UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 1

DESIGN OF CYCLONE SEPARATOR FOR POWDERED MILK RECOVERY

IN THE DAIRY INDUSTRY

An Equipment Design
Presented to the
Department of Chemical Engineering
University of Santo Tomas

In Partial
Fulfillment of the
Requirements for the Degree of
Bachelor of Science in Chemical Engineering
ChE 511 - Equipment Design

Submitted to:

Prof. Lola Domnina B. Pestaňo, Ph.D.

by

Patricia Daniele S. Lucas

November 2018
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TABLE OF CONTENTS

1. Introduction
1.1 Statement of the Problem
1.2 Objective or Goal of Design
2. The Design Project
2.1 Feedstock
2.2 Operating Conditions, Batch/Continuous
2.3 Assumptions and Constraints
**Include Sub-headings/sub-sub-headings (2.3.1 etc) in the next items if
needed**
3. Material of Construction
4. Rationale for equipment Selection –type?/ Relevance to Process (do not include
economics)
5. Material and Energy Balance / Flow diagram
6. Equipment Design Theoretical calculations
7. Heuristics –use sparingly if data cannot be computed theoretically
8. Equipment Specifications/ Specs Sheets for Summary
9. Conclusion & recommendation
10. Detailed Diagrams (Internal ); Rendered (3D)
11. References
12. Appendix
UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 3

CYCLONE SEPARATOR
LUCAS, PATRICIA DANIELE S.

INTRODUCTION.

Cyclone separators are the simplest and least expensive dust collection devices
used for pollution control application [1]. Most industrial cyclones are utilized as
a first stage, lower cost method for removing larger particulate matter (PM) from
effluent gas streams [2].
A rotating dust-laden air flow is established within a cylindrical or conical
container called a cyclone. This air stream enters the cyclone tangentially at the
top and the flow assumes a vortex pattern as it travels helically downward [1].
Centrifugal force from the air's tangential velocity causes the heavier dust
particles to move radically outward toward the cyclone's wall. When the particles
reach the wall, friction and gravity force them to descend and discharge into the
receiver called hopper. The cleaned air spirals upward and exits at the top of the
cyclone [1]. The performance of the cyclone separator can be seen in the figure 1
below.
In a conical system, as the rotating flow moves towards the narrow end of the
cyclone, the rotational radius of the stream is reduced, thus separating smaller and
smaller particles. The cyclone geometry, together with flow rate, defines the cut
point of the cyclone. This is the size of particle that will be removed from the
stream with a 50% efficiency. Particles larger than the cut point will be removed
with a greater efficiency, and smaller particles with a lower efficiency [3].
Particles larger than the cut point will be removed with a greater efficiency, and
smaller particles with a lower efficiency [3].
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Figure 1. Operation principle of

a cyclone separator

The operation and maintenance of a cyclone separator tends to be simple and

inexpensive since its performance are conducted through gravity and a vortex to
remove particulates from the gaseous streams [2]. Another factor that contributes
to this statement is its structure, this kind of mechanical separator do not
incorporate filter media or moving parts which could cause lower operating cost
and maintenance requirements [2]. The design of cyclone separator was
constructed to withstand harsh operating conditions like high temperature, and
since separation in cyclones is a dry process, the equipment is less prone to
moisture corrosion. Lastly, it could also handle liquid mists and requires relatively
small space. [2] Some of its disadvantages could cause low efficiencies
(particularly for small particles) and unable to process “sticky” materials [2].
One of the most commonly functions of a cyclone separator are devised as a pre-
cleaner and most of these were being operated by food processing industries. In
the production of a powdered milk, the use of cyclone separator was applied to
produce higher efficiency of clean powdered milk. It is used in the separation of
the fine milk particles from the hot air stream because as said in the previous
paragraph that the solids settle in the bottom making it easier to isolate via hot air
stream.
UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 5

Powdered milk production starts through the collection of raw milk from the dairy
cows. The cold raw milk will pass through either a clarifier to remove some
bacteria or sediments that may be present in the raw milk or separator which will
separate heavier milk fat from the lighter milk to produce cream and skim milk
products. The next step is pasteurization which utilize heat treatments to kill
bacteria or inactive enzymes found in the standardized milk. The most common
method used for pasteurizing was called the high-temperature, short-time (HTST)
process in which the milk is heated to 161° F (72° C) for 15 seconds as it flows
through the pasteurizer continuously. After pasteurizing, the preheated milk is fed
into an evaporator to increase its concentration of total solids. The milk
concentration is then pump into the spray drier which involves atomizing the
product into fine droplets. These droplets are milk powder which will fall to the
bottom of the drying chamber, from where it is removed. Then the fine milk
powder particles are carried out of the chamber along with the hot air stream and
collected in the cyclone separators. The exit pipe from the cyclone separator
includes exhaust air and ultra-fines while the bottoms (recycle fines) will be
recycled back to the chamber or to the fluidized bed to gather higher amount of
product.

