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Mahesh Dasar In the present study, cylindrical portion of conventional (nonfinned) cyclone separator
Department of Mechanical Engineering,
was reshaped by fixing triangular, semicircular, and rectangular cross section helical
BITS PILANI—K K Birla Goa Campus,
fins in order to make it as water wall having fin size 7 mm with fin pitch of 40 mm to
NH-17(B), Air Port Road, Zuarinagar,
improve its separation efficiency and to utilize the cyclone separator as heat exchanger.
Goa 403726, India
Fluid dynamic characteristics like axial velocity, tangential velocity, pressure drops were
e-mail: P20150015@goa.bits-pilani.ac.in
studied by varying the fin geometry (triangular/semicircular/rectangular). For the par-
ticles’ size less than 3 lm, proposed cyclone separator with triangular helical fin was giv-
Ranjit S. Patil1 ing comparatively improved collection efficiency than other selected cyclone separators.
Department of Mechanical Engineering, Improvement in the collection efficiency of triangular fin-based cyclone separators was
BITS PILANI—K K Birla Goa Campus, perceived from 5% to 10% over the conventional cyclone separator. Hence, helical fins
NH-17(B), Air Port Road, Zuarinagar, with triangular in cross section were selected further for heat transfer and scale-up stud-
Goa 403726, India ies. It was observed that for the small barrel wall height (h ¼ 400 mm) water temperature
e-mail: ranjitp@goa.bits-pilani.ac.in was enhanced by 4 C, and with scale-up (making h ¼ 800 mm) it was increased consider-
ably around 15 C. Thus based on improved separation efficiency to capture very-fine
particulate matter (PM 2.5, which otherwise causes serious health issues) and consider-
able temperature gain of water noted at lab level scale-up study, triangular helical fins
may be to fixed on the inner surface of barrel wall of conventional (nonfinned) cyclone
separators in order to use them as heat exchanger for energy conservation in industrial
applications. [DOI: 10.1115/1.4046303]
Keywords: finned cyclone separator, heat transfer, helical fins, scale-up, separation
efficiency
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tion efficiency have not been reported yet either by experimental !
study or by numerical study. However, while making cyclone sep- @u0i @u0j
/ij ¼ P þ (3c)
arator as heat exchanger via helical fins for possible heat loss @xj @xi
reduction from its hot wall, it is important to understand its fluid-
dynamic characteristics, since heat transfer characteristics are the eij is dissipative term:
function of them and also one should not forget main function of
separating particles from gases, which should not be altered or @u0i @u0j
affected (separation efficiency should not be decreased). eij ¼ 2l (3d)
Hence, this paper is investigating the best (optimal) helical fin’s @xk @xk
cross section out of triangular, rectangular, and semicircular
which were fixed on the inner surface of the conventional (non-
finned) cyclone separators’ barrel wall, which results in compara- 2.1 Discrete Phase Model. As the particles hit cyclone wall
tively improved collection/separation efficiency than conventional soon after entering through the gas-inlet, the particles affected by
(nonfinned) cyclone separator. It also compares fluid dynamic the centrifugal force having the higher inward drag force are
characteristics of three selected fin-based cyclone separators with forced to move downward, similarly the particles’ having the
nonfinned cyclone separator. It also investigates the effect of opti- lower inward drag force than the centrifugal force starts moving
mal fin-based cyclone separator on its heat transfer characteristics in upward direction. The particles affected by centrifugal force
such as gain in temperature of water flowing inside the optimal having the equal inward drag force to centrifugal force, they start
fin. Also, effects of scale-up of optimal fin-based cyclone separa- rotating in equilibrium and starts moving down and hits the slant
tor on its separation efficiency and temperature gain were edge of the cyclone separator and are collected at the bottom
