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Cyclone Separator Design
Cyclone Separator Design
by Esco Engineering
179 Lansdowne Avenue,
Kingsville, Ontario N9Y 3J2 Canada Revisions
ph 519 733 3122 26-Nov-98 Corrected error in cell D14 on efficiency sheets
fax 519 733 6094 18-Jan-99 Added diagram
Contact: Neil Stone, Chief Engineer 3-Apr-99 Corrected cell O7, Efficiency 1 - thanks to Laercio Frare for pointing out this error
e-mail jnstone@mnsi.net 2-Dec-99 Added metric option, NV sketch
Website www.mnsi.net/~pas/esco.htm 13-Dec-99 Corrected error in density calc (size!E9, Efficiency 1! and 2!E19)
NOTE: This spreadsheet is for the use of knowledgeable professionals, capable of evaluating the accuracy
of the results. The author is not responsible for the use to which these results are put.
1 The 'Cyclone size' sheet calculates dimensions for various standard cyclones.
Enter the flow rate, design inlet velocity and gas density in the colored squares
and the sheet will give dimensions for five standard cyclones - two high efficiency, and
three low efficiency. The table also gives the predicted pressure drop, but be aware that this is a
very uncertain calculation (see original references). See 'Diagram' sheet for nomenclature.
On the 'Cyclone size' sheet you specify the units you want to use - metric or US Customary (Imperial)
THIS UNITS SELECTION APPLIES TO ALL SHEETS
2 Two methods are provided for calculating cyclone efficiency. You can calculate both, and
compare the results on the chart. Both sheets are set up with the same layout, so data can be copied
between sheets easily.
3 The efficiency calculation requires particle size data, cyclone dimensions, and physical property
data for the gas and the solids. The calculation assumes that the size distribution of the particles
is log normally distributed. The sheet is set up so that you can enter either the mean and standard
deviation of the log normal distribution, or the particle size data, from which these data are then calculated.
5 The chart sheet graphs the penetration (col P = 1 - fractional efficiency) against particle size for the two efficiency
calculation methods. CAUTION: The two efficiency sheets are not linked, so make sure they are both calculating
from the same data if you want to compare the two efficiency calculations!
08/30/2017 364577927.xls
DEFINITION OF CYCLONE DIMENSIONS
b De
a S
h
NV = Neutral vane
Extension of inner
side if inlet to centerline
of cyclone
B ELEVATION PLAN
08/30/2017 364577927.xls
Cyclone size
Cyclone data from "New design approach boosts cyclone efficiency", W.H.Koch and W.Licht, Chem Eng Nov 7 1977, 80
Pressure drop vel head correlation from "A better way to calculate cyclone pressure drop" J.Casal and J.M. Martinez-Benet, C
Page 3
Cyclone size
r efficiency (alternates)
s of results of sheets 2/3
Page 4
Efficiency 1
Gas data
Flow rate Q m^3/h 2000 1176.67 19.61111 cfs
Density rg kg/m^3 0.0740 0.0046 0.066 air @ 1 atm, spec'd temp
Viscosity u cP 0.010 0.010 6.72E-06 lb/f-s
Temperature T C 60 140
Salt. temp fact fT 1.00 1
Salt dens. fact fp 1.00 1
References
Efficiency from "New design approach boosts cyclone efficiency",
W.H.Koch and W.Licht, Chem Eng Nov 7 1977, 80
Pressure drop vel head correlation from "A better way to calculate cyclone pressure
