Lecture 5 Cyclones

EVEN 4386 Air Quality and Pollution

Control

Contents

Particle removal mechanisms

Types of particle removal equipment
Cyclone dimension
Design and Process Parameters
Pressure drop
Cyclone collection efficiencies
Costs
2

Mechanisms to Remove Particulate

Contaminants from Gas Streams
The primary mechanisms for removal of particulate
material from gas streams are Brownian motion,
interception, and impaction.

Enhancement of these mechanisms can occur by using

external forces such as electrostatic, gravitational
and/or centrifugal forces.

Removal of Particles from a Gas Stream with a

Collector Body via Brownian Motion, Interception,
and Impaction
impaction

Brownian
Motion

interception
collector
body
fluid
streamline

Separation and Removal of

Particulate from Gas Streams

Particulate contaminants are typically removed from

industrial gas streams with the use of:
Settling Chambers (gravitational force)
Cyclones (centrifugal force)

Wet Collectors (Brownian motion, interception,

and impaction)
Electrostatic Precipitators (electrostatic force)

Fabric Filters (Brownian motion, interception, and

impaction)
5

Cyclones (Centrifugal Force)

Gravitational force is useful to remove coarse particles
(dp > 10 mm) from gas streams but is not very effective
for smaller particles.
The centrifugal force can be used to achieve larger
removal efficiencies for smaller particles.

The gas stream is forced to change its direction with the

particles following a different direction.
The centrifugal force causes the particle to be
transported in a different direction than the gas stream
allowing for separation and collection of particles from
gas streams.
6

Cyclone Schematic Flow

Koger Industrial Cyclones Type A-B

Source: Koger Air Corporation website: http://www.kogerair.com

Advantages
Low capital cost
Ability to operate at high
temperatures
Low maintenance
requirements
Can handle liquid mists or
dry materials
Eases re-use or disposal
Needs relatively small space
for installation

Disadvantages
Low efficiencies for small
particles < 1um
High operating costs due to
pressure drop
Unable to process sticky
materials

Classical Cyclone Dimensions

Lapple standard Conventional Cyclone
Cyclone Type
High Efficiency

Conventional High Throughput

(1)

(2)

(3)

(4)

(5)

(6)

Body diameter, D/D

1.0

1.0

1.0

1.0

1.0

1.0

Height of inlet, H/D

0.5

0.44

0.5

0.5

0.75

0.8

Width of inlet, W/D

0.2

0.21

0.25

0.25

0.375

0.35

Diameter of Gas Exit,

De/D

0.5

0.4

0.5

0.5

0.75

0.75

Length of Vortex , S/D

0.5

0.5

0.625

0.6

0.875

0.85

Length of Body, Lb/D

1.5

1.4

2.0

1.75

1.5

1.7

Length of Cone, Lc/D

2.5

2.5

2.0

2.0

2.5

2.0

Diameter of Dust,
Dd/D

0.375

0.4

0.25

0.4

0.375

0.4

Relationship of collection Efficiency

versus Particle for Cyclones
100

High efficiency
Conventional

Efficiency,
(%)

High throughput

50

10

20

dp (m)

10

Collection Efficiency: Effective Turns

L
H

1
Ne
H

Lc

Lb 2

Sc

De

LLb1

(4.1)
Do

where
N e number of effective turns

Lc2

H height of inlet duck

Lb length of cyclone body

Dd

Lc length (vertical) of cyclone cone

11

Terminal Velocity

12

Smallest particle that will be

collected
In theory, the size of the smallest particle that will
be collected:

9 mW
dp

N eVi p g

(4.5)

where
m gas viscosity
W width of the inlet duck
N e number of effective turns
Vi gas inlet velocity

p density of the particle

g gas density

13

Particle collected with 50%

efficiency

In practice, the diameter of particle collected with

50% efficiency (semi-emperical):
d pc

9 mW

2N eVi p g

(4.6)

where
m gas viscosity
W width of the inlet duct
N e number of effective turns
Vi gas inlet velo city

p density of the particle

g gas density

14

Control Efficiency jth Particle

j

1 pc __

d
pj

(4.7)

where
j collection efficiency for the jth particle size range
__

d pj characteri stic diameter of the jth particle size range

__

(usually d pj is the median diameter of particle size range)

15

Standard Cyclone Efficiency

16

Overall Control Efficiency

o j m j

(4.8)

where
o overall collection efficiency
m j mass fraction of particle in the j th size range

17

Effects of Design and Process

Parameters on Cyclone Efficiency
Parameter

If parameter increases, cyclone

efficiency will:

Particle size

Increase

Particle density

Increase

Dust loading

Increase

Inlet gas velocity

Increase

Cyclone body diameter

Decrease

Ratio of cyclone length to diameter

Increase

Smoothness of cyclone inner wall

Increase

Gas viscosity

Decrease

Gas density

Decrease

Gas inlet duct area

Decrease

Gas exit pipe diameter

Decrease

18

Example-Cyclone Particle Collection

Efficiency
For the following particle size distribution, calculate the
particle collection efficiency of a Lapple standard cyclone
with a body diameter of 0.50 meters. The particulate
density p = 1200 kg/m3, the gas density g = 0.90 g/m3,
the gas viscosity = 1.67x10-5 kg/ms, and the inlet gas
velocity Vi = 25 m/s.