predicted. (solid-outlet) of cyclone separator. Two-phase flow was modeled
with discrete phase model which is Eulerian–Lagrangian approach
2 Numerical Method in ANSYS-FLUENT 15.0.
Isolated particles’ flow simulation is performed with the help of
Two-phase flow simulations for the novel fin-based cyclone particle tracking method. Separation efficiency was obtained using
separators’ were accomplished with the help of ANSYS-FLUENT 15 Eulerian–Lagrangian approach [28]. Particle motion equation
research code. Turbulent flow was considered in the present study used was
since Reynolds number was calculated as 72,189 based on the
flow inlet criteria as reported by Elsayed and Lacor [21]. Reynolds dupi gi ðqp qÞ
¼ FD ðui upi Þ þ (4)
stress model was used in the present study since it is the most dt qp
opted turbulence model [4,5,7,8,21–23] over the k–e turbulence
models for the simulations of the complex swirling flows in the dxpi
¼ upi (5)
cyclone separator. dt
Most of the industries for the turbulent flow simulations uses
Reynolds stress model [24]. Reynolds stress model is best suitable where FD ðui upi Þ is the drag force per unit particle mass
turbulence model for the complex three-dimensional simulations 18l CD Rep
which are having strong streamline curvature, swirling motion FD ¼ (6)
with rotational flow [25]. qp dp2 24
Three-dimensional conservation equation for the steady, incom-
pressible, and isothermal flow as described by Safikhani et al. [26] qp dp ju up j
Rep ¼ (7)
and Hesham [27] l
@u i
¼0 (1) Drag coefficient CD is a function of relative Reynolds numbers,
@xj which is in the form of
CD ¼ 24=Rep For 0 < Rep 1
@ ðu i Þ @P @ @u i @u j @sij (8)
quj ¼ þ l þ þ (2) CD ¼ 24=Rep ð1 þ 0:15Re0:687 Þ For 0 < Rep 1000
@xj @xi @xj @xj @xi @xj p
where u i and u j are mean velocity in i and j directions, respec- 2.2 Modeling. When the barrel height and conical length are
tively, xj is the position, P is the mean pressure, q is the constant double the barrel diameter; Lapple proposed it as a 2D2D type
gas density, and sij is the Reynolds stress tensor given by cyclone separators[29]. The 2D2D type cyclone separator was
sij ¼ qu0i u0j . witnessed as highly performable and highly preferable in many
industries among all other types of cyclone separator available
The Reynolds stress model transport equation [27,28] can be [30]. In the present study, 2D2D type conventional (nonfinned)
written as cyclone separator (Fig. 1) was used with geometrical dimensions
shown in Table 1. Three geometries were proposed: triangular,
@
uk quk u0i u0j ¼ Dij þ Pij þ /ij eij (3) semicircular, and rectangular geometries as shown in Fig. 2 which
@xk are fixed on the inner surface of barrel wall (cylindrical portion)
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Table 2. Mixture inlet (as shown in Fig. 1) through which
gas þ solid mixture enters the cyclone separator was given as
velocity-inlet boundary conditions with 20 m/s velocity magnitude
constant with 3% turbulence intensity and hydraulic diameter as
0.06 m was used [8,31].
Pressure-outlet boundary condition was applied at gas-outlet
with 3% turbulent intensity and hydraulic diameter as 0.1 m. No-
slip wall boundary condition was chosen for the solid outlet and
cyclone body. Solution was controlled using 40 as flow courant
number, explicit relaxation factor as 0.6 for the pressure and 0.08
for the momentum.
In the present study, steady-state solver with Reynolds stress
model was utilized by setting the convergence criteria as 105
since many researchers [8,18,31,32] have implemented it. Study
on the flow behavior by changing the outflow length was proposed
by Wang et al.[8]. They have conducted steady and unsteady-state
simulations on the cyclone separator and observed that the
unsteady-state solver may affect slightly on the flow-field
behavior. However, qualitatively and quantitatively, axial and
tangential-velocity profiles were noted to be very close for the
steady and unsteady-state solver.