drop" J.Casal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99
Page 5
Efficiency 1
0.001308
Page 6
Efficiency 1
Calculated data
Log SD 1.133907
GREATER THAN OUTLET LENGTH - CAUSES SHORT-CIRCUITING Inlet velocity fps 0.018979
DTH TOO GREAT - CONTRACTION AT INLET Ratio inlet/salt vel -0.010114
Corrected L ft 29.64123
Core dia ft 38.11984
OUTSIDE CYCLONE Eff vol cf 26594.11
Inlet vol cf 41777.45
Cycl const Kc 90.67049
G 3.494537
Vortex exp n+1 1.754356
17.8 %
Efficiency calcs
Dia, um
m, spec'd temp Min Max Inlet mass
fraction
0 0.4 0.0020
0.4 0.6 0.0028
0.6 1.2 0.0168
1.2 1.8 0.0260
1.8 2.4 0.0309
2.4 3 0.0330
3 3.6 0.0336
n - adjust input ranges (cols Q,T) to suit data 3.6 4.2 0.0333
4.2 4.8 0.0324
4.8 7 0.1080
7 10 0.1197
10 13 0.0926
13 16 0.0724
16 22 0.1052
22 28 0.0698
28 34 0.0486
34 40 0.0351
40 49 0.0372
49 64 0.0384
64 79 0.0220
79 94 0.0136
0.9736
Overall efficiency
Page 7
Efficiency 1
Distribution data
Size, um Cum %
Min Max
0 2 6
2 3 11
3 5 22
5 10 44
10 20 67
20 30 80
30 40 85
40 50 90
50 100 97
Page 8
Efficiency 1
Int calcs
Distribution Relax time Penetration
Penetration Outlet amt Outlet mass fl fh tl th pl
fraction
0.9890 0.0020 0.0024 0 0.009991 0 7.108E-07 1
0.9751 0.0028 0.0033 0.009991 0.018218 7.108E-07 1.599E-06 0.977949
0.9657 0.0162 0.0198 0.018218 0.037832 1.599E-06 6.397E-06 0.972296
0.9540 0.0248 0.0302 0.037832 0.048784 6.397E-06 1.439E-05 0.959149
0.9444 0.0291 0.0355 0.048784 0.054068 1.439E-05 2.559E-05 0.948804
0.9360 0.0309 0.0376 0.054068 0.056018 2.559E-05 4E-05 0.93996
0.9285 0.0312 0.0380 0.056018 0.05603 4E-05 5.758E-05 0.932099
0.9216 0.0307 0.0373 0.05603 0.054921 5.758E-05 7.837E-05 0.924949
0.9153 0.0297 0.0361 0.054921 0.053178 7.837E-05 0.000102 0.918345
0.9022 0.0975 0.1186 0.053178 0.04504 0.000102 0.000218 0.912179
0.8810 0.1055 0.1283 0.04504 0.034769 0.000218 0.000444 0.892282
0.8600 0.0797 0.0969 0.034769 0.026983 0.000444 0.000751 0.869646
0.8417 0.0609 0.0741 0.026983 0.021255 0.000751 0.001137 0.850272
0.8183 0.0861 0.1048 0.021255 0.013811 0.001137 0.00215 0.833119
0.7906 0.0552 0.0672 0.013811 0.009455 0.00215 0.003483 0.803387
0.7666 0.0373 0.0453 0.009455 0.006743 0.003483 0.005136 0.777883
0.7452 0.0262 0.0319 0.006743 0.004969 0.005136 0.007108 0.75535
0.7214 0.0268 0.0327 0.004969 0.003297 0.007108 0.010667 0.735057
0.6883 0.0265 0.0322 0.003297 0.00183 0.010667 0.018197 0.707827
0.6520 0.0144 0.0175 0.00183 0.001106 0.018197 0.027727 0.668731
0.6206 0.0085 0.0103 0.001106 0.000711 0.027727 0.039256 0.635282
0.8217 1.0000
Overall efficiency 17.8 %
Page 9
Efficiency 1
Coefficients
Standard Error
Intercept 2.477006 0.007748
X Variable 1.133907 0.006796
Page 10
Efficiency 1
Penetration
ph
0.977949
0.972296
0.959149
0.948804
0.93996
0.932099
0.924949
0.918345
0.912179
0.892282
0.869646
0.850272
0.833119
0.803387
0.777883
0.75535
0.735057
0.707827
0.668731
0.635282
0.605957
Page 11
Efficiency 1
MS F Significance F
14.59118 27837.76 7.332E-14
0.000524
Page 12
Efficiency 2
Gas data
Flow rate Q m^3/h 2000 1176.67 19.61111 cfs
Density rg kg/m^3 0.0740 0.0046 0.066 air @ 1 atm, spec'd temp
Viscosity u cP 0.010 0.010 6.72E-06 lb/f-s
Temperature T C 60 140
Salt. temp fact fT 1.00 1
Salt dens. fact fp 1.00 1
References
Efficiency from "A new collection theory of cyclone separators",
L.Enliang & W Yingmin, AIChEJ Vol 35, #4 April 1989, 666
