Field Operator Certification

Cyclone Separators
Learner Guide
 Cyclone Separators Learner Guide

Introduction
This lesson on Cyclone Separators, as with your other lessons on auxiliary Equipment, consists of
two main learning components: a self-directed/in-class component and an on-the-job component.
You are expected to complete both components as part of your Certification Program.

Review the remaining information contained in the Introduction section of this document prior to
beginning the Content section. If you have any questions about it, speak with your Instructor.

Objectives
Your learning objectives are broken down into two categories: learning objectives for the self-
directed/in-class portion of your learning, and learning objectives for the on-the-job portion of your
learning. They are listed below for your information.

Self-Directed/In-Class Learning Objectives

1. State the purpose of Cyclone Separators
2. Name the main components of a Cyclone Separator
3. Explain the principle of operation for a Cyclone Separator
4. State the applications for Cyclone Separators in cement manufacturing
5. Describe the running and static inspections for a Cyclone Separator
6. State common problems and troubleshooting for Cycle Separators
7. State safety concerns related to Cyclone Separators

On-the-Job Learning Objectives

1. Performing a running inspection on a Cyclone Separator
2. Perform a static inspection on a Cyclone Separator

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Lesson Outline
The first portion of this lesson, whether self-directed or in-class, involves reviewing specific
information about Cyclone Separators

Purpose and basic principle of operation, including primary components of Cyclone

Separators
Applications
Troubleshooting
Safety concerns
Pictures and graphics are included, where appropriate, to help you understand how a Cyclone
Separator works. At the end of this section, there are a series of questions which you are required to
answer and then review with your Instructor.

The second portion of the lesson, the on-the-job portion, primarily involves the completion of
several inspections on Cyclone Separators, including both a running and static inspection. When
youre ready to perform these inspections, inform your instructor.

If youre a new Field Operator, you will complete a series of steps in your OJT portion of this lesson,
as listed below:

Step 1
Your Instructor will walk through an inspection procedure with you. At that time,
you can ask questions and take down any notes required
This walk-through may be completed out in the field or during a meeting with your
Instructor.
Step 2
Your Instructor will demonstration an inspection procedure in the field.
Step 3
You will conduct an inspection procedure in the field under the supervision of your
Instructor
Your Instructor will provide you with feedback about your performance during the
inspection.
Step 4
You will complete a full inspection procedure without any assistance from your
Instructor

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This inspection will be assessed against the inspection checklist contained in this
document. If you do not achieve 100%, your Instructor will provide you with further
feedback and you will have the opportunity to be re-assessed.
If youre an experienced Field Operator, you may already be quite familiar with inspection
procedures. Discuss this with your Instructor; you may only be required to complete Step 4
as described above.

Reference Material
NA

Pre-Requisites
NA

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Cyclone Separators Learning Content

Purpose
To separate material from a gas stream
Efficiency can be as high as 96+%
(meaning that 4% of the material wont be
separated)
Dust Collectors have a much higher
efficiency (99.9%) and are commonly
located downstream from a Cyclone
Separator

Components
C YCLONE S EPARATOR
Metal case, consisting of a cylindrical
section with an attached cone
Thimble/dip tube/centre pipe
Inlet duct
Liner/refractory
Gas exit
Material exit
Airlock at material exit
Inspection ports and doors

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Principle of Operation
The gas/material stream enters the cyclone tangentially at high speed
A downward spiraling vortex is created due to the geometry within the Cyclone Separator
and the high velocity gas stream. Particles move outward under the influence of centrifugal
force
Particles are caught in the thin laminar layer of air next to the wall of the Cyclone Separator
and are carried down by gravity to be collected in the hopper
When the gas reaches the con-shaped section, the increased rotational gas velocity helps to
keep the dust against the wall
A second ascending vortex is created as the gas changes direction from the bottom of the
cyclone and rises towards the exit thimble. As the gas changes direction, the inertia of the
particles causes them to continue in the original direction and be separated form the gas
stream
Heavier particles are released from the gas stream as the descending vortex changes direction
to become the ascending vortex exiting the Cyclone Separator thimble. These heavier
particles are deposited into the Cyclone Separator hopper and they exit through an airlock
Finer particles continue with the ascending vortex and exit with the gas flow out of the
Cyclone Separator thimble
The factors contributing to separation are:
Centrifugal force

Gravity

Inertia

Velocity, and

Abrupt change in direction.

C YCLONE

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 Animated cyclone, but not animated And if
it could be on the previous page, that
would be wonderful!
Cyclone Separators Learner Guide

Applications
Three applications for Cyclone Separators are:

Rotary Kilns
Clinker Coolers
Grinding Mills
Cyclone Separators are a primary means of separation and so are commonly located upstream from
dust collectors.

M ULTICLONES

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Inspection Points

Cyclone Separators Running Inspection

OK

Check for material leaks

Listen for in-leakage of air
Check Cyclone Separator metal for cracks or missing bolts
Check metal for discoloration caused by excessive heat
Verify the condition and seal of inspection ports and doors
Inspect any electrical connections for damage or strain (Thermocouples, etc.)
Check that the airlock is operating properly. Inspect drive, couplings, final drive, if applicable

Cyclone Separators Static Inspection

OK

Visually inspect inside of Cyclone Separator for liner/refractory condition and build-up
Check the condition of the thimble
Check the condition of the discharge airlock. Inspect drive, couplings, final drive, if applicable
Check Cyclone Separator metal for cracks or missing bolts
Verify the condition and seal of inspection ports and doors
Inspect any electrical connections for damage or strain (Thermocouples, etc.)

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Troubleshooting
Problem Causes Actions to Take
No discharge of material Bottom of cone is plugged Remove build-up and determine cause
Airlock is not operating Inspect air lock and repair
Airlock is worn and creating in-leakage
re-entraining material
Cyclone Separator Thimble wear Check differential pressure across the
efficiency lost Cyclone Separator
Build-up in inlet duct creating turbulent
flow Check thimble condition and position
In-leakage Clean Cyclone Separator inlet duct
Inspect airlock and duct work for in-
leakage
Metal of Cyclone Loss of refractory Inspect Cyclone Separator for refractory
Separator discolored by damage
heat

Safety

Be cautious while inspecting Cyclone Separator surface, related duct work and material
leaks can be very hot
Follow procedure for Cyclone Separators plugs in pre-heaters and pre-calciners
Keep the work area clear of grease, oil, water and other objects that could cause a slip or fall
If a Cyclone Separator is plugged, determine the level of material before opening lower
inspection doors
Report all unsafe conditions or practises immediately.

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Review Exercise
Complete each of these questions and review your answers with your Instructor.

1. What is the purpose of a Cyclone Separator?

2. Name 6 components of a Cyclone Separator

3. What are 4 actions which contribute to separation?

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4. Where are Cyclone Separators used in the cement industry?

5. List the running and static inspections to be performed

6. Define the troubleshooting methodology for a loss of Cyclone Separator efficiency

7. Describe 5 safety points associated with Cyclone Separators

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