Fin shape Pitch size (mm) Fin size (mm) Chosen number of nodes (K) Yþ value measured
3 Results and Discussion—Part-I: Fluid Dynamics height of cyclone separator from where the axial-velocity data
Study were extracted are, 300 mm which is in cone region, 500 mm
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which is at the end of cylindrical drum portion where helical fins
In this section, the output of triangular, semicircular, and rec- turn ends, and 700 mm which is just below the vortex finder in the
tangular fin-based cyclone separators in terms of fluid dynamics cylindrical region of cyclone separators. The axial-velocity pro-
characteristics influencing the separation efficiency were dis- files proposed by Wang et al. [8,37–40] are qualitatively similar to
cussed in detail. Also results of the fin-based cyclone separators those presented in the current study for fin-based cyclone separa-
were compared with conventional (nonfinned) cyclone separator. tors and conventional (nonfinned) cyclone separator.
As observed from Fig. 4(a) at 700 mm location because of the
3.1 Axial Velocity. Collection efficiency of cyclone separa- swirling flow and centrifugal force inside the cyclone separators,
tors is strongly influenced by axial velocity. Figure 4(a) shows the high self-weight particles were pushed toward wall and particles
comparison of axial-velocity profiles of triangular fin-based within the region measured 40 mm from the wall were moving
cyclone separator with conventional (nonfinned) cyclone separator downward as the axial velocity is observed to be negative, means
at various locations 300 mm, 500 mm, and 700 measured from the the axial velocity’s direction was in downward direction. In this
bottom of cyclone separator. The different locations along the regime due to friction, axial velocity continuously decreases till
the end of barrel wall length of the cyclone separator and then
increases due to sloping edges of the conical regime.
Effects of fins’ shape variations at 700 mm location on axial-
velocity profile of fin-based cyclone separators is as shown in
Fig. 4(b). Influence of fins’ shape variations on axial velocity was
observed to be very minute as realized from Fig. 4(b). However,
as shown in Fig. 4(b), fins with triangular cross section were hav-
ing higher axial velocity in the upward direction at the core region
of cyclone separator. Hence, separation efficiency (Sec. 3.4) for
fins with triangular cross section was noted to be higher than that
of semicircular and rectangular fin-based cyclone separators.
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also observed from Fig. 5(a), as the tangential velocity of mixture
flow decreases as flow moves downward along the wall of cyclone Fig. 5(a)) in the higher particle concentration region (close to inlet
separator and becomes zero at 100 mm radial distance from the of cyclone separator, i.e., about 700 mm measured from the bot-
center due to available friction between fluid and wall and no-slip tom of cyclone separator) where tangential velocity forces the par-
boundary condition, which helps solid particles’ stick to wall till it ticles toward wall. Hence, more particles were pushed toward
reaches collection point (solid outlet at the bottom of the cyclone wall in fin-based cyclone separators than conventional (nonfinned)
separator). cyclone separator. Subsequently, improved axial velocity
Comparisons of tangential-velocity profile for three different (Fig. 4(a)) which helps to push these particles in the downward
fin-based cyclone separators is shown in Fig. 5(b) which repre- direction toward bottom solid-outlet.
sents the effects of different fin geometry variations made at Additionally, helical path formed between the subsequent turns
500 mm measured from the solid-outlet. Influence of geometry of the fin help to provide the space for the particles to gather and
variations on tangential velocity was observed to be very minute to move downward toward following helical path. These particles
as realized from Fig. 5(b). However, tangential velocity for experiences additional frictional force due to fin other than fric-
tion caused due to cyclone separator’s wall which helps to avoid
their movement toward the central core of air jet moving in the
upward direction toward gas-outlet at the top.
Hence, the number of particles collected at the bottom of fin-
based cyclone separator was more than those with conventional
(nonfinned) cyclone separator. Also reversal of air jet takes place
close to the bottom solid outlet for the fin-based cyclone separa-
tors (341 mm above solid outlet for triangular fin, 347 mm for
semicircular fin, 377 mm for rectangular fin, and 454 mm for non-
fined cyclone separator), hence due to close reversal to solid outlet
chances of more particles’ separation were increased for triangular
fin-based cyclone separator having fin size 7 mm with 40 mm
pitch (Fig. 6). In this way, the triangular fin-based cyclone separa-
tor used in Secs. 4 and 5 to make the cyclone separators as heat
exchanger.
