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UNIVERSITY OF WAH
WAH ENGINEERING COLLEGE
Department of Chemical Engineering
Assignment # 05
Course Title: Mechanical Separation
Semester:3rdSemester Course Teacher: Dr. SaleemIqbal
Total Marks: 10 Time: 1 week (19/12/2018)
Course Code:Ch.E-204
Student Name_____________________Reg No._______________________

Assignment Title:Cyclone Separator

Course Program Learning Domain

Learning Learning
Outcome Outcome
CLO-2 PLO-12 Cognitive 2

Part 1: Instructions:.
If any

Part 2: Question
a) What do you understand by the sentence “how to size a cyclone separator”?

b) Explain when it is better to use horizontal cyclone separator. Elaborate?

c) Explain selection criteria for application single and multiple cyclones separators?
Elaborate arrangement of multiple cyclone separators as well?

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How to size a cyclone separator

To design a cyclone abatement system for particulate control, it is necessary to accurately

estimate cyclone performance. In this cyclone study, new theoretical methods for
computing travel distance, numbers of turns and cyclone pressure drop have been
developed. The flow pattern and cyclone dimensions determine the travel distance in a
cyclone.

The number of turns was calculated based on this travel distance. The new theoretical
analysis of cyclone pressure drop was tested against measured data at different inlet
velocities and gave excellent agreement. The results show that cyclone pressure drop
varies with the inlet velocity, but not with cyclone diameter.

Cyclone cut-points for different dusts were traced from measured cyclone overall collection
efficiencies and the theoretical model for calculating cyclone overall efficiency. It is
important to consider the air density effect on cyclone performance in the design of cyclone
abatement systems.

The tangential inlet generates the swirling motion of the gas stream, which forces particles
toward the outer wall where they spiral in the downward direction. Eventually the particles
are collected in the dustbin located at the bottom of the conical section of the cyclone body.
The cleaned gas leaves through the exit pipe at the top.

Chemical processes consist of reaction stages and/or separation stages in which the process
streams are separated and purified. Such separations involve physical principles based on
differences in the properties of the constituents in the stream. Heterogeneous mixtures
consist of two or more phases which have different composition better to use
horizontal cyclone separator

Horizontal and High-Efficiency Cyclone

One challenge to designing a manufacturing process is choosing an effective dust collection

system that will fit the limited available plant space. Low ceilings pose a challenge for high-
efficiency cyclones due to their long tapered bodies. In many cases the dust collector must
be placed outdoors or partially protruding through the roof. This can be an unfavorable
arrangement. If a traditional cyclone dust collector is installed horizontally, then it loses
efficiency due to particulate settling on the side of the collector and being carried out with
the exhaust gas.

In contrast, counter-cyclonic dust collectors, such as the Aerodyne Split Stream™ Dust
Collector, use a secondary air stream that directs material toward the collection hopper, and
may be installed horizontally with virtually no loss of efficiency.

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. A powerful secondary air stream is injected into a manifold where it enters the

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separation chamber through a series of nozzles. The secondary air stream intercepts the
collected particulate and carries it to the hopper. 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. It also saves money compared to cutting a hole through the roof or
building a site for the dust collector outdoors. By the way, outdoor installation may
encourage condensation that can shorten service life and reduce efficiency. Finally,
horizontal, high-efficiency cyclones may be maintained without the need for tall scaffolding
that can pose a safety hazard to workers.

The cyclone and the multi-cyclone use centrifugal action as the basis of operation. The
particle-laden air enters the cyclone through a tangent intake. The centrifugal action
projects the particles against the cylinder wall, thereby causing a descending spin motion
that forces the particles out. As for the air, it is evacuated to the central chimney created by
the difference in internal pressure of the cyclone.

SELECTION CRITERIA

 air volume
 particle density and grain size
 temperature
 Particle abrasiveness
 Permitted emission standards of the procedure

CONSTRUCTION

 mild steel
 wear-resistant steel
 stainless steel
 galvanized steel
 aluminum
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The multi-cyclone is made up of several cyclones from our HE series, which allows the
treatment of a high volume of air.

Design parameters to remove solids from gas using a cyclone separator.

Input Data:

 Diameter of Separator
 Flow
 Target Efficiency
 Max Pressure Drop
 Particle Density
 Gas Density
 Gas Viscosity
 Number of Turns Inside the Cyclone
 Diameter of Particle Collected with 50% Efficiency

Preliminary Calculations to Determine Overall Size of Separator:

 Height
 Width
 Volume
 Diameter of Exit
 Length of Body
 Length of Cone

Other Important Considerations:

 Overall Collection Efficiency Calculation

 Pressure Drop Calculation

Advantages

- Low capital cost.

- Ability to operate at high temperatures.
- Can handle liquid mists or dry materials.
- Low maintenance requirements (no moving parts).
- Small footprint - requires relatively small space.

Disadvantages

- High operating costs (due to pressure drop).

- Low efficiencies (particularly for small particles).
- Unable to process "sticky" materials
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There are many situations wherein one cyclone or swirl tube is inadequate for the
separation task at hand. In such situations, it is often feasible to use multiple units either in
series or in parallel or both.

Cyclones in Series

When the solids concentration is high, and the emission from just one separator stage
would be too high, a second – or even a third – separator can be added in series with the
first stage separator to collect additional solids.. It is customary to refer to the individual
stages as the ‘primary’, ‘secondary’, and ‘tertiary’ stages or as the ‘first’, ‘second’, and ‘third’
stage. In some industries, the primary cyclone is also called a ‘rough-cut’ cyclone despite the
fact that its overall efficiency (mainly arising from high inlet mass loading) will normally
greatly exceed the efficiency of subsequent stages.

Cyclones in Parallel

There are two common reasons for choosing to install more than one cyclone or swirl tube
in parallel. One is that one device handling the whole gas stream

Design Features

• Low Maintenance cyclone elements are self-cleaning; periodic blow down for removal of
collected materials is all that is required.

• Uses no scrubbing oils or liquids.

• Wider flow range compared to centrifugal type separators.

• High capacities with each design arrangement; single stacked, double stacked, vertical gas,
and horizontal. Two sizes of cyclone elements available.

• Sized per application for optimum flow per cyclone tube.

• Optional cyclone reduction device to keep internal velocities at factory specified levels.
This allows for maximum efficiency over a wide range of process production volumes.

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