D E S IG N O F P A R T IC U L A T E C O L L E C T O R S Six d iffe r e n t m e c h a n ism s a re o p e ra ti v e i n t h e d e sig n o f p a rtic u la te c o lle c to rs: G ra v ita tio n a l s e ttlin g - g ra vity. C e n t r i f u g a l i m p a c ti o n - c e n t r i f u g a l f o r c e In e r t i a l i m p a c t i o n - p a rt i c u l a t e s i n f l o w h a v e i n e r t i a t h a t b r i n g s i t t o th e c o l le ct o r .

E l e c t r o s t a t i c p r e c i p i t a to r - e l e c t r i c f i e l d D ire c t i n te rc e ptio n - s tre a m lin e s o f flo w d ire c tly g o e s o v e r th e s o l i d c o l le c t o r s . D i f f u s i o n - p a r t i c l e s i n f l o w h a v e r a n d o m B r o w n i a n m o ti o n t h a t b ri n g s it c lo se to t h e c o lle c to r.

C h o i c e o f a p a r t i c u l a r c o l le c t i o n d e v i c e d e p e n d s o n : ( A ) p a r t i c u l a t e c h a r a c t e ri s t i c s - p h y s i c a l a n d c h e m i c a l n a t u r e . (B ) g a s flo w ra te (C ) T a n d P o f th e str e a m (D ) N a tu r e o f g a s stre a m , su c h a s c o rro siv it y (E ) T re a tm e nt a n d d isp o sa l o f e fflu e n t a n d c o lle c te d p a rtic u la te s. C o m m o n typ e s o f e q u ip m e n t: G ra v ity S e ttle r, C e ntrifu g a l (c yc lo n e ) s e p a ra to r, w e t c o lle c to rs , f a b r i c f i l t e r , e l e c t r o s t a t i c p r e c i p it a t o r . C o lle c tio n e ffic ie n c y is a lw a y s d e fin e d a s = ( r e s i d e n c e t i m e i n t h e r e a c t o r ) / ( t i m e o f c o l l e c ti o n )

Examples of Particulate Collectors

GRAVITY SETTLER

L
x y z

H
hoppers

Applicable mainly to particulates of dp > 10 m. Applicable to streams with gas velocity < 300 cm/s

Two types of models: (A) Block flow or Plug flow model - Very little or no mixing in the z - direction. (B) Mixed flow (Backmixing) model - Very good mixing in the zdirection.

B lo c k f lo w o r P lu g f lo w M o d e l: F o r a p a r tic u la te to s e tt le o u t i n to th e h o p p e r a t a d is ta n c e H a n d e s c a p e fr o m th e g a s T = H / Vt R e s id e n c e ti m e , tR = L / V C o l le c tio n e f fi c ie n c y ,
d

= t R / t = (V t L/ H V ) = V t L W / Q

N o t e th a t V t i s a f u n c t io n o f p a rtic u la te d ia m e t e r. M in im u m p a r tic u l a te s iz e c o ll e c te d is w h e n t = t R .

> R e d u c i n g H / L d e c r e a s e s d p ,m in , ie , in c r e a s e L o r d e c r e a s e H . > In s t e a d o f o n e lo n g L , s m a ll H c h a m b e r , s e v e ra l b a ff le s are pl a c e d a c ro s s t h e c h a m b e r h o r iz o n t a lly, s p a c e d s e v e r a l in c h e s a p a r t. F o r a c h a m b e r w i th N h o ri z o n ta l b a ff le s , o = N d . P r o b l e m s w ith g r a v ity s e ttl e r: ( i) tu rb u le n c e in g a s s tr e a m c h a n g e s th e p a r tic l e tr a je c to ry, (i i) R e - e n tr a i n m e nt o f d u s t a l re a d y o n th e c o l le c to r is a p o s s i b il it y.

M IX E D F L O W ( B A C K M IX IN G )M O D E L : If m i xi ng is go o d in the z-directio n, bu t no t in the the x-directio n, w e have to do a m ass balance o ver a length dx

Vt
(V t/H ) dt

F r actio n co llected is

(V t dt is the vertical height travell ed by a particle, H is t he to tal fall height) . C hange in co ncentratio n in passing sectio n dx is and dt = dx/V H ence w e have dc = -c. (V tdt)/H

Integrating

ADVANTAGES OF A GRAVITY SETTLER:

Low energy Low maintenance expense Reliability

DISADVANTAGES:

Large size Low collection efficiency for smaller particulates

CYCLONE SEPARATORS ** Works on the principle of spinning the gas stream so that particles of higher mass fall out in proportion to the velocity. ** The tendency of particles to move in a straight line when the direction of the gas stream is changed is the primary mechanism of imparting centrifugal motion. ** Removes particles of diameter > 10 microns. But efficiency is > 95% only for particles greater than 25 microns. ** There are however three different types: high volume cyclone (low efficiency), medium cyclone and high efficiency cyclone (low throughputs).