Pressure drop vel head correlation from "A better way to calculate cyclone pressure
drop" J.Casal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99
Page 13
Efficiency 2
0.001308
Page 14
Efficiency 2
Calculated data
Log SD 1.133907
GREATER THAN OUTLET LENGTH - CAUSES SHORT-CInlet velocity fps 0.011387
DTH TOO GREAT - CONTRACTION AT INLET Ratio inlet/salt vel -0.004553
Vortex exp 1-n 0.065925
theta 6.462466
OUTSIDE CYCLONE rw 5.466667
rn 32.80833
uw -0.071855
Dr 0.005108
2.6 %
Efficiency calcs
Dia, um
m, spec'd temp Min Max Inlet mass Penetration Outlet amt
fraction
0 0.4 0.0020 1.0000 0.0020
0.4 0.6 0.0028 1.0000 0.0028
0.6 1.2 0.0168 1.0000 0.0168
1.2 1.8 0.0260 1.0000 0.0260
1.8 2.4 0.0309 1.0000 0.0309
2.4 3 0.0330 1.0000 0.0330
3 3.6 0.0336 1.0000 0.0336
n - adjust input ranges (cols Q,T) to suit data 3.6 4.2 0.0333 1.0000 0.0333
4.2 4.8 0.0324 1.0000 0.0324
4.8 7 0.1080 1.0000 0.1080
7 10 0.1197 1.0000 0.1197
10 13 0.0926 1.0000 0.0926
13 16 0.0724 1.0000 0.0724
16 22 0.1052 1.0000 0.1052
22 28 0.0698 1.0000 0.0698
28 34 0.0486 1.0001 0.0486
34 40 0.0351 1.0001 0.0351
40 49 0.0372 1.0003 0.0372
49 64 0.0384 1.0007 0.0385
64 79 0.0220 1.0018 0.0221
79 94 0.0136 1.0039 0.0137
0.9736 0.9737
Overall efficiency 2.6
Page 15
Efficiency 2
Distribution data
Size, um Cum % % in ln dia max
Min Max range
0 2 6 6 0.693147
2 3 11 5 1.098612
3 5 22 11 1.609438
5 10 44 22 2.302585
10 20 67 23 2.995732
20 30 80 13 3.401197
30 40 85 5 3.688879
40 50 90 5 3.912023
50 100 97 7 4.60517
Page 16
Efficiency 2
Int calcs
Distribution Penetration
Outlet mass fl fh kh wh lh pl ph
fraction
0.0021 0 0.009991 -1.56E-06 4.19E-09 -2.61E-13 1 1
0.0029 0.009991 0.018218 -3.51E-06 9.428E-09 -1.32E-12 1 1
0.0173 0.018218 0.037832 -1.4E-05 3.771E-08 -2.12E-11 1 1
0.0267 0.037832 0.048784 -3.15E-05 8.485E-08 -1.07E-10 1 1
0.0317 0.048784 0.054068 -5.61E-05 1.508E-07 -3.39E-10 1 1
0.0339 0.054068 0.056018 -8.76E-05 2.357E-07 -8.27E-10 1 1
0.0345 0.056018 0.05603 -0.000126 3.394E-07 -1.72E-09 1 1
0.0342 0.05603 0.054921 -0.000172 4.62E-07 -3.18E-09 1 1
0.0333 0.054921 0.053178 -0.000224 6.034E-07 -5.42E-09 1 1
0.1110 0.053178 0.04504 -0.000477 1.283E-06 -2.45E-08 1 1
0.1229 0.04504 0.034769 -0.000974 2.619E-06 -1E-07 1 1.000001
0.0951 0.034769 0.026983 -0.001646 4.426E-06 -2.92E-07 1.000001 1.000002
0.0743 0.026983 0.021255 -0.002493 6.704E-06 -6.69E-07 1.000002 1.000004
0.1080 0.021255 0.013811 -0.004713 1.267E-05 -2.39E-06 1.000004 1.000015
0.0717 0.013811 0.009455 -0.007634 2.053E-05 -6.28E-06 1.000015 1.000041
0.0499 0.009455 0.006743 -0.011257 3.027E-05 -1.36E-05 1.000041 1.000088
0.0361 0.006743 0.004969 -0.01558 4.19E-05 -2.61E-05 1.000088 1.000169
0.0382 0.004969 0.003297 -0.02338 6.288E-05 -5.89E-05 1.000169 1.000381
0.0395 0.003297 0.00183 -0.039885 0.000107 -0.000171 1.000381 1.001108
0.0227 0.00183 0.001106 -0.060773 0.000163 -0.000398 1.001108 1.002574
0.0141 0.001106 0.000711 -0.086042 0.000231 -0.000797 1.002574 1.005167
1.0000
%
Page 17
Efficiency 2
SUMMARY OUTPUT
Coefficients
Standard Error t Stat P-value
Intercept 2.477006 0.007748 319.6806 7.739E-16
X Variable 1.133907 0.006796 166.8465 7.332E-14
Page 18
Efficiency 2
Significance F
7.332E-14
Page 19
charts
EFFICIENCY
1.2000
1.0000
Penetration
0.8000
0.6000
0.4000
0.2000
0.0000
0 5 10 15 20 25 30
Particle dia um
Page 20
charts
25 30
Page 21