I. OBJECTIVE AND GOAL OF DESIGN.

The goal of the design is to suggest an equipment that can handle separating fine
milk particles from the exhaust air. The overflow should consist of the exhaust
air, without any milk particles. And the underflow must consist of the fine milk
particles to recycle it back to the drying chamber or the fluidized bed. The
separator must reduce milk composition in the air during and after its processing
to achieve higher product efficiency.

II. EQUIPMENT SELECTION

 Mode of Operation: Batch

Batch operation is used in the process to ensure that all fines

particles that settle at the bottom are recycled back to drying
chamber and releasing exhaust clean air from the over pipe.

 Assumptions and Constraints:

UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 6

 Constant composition of feed

The composition of the feed is assumed to be constant to make the
calculations of its velocity, tangential and radial. The computations for its
velocity depend on the density of the particle and its airstream. Since there
are no other addition of new inputs and no chemical reaction has been
accumulating, the composition is assumed to be constant.
 Temperature
Just like the composition of the feed, the temperature inside the separator
is assumed to be constant due to the constant operating temperature of the
processed powdered milk in the spray drier. In addition, there was no heat
gained or lost into the environment during the separation.

FEEDSTOCK AND OTHER PROCESS FLUIDS.

The feed stock consists of fine milk particles distributed into different particles
sizes and hot air stream from the drier which are supplied at 72oC. The density is
assumed to be based on the composition of the feed. It is assumed that the
operating temperature at the cyclone separator remains constant to make the
calculations made below consistent. The underflow is composed of the fine milk
particles that are brought back to the operation. And the overflow consists of the
clean exhaust air.

The following feedstock are given with its magnitude:

FEEDSTOCK MAGNITUDE
Powdered Milk Air flow rate 22 600 𝑚3 /hr
Powdered Milk Concentration 3.2 g/𝑚3
Powdered Milk Density 449.94 kg/𝑚3
Operating Temperature 72oC
Desired Powdered Milk Concentration 600 mg/𝑚3
Fan Efficiency 0.7
Motor Efficiency 0.8

The table below is consisting of particle sizes of a powdered milk:

Particle Size Range, µm Mass Percent in Size Range (%)
218.9 6
203.9 2
203.3 6
199.6 7
96.6 12
UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 7

91.2 9
78.5 14
75.4 10
64.5 12
51.2 14
49.6 8

MATERIAL OF CONSTRUCTION

 Stainless Steel Type-304

Stainless steels (SS) were invented to overcome the problem of corrosion which is
a major concern of food and many other industries. The alloy of steel containing
iron-chromium-nickel is known as stainless steels. Stainless Steel type-304 is used
for food applications because of its corrosion resistance. It is considered to be
universally used for food stuff. It is highly suitable and applied in dairy equipment
such as milking machines, containers, homogenizers, sterilizers, and storage and
hauling tanks.

EQUIPMENT SPECIFICATIONS

In the food processing industry, 2D2D (Shepherd and Lapple model, 1939)
cyclone designs are the most commonly used abatement devices for particulate
matter. This equipment model is one of the most efficient cyclone collectors for
fine dust [4]. All dimensions are related to the body diameter of the cyclone so
that the results can be applied generally.

Table 1. Standard Cyclone Dimension (Lapple Dimension)

Dimensions Ratio Value (m)
Diameter of
Cyclone Body D 1 2.1195
(Barrel)
Length of the Body 𝐿𝑏 2 4.239
Length of the cone 𝐿𝑐 2 4.239
Height of the inlet H 0.5
1.05975
Width of the inlet W 0.25
0.529875
UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 8

Length of Vortex 0.625

Finder S 1.3246875
Diameter of Dust 0.25
Outlet 𝐷𝑑 0.529875
Diameter of Gas 0.5
Outlet 𝐷𝑒 1.05975
Inlet velocity head 𝑁𝐻 - 8
Configuration No. K - 16
Overall Height H 0.5 1.05975

For the determination of the measurements and specifications of the equipment,

the needed equations are enlisted in the table below.