Important conclusions can be made from the fluid dynamic
study.
Axial pressure drop was increased because of the helical fin
fixed on the inner surface of the cylindrical portion of the
cyclone separator. Axial pressure drop for the nonfinned
cyclone separator was 0.18 kPa, while it was observed in the
range of 0.32–0.37 kPa for the fin-based cyclone spectators.
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geometry which was used for the fluid dynamics study (Secs.
3.1–3.4) with additional water inlet and water outlet arrangements
as shown in Fig. 7.
Fig. 8 Mass flow rate comparison along the cyclone separator barrel wall
p v2
E¼h þ (12)
q 2
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and for incompressible flows as
X p
h¼ Yj hj þ (14)
j
q
@ X
ðqEÞ þ r:ðmðqE þ pÞÞ ¼ r: keff rT hj Jj þ ðs eff :vÞ þ Sh 4.3 Grid Independence Test. Grid independency test were
@t
carried out to check the dependency of grid on performance of tri-
(11) angular fined cyclone separator. Three different mesh volume
were created for triangular fin-based cyclone separator, for the
where keff is the effective conductivity (k þ kt where kt is the tur-
bulent thermal conductivity, defined according to the turbulence
model being used) Jj is the diffusion flux of species j.
The first three terms on the right-hand side of Eq. (11) represent
energy transfer due to conduction, species diffusion, and viscous
dissipation, respectively.
Fig. 10 Scale-up of fin-based cyclone separator by doubling Fig. 11 Contours of total temperature measured along the
the size (mm) length of helical fin for scaled-up fin-based cyclone separator
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fins, then conduction heat transfer in the triangular helical fin
which is having thickness of 1.5 mm and again convection heat
transfer between the water flowing inside the triangular fin and
surface of the triangular fin. The heat will be transferred into the
cyclone separator body as the gas and solid mixture enters through
the inlet at 900 C temperature. The novel fin-based cyclone sepa-
rator having barrel wall with helical triangular fins attached in
which the water will be entering at a 30 C temperature as shown
in Fig. 7. Optimized water mass flow is necessary to extract the
Fig. 12 Comparison of collection efficiency for scaled-up tri- maximum heat from the hot gas þ solid mixture flowing outside
angular fin-based and scaled-up nonfinned cyclone separators
the fin. Therefore, simulations were carried out in order to investi-
gate the optimized mass flowrate (kg/s) of water entering the heli-
first set numbers of nodes were 5,65,868 (565 K), for the second cal fin triangular in cross section. Accordingly, six various mas
set number of nodes were 7,58,088 (758 K), and for the third set flow rates such as 0.5 kg/s, 1 kg/s, 1.5 kg/s, 2 kg/s, 2.5 kg/s, and
number of nodes were 12,51,461 (1251 K). Temperature of water 3 kg/s were tested. Results obtained on increase in temperature of
flowing inside the triangular fin was measured along the helical water are presented as shown in Fig. 8.
path way of fin attached on the barrel wall for all three sets of Water enters the helical pathway of triangular fin at 30 C
nodes. Temperature measured for all three sets of triangular fined through the water inlet port, flows through 9 turns of helical fin
cyclone separator were compared, and it is observed that the tem- and finally reaches the water outlet port as shown in Fig. 7. As
perature measured for the 758 K nodes and 1251 K nodes were shown in Fig. 9, per turn, temperature was measured at two points
close to each other. Hence, the mesh closer to 758 K nodes with separated by a distance approximately equal to diameter of
Fig. 13 Comparison of temperature measured along fin length for normal triangular fin-based
cyclone (Fig. 10) separator and scaled-up triangular fin-based cyclone separator (Fig. 10)
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based cyclone separator as shown in Fig. 10. As shown in Fig. 11,
reduction in temperature of gas–solid mixture is observed as it
moves downward since the water flowing inside the fin extracting
the heat from the gas–solid mixture hitting the fin. References
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