Top Inlet Cyclone Separator

Vane Axial Entry Cyclone Separator

Bottom Inlet Cyclone Separator

C o lle c t io n E f f ic ie n c y o f a C y c lo n e : * * F i r s t , t h e n u m b e r o f r e vo l u t i o n s N e i n t h e o u t e r v o r t e x i s gi v e n b y (1 )

* * T o b e co llected th e p articles m u st strike the w all w ithin th e am o u nt o f tim e th e g as tr av els i n t h e o u ter vo rtex. T h e g as residen ce tim e i n the o u ter v o rtex is g iven b y (2 ) * * M a xi m u m r a d i a l di s t a n c e t r a v e l l e d b y a p ar t i c l e i s t h e w i d t h o f t h e i n l e t d u c t W . A s s u m e t h a t c e n t ri f u g a l f o r c e q u i c k l y a c c el e r a t e s t h e p a r t i c l e t o i t s t e r m i n a l v e lo c i t y i n t h e r a di a l di r e c t i o n . T h e t e r m i n a l v e lo c i t y t h a t w i l l a l l o w a p a r t i c l e t o b e c o l l e c t e d i n t i m e t i s (3 ) R e m e m b e r t h at V t i s gi v e n b y t h e S t o k e s l a w (4 ) E lim inatin g t b e t w e e n ( 2 ) a n d ( 3 ) a n d e qu a t i n g ( 3 ) t o ( 4 ) w e g e t

T h e a bo v e gi v e s t h e m i n im u m p a r t i c l e d i a m e t e r t h at w i l l b e c o l l e c t e d .

T h e theo retical equ atio n deri ved h as a m ajo r flaw it states th at all p articles w ith diam eter larger than d p w ill be co llected w ith 1 0 0% efficiency, w hich is N O T co rrect. L app le derived a sem i-em pirical relatio nship w hich gives the 5 0 % cu t diam eter d pc ., w hich is the diam et er o f p articles co llected w it h 5 0% efficiency.

L app le then derived a general cu rve fo r stand ard co nventio nal cyclo nes that can be u sed to predict the co llectio n efficiency o f any g iven parti cle size. T his has been fu rther en han ced by an algebraic rel atio n ship b etw een co llectio n efficien c y and cu t diam eter o btained by T heo do re and D eP ao la:

N o te that j is the co llectio n effici ency fo r the jth particl e size ran ge and d pj is the characteristic diam eter fo r that size rang e. T h e o verall efficiency o f t he cyclo n e is th e w eighted averag e o f the efficiencies fo r v ario u s size ranges

Standard Cyclone Proportions

Percent collection efficiency

L1 = L2 = 2Do H = W/2 = Do/2 De = Dd/2 = Do/2

dpj/dpc

TYPICAL CYCLONE DIMENSIONS Diameter: 6 to 10 (15 to 25 cm) Inlet Velocities: 50 to 60 ft/s (15 to 20 cm/s) Volumetric Rates:
500 to 1000 ft3/s (15 to 20 m3/min) Capacities as high as 30,000 ft3/min have been manufactured.

Pressure Drop in Cyclones

Large diameter cyclones are less efficient than small diameter ones. However, large D will have lower P. P in cyclones related to the number of velocity heads of loss, Hv

Vg2 g H v P(inches of fluid ) = 2 g L

Note: Vg2/2g is one velocity head (Vg is the inlet gas velocity) L corrects for P in terms of fluid height. * Lapples observation: HW K = 16 for std. Cyclone Hv K 2 (tangential gas entry) D
e

Vg2 g HW P = K 2 2 g L De
P : simple cyclones (0.5 to 2 of water); high efficiency (2 to 6 water).

Cyclone Design Optimization

(Know dp from size distribution curve, Qp, Tg,
P from

stack sampling)

Choose a dpc

Repeat with different dpc (Obtain required efficiency) Locate optimum dpc on optimization curve to get correct D)

P 2Q2 D2 = D1 Q P1 1
Note: Q1 = 0.094 m3/s;

1 3

Q2 D1 and P2 = P1 Q D2 1 2
2

P1

= 1,000 kg/m3; D1 = 0.254 m.