, or the particle
density will decrease the cut size as one would expect. A decrease in viscosity will
decrease the drag force opposing the centrifugal force and therefore also reduce the cut
size (i.e., smaller particles will be collected).
2.4 COLLECTION EFFICIENCY
A number of equations have been developed for determining the fractional cyclone
efficiency Ei for a given size particle. As noted earlier, fractional efficiency is defined as
the fraction of particles of a given size collected in the cyclone, compared to those of that
size going into the cyclone.
No efficiency theory or calculation method provides a description for all cyclones. The
modification of inlets and outlets, addition of fines educators, etc., introduce variables
that are difficult to treat theoretically. Although theoretical efficiencies can give
estimations of cyclone performance, it should be kept in mind that designers of
equipment commonly rely on comparative evaluations between similar designs and on
experience.
i.

Theoretical collection efficiency

The force balance between centrifugal and drag forces determines the velocity of the
particles toward the wall. Resident time of particles in the cyclone, which allows time for
particles to move toward the wall, is determined by the number of effective turns that the
gas path makes within the cyclone body. An empirical relationship for the number of
effective turns is provided in Equation
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 (3)

The theoretical efficiency of a cyclone can be calculated by balancing the terminal

velocity with the residence time resulting from a distance traveled in the cyclone. This
force and time balance results in Equation

.. (4)

ii.

Lapples efficiency correlation

Unfortunately, the theoretical efficiency relationship derived above does not correlate
well with real data. The relationship works reasonably well for determining the 50% cut
diameter (the diameter of the particle that is collected with 50% efficiency). To better
match data with reasonable accuracy, the efficiency of other particle diameters can be
determined from Lapples empirical efficiency correlation, which is shown in Figure 12.
This correlation can be set up for automated calculations using the algebraic fit given by
Equation 5:

. (5)

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Figure 12 Lapples efficiency curve.

iii.

Leith and licht efficiency model

Other models have been developed to predict cyclone performance. One is the Leith and
Licht model shown in Equation 6:
. (6)

(6a)

(6b)

.. (6c)

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iv.

The barth model

The Barth model (12) predicts the collection efficiency as a function of the relation
between the terminal velocities of a particle of a given diameter and the particle collected
with 50% efficiency, which has equal probability of being or not collected. For a particle
of diameter Di, the efficiency is thus given by

(7)
Where Vts and Vtsm are the terminal velocities for the particle and for the one with 50%
collection respectively. The ratio Vts / Vtsm can be related to the mean radial velocity of
the gas in the central axis of the cyclone, where the maximum tangential velocity, V tmax,
occurs. Assuming Stokes law and negligible gas density, this ratio can be expressed as

. (7a)
The height of the cyclone central axis, hm, is limited by the gas exit duct diameter,
De, and by the dust exit diameter, B, and can be estimated from Eq (7b) & (7c)
.. (7b)

. (7c)
According to Barth, the maximum tangential velocity,Vtmax, can be obtained by the
following correlation:

. (7d)
where V0 is gas velocity at the cyclone exit, given by

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.. (7e)
The parameter is the friction factor, for which the value 0.02 is suggested. The
parameter can be related to the dimensions b and Dc by
. (7f)
2.5 PRESSURE DROP
The pressure drop across a cyclone is an important parameter to the purchaser of such
equipment. Increased pressure drop means greater costs for power to move an exhaust
gas through the control device. With cyclones, an increase in pressure drop usually means
that there will be an improvement in collection efficiency (one exception to this is the use
of pressure recovery devices attached to the exit tube; these reduce the pressure drop but
do not adversely affect collection efficiency). For these reasons, there have been many
attempts to predict pressure drops from design variables. The idea is that having such an
equation, one could work back and optimize the design of new cyclones.
An expression occasionally used is

.. (8)
Where q = volumetric flow rate.
(In this case kc is a dimensionless factor descriptive of cyclone inlet vanes. It is equal to
0.5 for cyclones without vanes, 1.0 for vanes that do not expand the entering gas or touch
the outlet wall, and 2.0 for vanes that expand and touch the outlet wall.)
The most popular of the empirical pressure drop equations has the form
consistent units ..(9)
Where Kc = a proportionality factor.
Pressure drops for single cyclones vary depending on both size and design. Common
ranges are
Low-efficiency cyclones
Medium-efficiency cyclones
High-efficiency cyclones

24 in H2O (510 cm H2O)

46 in H2O (1015 cm H2O)
810 in H2O (2025 cm H2O)

2.6 OTHER RELATIONS OF INTEREST

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i.

Cyclones in parallel (multicyclones)

The pressure drop in multicyclones (dozens, or even hundreds of cyclones associated in

parallel) can be estimated by Eq. (10), which is a function of the total volumetric flow
rate, Q, the geometrical parameters Ka and Kb, and the diameter of the cyclone body, Dc :

.. (10)
Multicyclones present a P considerably smaller than a single cyclone, for the same
collection efficiency.
Nevertheless, the difficulties arising from distributing the dust-laden gas uniformly
among the cyclones results, in practice, in smaller collection efficiencies than that
predicted by Equations.
ii.