Table 2. Equations and Formula used for cyclone design

Formula Equation

Velocity of Air Inlet Duct 𝑄

𝑉𝑖 =
𝑊∗𝐻

Number of Effective Turn 1 𝐿𝑐

𝑁𝑒 = ∗ [𝐿𝑏 + ]
𝐻 2

Gas Residence Time 𝜋 ∗ 𝐷 ∗ 𝑁𝑒

Δ𝑡 =
𝑉𝑖

Particle Drift Velocity 𝑊

𝑉𝑡 =
Δ𝑡

Cut size diameter of particle removed 9𝜇𝑊

with 50% efficiency 𝑑𝑝𝑐 = √
2𝜋𝑁𝑒 𝑣𝑖 𝜌𝑝
UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 9

Saltation Velocity 4𝑔𝜇(𝜌𝑝 − 𝜌𝑓 ) 3

𝑣𝑠 = [ ]
3𝜌𝑓 2

Efficiency of removal of particle j 1

𝜂𝑗 =
𝑑𝑝𝑐 2
1+( )
𝑑𝑝𝑗

Pressure Drop 1
∆𝑃 = 𝜌𝑣𝑖 2 𝐻𝑣
2

Number of inlet velocity heads 𝐻𝑊

𝐻𝑣 = 𝐾
𝐷𝑒 2

Overall Efficiency 𝑂
𝜂𝑜 = 1 −
𝐹

Relative Effect of Centrifugal force 𝐹𝑐 𝑣𝑖 2

=
𝐹𝑔 𝑔𝑅

Power Requirement 1 1
𝑊𝑓 = 𝑄∆𝑃
𝜂𝑓 𝜂𝑚

DIAGRAM

2D DIAGRAM OF EQUIPMENT
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FLOW DIAGRAM
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UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 12

3D DIAGRAM OF EQUIPMENT
UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 13

CONCLUSION AND RECOMMENDATION

Design of Cyclones Separators with proper integrated design having regard to

various operating conditions and compatible input parameters can control. Dust
emissions to the extent of more than 70 percent and can achieve the emission
norms prescribed for different industries. Moreover, the cyclones are easy to
maintain and operate with cost-effectiveness on capital and recurring expenditure
front.

REFERENCE

[1] Understanding Cyclone Dust Collectors. (n.d.). Retrieved from

http://blog.fluid-eng.com/2013/09/understanding-cyclone-dust-
collectors/?fbclid=IwAR1EdGABolkMsEdy0MZBAfl8ynaLTlIJXFyHVG0pPKX
IJ0d1qqPmKPZGIro

[2] Cyclone Separators Information. (n.d.). Retrieved from

https://www.globalspec.com/learnmore/manufacturing_process_equipment/air_qu
ality/cyclone_separators

[3] (n.d.). Retrieved from

https://nptel.ac.in/courses/103103027/module5/lec2/2.html

[4] Introduction. (2008). Air Pollution Control Equipment Calculations, 1-7.

doi:10.1002/9780470255773.ch

[5] Bashir, Kashan. (2015). Design and fabrication of cyclone separator.

doi:10.13140/RG.2.2.20727.83368.

[6] Iinoya, K. (1952). On the Air flow of a Cyclone Dust Separator: (Study on a
Cyclone Dust Separator, the 2nd Report). Transactions of the Japan Society of
Mechanical Engineers, 18(69), 42-48. doi:10.1299/kikai1938.18.69_42

[7] Cyclone Separator. (n.d.). A-to-Z Guide to Thermodynamics, Heat and Mass
Transfer, and Fluids Engineering. doi: 10.1615/atoz.c.cyclone_separator

[8] Molerus, O., & Glückler, M. (1996). Development of a cyclone separator with
new design. Powder Technology, 86(1), 37-40. doi:10.1016/0032-
5910(95)03035-2
UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 14

APPENDIX
EQUIPMENT DESIGN THEORETICAL CALCULATIONS

THEORETICAL CALCULATIONS:

Basis: Volumetric flowrate of powdered milk air = 22 600 𝑚3 /ℎ𝑟

Properties:

Powdered Milk Air flowrate (Q) = 22 600 𝑚3 /ℎ𝑟

Powdered Milk Concentration = 3.2 g/𝑚3
Powdered Milk Density (𝜌𝑝 ) = 449. 94 𝑘𝑔/𝑚3
Operating Temperature = 72℃

Requirements: Design a cyclone to specify removal efficiency and pressure drop

Velocity of Air inlet Duct

𝑉𝑖 = 𝑎𝑠𝑠𝑢𝑚𝑒 = 11.18 𝑚3 /𝑠

Number of Effective Turns

1 𝐿 1 2𝐷
𝑁𝑒 = ∗ [𝐿𝑏 + 𝑐 ] = ∗ [2𝐷 + ] = 5.99 = 6 turn
𝐻 2 0.5𝐷 2

Cut Size Diameter of particle removed with 50% efficiency

𝑚3 ℎ𝑟
𝑄 22 600 ∗
D=√ =√ ℎ𝑟 3600 𝑠
= 2.1195 𝑚
𝐻∗𝑊∗𝑣𝐼 0.5∗0.25∗11.18

9∗𝑊∗𝜇 9 ∗ (0.25 ∗ 2.1195) ∗ (0.00002061)

𝑑𝑝𝑐 = √ =√
2𝜋 ∗ 𝑁𝑒 ∗ 𝜌𝑝 ∗ 𝑉𝑖 2𝜋 ∗ 6 ∗ 449.94 ∗ 11.18
= 22.77 𝜇𝑚

Particle Collection Efficiency for each size

1
𝜂𝑗 = 2
𝑑𝑝𝑐
1+( 𝑑 )
𝑝𝑖
UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 15

dpi, µm Mass Fraction, Grade Removal Grade Removal

mi (%) Efficiency, 𝜼𝒊 Efficiency *
Mass Fraction,
mi*𝜼𝒊
218.9 6 0.98930 0.059358
203.9 2 0.98768 0.0197536
203.3 6 0.98761 0.0592566
199.6 7 0.98715 0.0691005
96.6 12 0.94736 0.1136832
91.2 9 0.94132 0.0847188
78.5 14 0.92239 0.1291346
75.4 10 0.91642 0.091642
64.5 12 0.88918 0.1067016
51.2 14 0.83488 0.1168832
49.6 8 0.82594 0.0660752

Desired Removal Efficiency / Overall Efficiency for all particles

The overall efficiency, Total = 0.9163073, computed is higher than the specified
efficiency therefore; the computed diameter of the cyclone is compatible for the
application.

600
𝜂𝑜 = 1 − = 0.8125
3.2(1000)

Pressure Drop

 K = 16 (direct tangential entry)

 T = 72°C

 ρ = 7.7 kg/m3 (computed by ideal gas law)

𝐻𝑊 (0.5𝐷)(0.25𝐷)
𝐻𝑣 = 𝐾 = 16 =8
𝐷𝑒 2 (0.5𝐷)2
UNIVERSITY OF SANTO TOMAS CHEMICAL ENGINEERING 16

1 1
∆𝑃 = 𝜌𝑣𝑖 2 𝐻𝑣 = (7.7)(11.18)2 (8) = 3849.77 𝑃𝑎
2 2

Gas Residence Time

𝜋 ∗ 𝐷 ∗ 𝑁𝑒 𝜋 ∗ 2.1195 ∗ 6
Δ𝑡 = = = 3.5735 𝑠𝑒𝑐
𝑉𝑖 11.18

Saltation Velocity
1 1
4𝑔𝜇(𝜌𝑝 − 𝜌𝑓 ) 3 4 ∗ 9.81 ∗ (0.00002061) ∗ (449.94 − 7.7) 3
𝑣𝑠 = [ ] = [ ]
3𝜌𝑓 2 3(7.7)2
= 0.1262 𝑚/𝑠

Particle Drift Velocity

𝑊 0.25 ∗ 2.1195
𝑉𝑡 = = = 0.14828 𝑚/𝑠
Δ𝑡 3.5735

Relative Effect of centrifugal force

𝐹𝑐 𝑣𝑖 2 11.182
= = = 12.0229537
𝐹𝑔 𝑔𝑅 (9.81) ∗ (2.1195)
2

Power Requirement
1 1 22 600 1 1
𝑊𝑓 = 𝑄∆𝑃 = (3849.77) ( ) = 43157.14 𝑊 ≈ 43.157 𝑘𝑊
𝜂𝑓 𝜂𝑚 3600 0.8 0.7