19

Example-Cyclone Particle Collection

Efficiency 2/3
Strategy:

N e d pc j o
1
Ne
H

Lc

Lb 2

20

Example-Cyclone Particle Collection

Efficiency 3/3
j

d pc
1
__

d
pj

o j m j

__

__

d pj

d pc d pj
2.04
0.58
0.27
0.14
0.07
0.05
21

Pressure Drop for Cyclones

Pressure drop (DP) across air quality control devices is also important
because operating cost of the device can depend heavily on pressure drop.
An empirical expression describing pressure drop for cyclones is
presented below:

DP K
where,

gVi 2 HW
2

De2

DP = pressure drop [N/m2]

Vi = inlet gas velocity [m/sec]
g = gas density [Kg/m3]
22

Pressure Drop for Cyclones 2/2

DP K
K

gVi 2 HW
2

De2

= empirical constant (range from 12 to 18)

H = height of inlet [m]

W = width of inlet [m]
g = gravitational force constant [9.8 m/sec2]
De = diameter of cyclones outlet for gas stream [m]
23

Fluid Power for Cyclones

w f Q DP
where

w f work input rate into the fluid, W

Q volumetric flow rate, m 3 / s
24

Costs
EPA estimates:
Capital costs: $ 2.20/scfm to $3.50/scfm
Operating and maintenance costs: $0.7/scfm to $8.5/scfm per
year

Total purchased cost (1988 dollars) of a cyclone system

= Pc + Pv
Where
Pc is the cost of the cyclone system, Pc=6520 A0.903
Pv is the cost of the rotary air lock valve, Pv=273 A0.0965
A is the cyclone gas inlet area, ft2
25

Additional Information
(not required for tests)

26

Multiple-tube Cyclones

27

Vane-axial cyclone
outlet for
clean gas
stream
inlet for particle
laden gas
stream

inlet for particle

laden gas
stream

vane

vortex finder

outlet for
particles

28

Multiple-tube Cyclones

FCC Cyclones

MultiCyclones

29

L1 = 2Do

De

Sc

L2 = 2Do

L1

Standard (Involute) Cyclone

dimensions and standard
proportions

H = Do/2

Do

Sc = Do/9
De = Do/2

L2

Dd = Do/4
W = Do/4 (width of
cyclone inlet)

Dd

Ro
Ri
W
R*

= Cyclone body radius (= Do/2)

= radius to the inner end of gas inlet
= Ro - Ri = width of the cyclone's inlet
= minimum radius for which a particle
of diameter, dp, will just reach the
outer wall of the cyclone and be
removed from the gas stream

R*

Ro

Ri

30

Involute Cyclone: Particle Removal Efficiency

Ro R* represent the particles of diameter dp that will be
collected; and Ro Ri represent the total particles of size dp
entering the device inlet. Then the graded collection efficiency
of an involute cyclone, (dp), can then be described by:

Ro R * Ro R *
(dp )

Ro Ri
W
A force balance can be used to describe the normal velocity
vector of a particle that is located in a gas stream that is turning
with radius R.

31

Particle Force Balance in a Cyclone

mp ap Fi

Vp, tang
R

mp

d(Vp )
d(t)

Vp, rad

Fac Fd
particle

where,
ap acceleration of particle
Fac centrifugal force mp
Vp, tang

Vp,2 tang

R
tangential velocity vector of particle

R radius of curvature
32

Drag Force, Fd, in a Cyclone

recall from slide 44 Lecture 4 drag force Fd with
particle radial velocity V p ,rad :
1
Fd g ApV p2,radC D
2
1 2
24
V p ,rad d p g
Substituting : Ap d p , C D
(Stokes regime), Re m g
4
Re
1
1 2 2 24
Fd g d pV p ,rad V p ,radd p g
mg
2
4
Fd 3d p2 m gV p2,rad
33

Particle Force Balance in a Cyclone

Principle: A particle will deviate from the vortex stream flow when
the centrifugal force equals the drag force, then travels at the
resulting terminal velocity in radial direction, and is removed when
it covers the distance to the outer diameter of the cyclone.
Assumptions: transition to terminal velocity is ignored and
particle mass remains constant, thus,

d( Vp )
m
0
and Fac Fd
p

d( t )

mp

Vp,2 tang
R

3 mg dp Vp, rad

Vp, rad

mp Vp,2 tang
3 mg dpR

34

Particle Force Balance in a Cyclone

Assuming spherical particles with density (p)

1 3
mp dp p
6

Vp, rad

1 3 2
dp p Vp, tang
6
3 m g dpR
2
2
dpp Vp, tang
18m gR

35

 It is also assumed that the tangential velocity of the

particles is the same as that of the gases, or:

Qg
Vp, tang ug
WH
Radius (R) has some value between the inner radius Ri
(Ri = Ro - W) and the outer radius Ro of the cyclone.