Cyclones in Series

In case a second cyclone in series is needed, it is necessary to calculate the size

distribution in the exit of the first cyclone, which will be the feed of the next. This size
distribution is easily obtained from a mass balance for each mass fraction that can be
expressed in terms of mass flow rate of particles with diameter D i at the exit by the
relation
(11)
Therefore, the size fraction of a particle of diameter Di at the first cyclone exit is

(12)

3. OPERATION
AND
PERFORMANCE

MAINTENANCE,

AND

IMPROVING

There are many operating variables in cyclone performance. These include characteristics
of both the gas and the particles. Gas operating variables include temperature, pressure,
and composition. Dust characteristics include size, size distribution, shape, density, and
concentration.
As the temperature of a gas increases, its density decreases while its viscosity increases.
Since the gas density is negligible compared to the particle density, this has no direct
effect on efficiency. A higher temperature will increase the inlet velocity, increasing the
particle velocity toward the wall. However, the increasing viscosity decreases the particle
velocity toward the wall. The net effect of this is that within the normal operating range
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of 40700o F the collection efficiency is essentially constant. As the temperature rises

above 1000o F, the viscosity effect dominates, causing a decrease in efficiency. The gas
composition can also affect gas viscosity and density.
The influence of gravity on the dust separation in a cyclone is slight, so that the efficiency
is almost independent of the position of the cyclone. Separations remain satisfactory
whether the cyclone is vertical, horizontal, or even upside-down with the dust carried off
upward from the cyclone. A good cyclone separates the dust satisfactorily in any position.
However, coarse particles of dust may keep rotating in the conical part of the cyclone,
never reaching the outlet. This difficulty can arise no matter how the cyclone is
positioned, but less so if the cyclone is in its normal vertical position.
To operate efficiently, cyclone dust collectors should be airtight. Gaskets must be used to
close the gaps between flanges. For axial entry collectors, header sheets must be sealed
without any breaks in the welds. All doors, ports, and poke holes should also be sealed to
prevent reentrainment. Since there is always some fine dust particles suspended in the air,
even slight leaks can cause reentrainment and escape of dust particles from the cyclone.
Detection of leaks in cyclones is not very complicated. Bright floodlights can be used to
check for leaks. Erosion holes, gasket leakage, and weld breaks can be detected by
shining a light up from the bottom of the cyclone. For axial-entry cyclones, breaks in
header sheets, decomposed gaskets, and cracks in material can be detected when directing
the light up from the hopper. The prevention of leaks is very important. Because a
cyclone operates on an inertial principle and leakage disrupts the flow pattern, fine
particles can be reentrained through the outlet vortex. Collection efficiency will decrease
due to dust reentrainment, so it is very important to seal the cyclones.
Collection efficiency in a cyclone is primarily determined by the pressure drop and/ or
the inlet velocity. The pressure drop can be increased or decreased by varying the
diameter of the cyclone body or by varying the volumetric flow rate per tube. These
features must be designed into the system. If the cyclone is operated at a lower
volumetric flow rate, dampers should be used so that the gas velocity will be increased.
Since cyclones have no moving parts, fine tuning them is very difficult. Spiral vanes are
used in axial entry cyclones, allowing some control of volumetric flow rate by moving a
vane in and out of a constricted opening in the collector element. When fully in,
maximum rotation is induced, resulting in greater centrifugal action. When fully out
much of the gas bypasses the vanes.
Dampers at the inlet are used to control turndown of gas flow. This can be accomplished
if the collector is sectionalized and allows for the designed pressure drop to be
maintained. The excess tubes can be capped off if the turndown is permanent. Efficiency
can be improved by arranging cyclones in series or parallel; however, these gains can be
offset by increased maintenance problems. Multicyclone arrangements plug more easily
and, when common hoppers are used, uneven flow distribution can lead to reentrainment
problems.
A summary of changes in performance characteristics produced by changes in cyclone
design and exhaust gas properties is given in Table 2; quantitative equations are provided
in Table 3.
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TABLE 2 Changes in Performance Characteristics

TABLE 3 Effects of Operation Variables on Cyclone Operation and Performance

4. AREAS OF APPLICATION
Cyclones are utilized in various industries such as chemical, coal mining and handling,
combustion fly ash, metal working, metal mining, etc. Common uses of cyclones are the
collection of grinding, crushing, conveying, machining, mixing, sanding, blending and
materials handling dust and for particle collection.
5. ADVANTAGES AND DISADVANTAGES
The advantages of a cyclone as separator for substance are
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Simple construction.
No moving components.
Little maintenance.
Low investment and functioning costs.
Constant pressure drop.
Saves room.
Dry relief during wet cyclone.

The disadvantages are:

High pressure drop (0.5 - 2.5 kPa), depending on of the construction version.
Low output for low particle diameter (for particles of diameter less than 10
micrometer).
Emission of effluent at wet cyclone.
Erosion sensitive and constipation danger to the entrance.
Possibly noise nuisance.

6. CONCLUSION
From the study above design parameter we can conclude that
i.

Cyclone efficiency generally increases with:

ii.

Particle size and/or density

Inlet duct velocity
Cyclone body length
Number of gas revolutions in the cyclone
Dust loading
Smoothness of the cyclone wall

Cyclone efficiency decreases with increase in

Gas velocity
Body diameter
Gas exit diameter
Gas inlet duct area, and
Gas density.

REFERENCES
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 Fundamentals Of Air Pollution Engineering, John H. Seinfeld,

California Institute of Technology, page no. 402-411
Air Pollution Control Equipment Calculations, Louis Theodore, John
Wiley & Sons, Inc., Page No.363-376.
Air Pollution Control Engineering, Lawrence K. Wang et al, Humana
Press Inc., New Jersey, Page no. 101, 102, 106, 107

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