The magnitude of Vp, rad is then described by,

Vp,rad

Ro R

Dt

where Dt is some time period for the particle to be

transported from R* to Ro.

36

Particle Force Balance in a Cyclone

Therefore,

Vp,rad

dp2 p ug2

Ro R

Dt
18mgR
*

Ro R
*

2
2
dp p ug D t

18mgR

37

 It is now necessary to determine Dt.

some displaceme nt of the gas

stream in the tangential direction

Dt
(superfici al gas velocity)
circumfere nce of the

(number of turns)
vortex wit h radius R

(superfici al gas velocity)

(2R)(Ne )

ug

38

where,
Ne number of equivalent turns of
the gas stream in the cyclone

L1 =

H
Sc

De

L2 =

L1

H=

Do

L2
1
L1
H
2

Sc =

L2

De =

Dd =

W=

Dd

H = height of inlet to involute cyclone

L1 = height of cylindrical portion of cyclone

L2 = height of conical portion of cyclone
39

Particle Force Balance in a Cyclone

Therefore,

Ro R
*

2
2
dp p ug (2R)(Ne )

18m gR ug
dp2p ug Ne
9m g

and,
2
d
u Ne
Ro R
p p g
(dp )

W
9m g W
*

40

Involute Cyclone: Particle Removal Efficiency

But,

Qg
ug
WH

Then,

(dp )

2
dppQgNe
2
9mgW H

This expression for (dp) exhibits some problems

because (dp) can be calculated to be 100% for all

particles > dp and the other assumptions in its derivation.
41

Involute Cyclone: Particle Removal Efficiency

Therefore, define dp,50 as the particle diameter that is
collected at (dp) = 0.5.

(dp ) 0.5

dp2,50pQgNe
9mgW 2H

dp,50

1/ 2

9m g W H

2pQ g Ne

42

 This expression for dp,50 is similar as the equation 4.6

shown on page 141 of the textbook.

Now the problem is how to apply the equations to

calculate collection efficiency for the cyclone.
A calibration curve can be used for cyclones of
standardized proportion (see Figure 4.3 in the text).

43

Calibration Curve for Cyclones of Standardized

Proportions

(dp)

C
B
A
A = High throughput
B= Conventional
C = High efficiency

dp / dp,50
44

Involute Cyclone: Particle Removal Efficiency

dp,50 can be readily calculated given the geometry of
the cyclone, density of the particles, viscosity of the
gas and volume flow rate of the gas stream.
dp/dp,50 values can then be determined for the particle
size distribution of interest.
Values of (dp) can then be read from the calibration
curve for calculated values of dp/dp,50.

45

Involute Cyclone: Overall Removal Efficiency

The overall collection efficiency (T) can then be
calculated:
m i (d pi )
(d p )
T
i
T ,in
i 1 m

46

Typical Values for Involute Cyclones

(dp ) 50% for dp 1 10 mm
Do 0.5 to 3 m
L1 = 2Do

H
Sc

De

L2 = 2Do

L1

Do

u 10 20 m/sec

H = Do/2 g
Sc = Do/9

L2

De = Do/2
Dd = Do/4

Dd

W = Do/4 (width of
cyclone inlet)

47

Example (Cyclone)
An involute cyclone of standard proportions with a 2 m
diameter is operated at a gas flow rate of 10 m3/sec.

The gas stream consists of air at 500 K and 1 atm.

What is the collection efficiency for a 10 mm diameter

particle?
Use the calibration curve for the cyclone is presented
in Figure 4.5 (p.142) of textbook.

48

Pressure Drop (DP) for Cyclones

An empirical expression describing pressure drop
(DP) for cyclones is presented below:

u g
2
g

HW
DP
K 2 (PT 2 PT1 )
2gL De
where,
DP = pressure drop [N/m2]
g = inlet superficial gas velocity [m/sec]
g = gas density [Kg/m3]
49

Pressure Drop (DP) for Cyclones

K = empirical constant
= 16 for standard tangential inlet
= 7.5 for vane axial entry
H = height of cyclones inlet [m]

W = width of cyclones inlet [m]

g = gravitational force constant [9.8 m/sec2]
L = density of liquid water [1,000 Kg/m3]
De = diameter of cyclones outlet for gas stream
[m]
50