Design Practices for Fluid Solids Particle Collection Cyclones

DESIGN PRACTICES
FLUID SOLIDS Section Page

VI-C 1 of 67
EXXON PARTICLE COLLECTION
Date
ENGINEERING PROPRIETARY INFORMATION — For Authorized Company Use Only December, 1995
CONTENTS
Section Page
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADDITIONAL REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CYCLONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cyclone Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Multiclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Typical Cyclone Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CYCLONE DESIGN CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Design Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inlet Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gas Outlet Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cyclone Size and Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Number of Cyclones, Number of Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Other Design Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gas Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Solid Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Collection Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CYCLONE CALCULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cyclone Collection Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cyclone Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calculation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Vendor Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reliability of Cyclone Calculation Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIPLEG DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dipleg Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dipleg Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dipleg Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CYCLONE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TERTIARY CYCLONE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OTHER GAS, SOLIDS SEPARATION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SOLIDS LOSSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SAMPLE CALCULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cyclone Efficiency, Particle Size Distributions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cyclone Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

DESIGN PRACTICES
Section Page FLUID SOLIDS
VI-C 2 of 67
PARTICLE COLLECTION EXXON
Date
December, 1995 PROPRIETARY INFORMATION — For Authorized Company Use Only ENGINEERING
CONTENTS (Cont)
Section Page
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
APPENDIX A
PROGRAM T-3575, FLUIDIZATION AND PARTICULATE EMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Entrainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Dilute Phase Holdup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cyclone Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ESP Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Program Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Program Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TABLE & FIGURES
Table 1 Cyclone Sample Calculation – Efficiency, Particle Size Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 1 Typical Cyclone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 2 Variations of Cyclonic Inlet and Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 3 Two Stage Cyclone System Installed in Process Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 4 Internally Mounted Cyclone Used in Solids Transfer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 5A Ducon Model 810 Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 5B Ducon Model 800 Cyclone L / D = 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 6A Van Tongeren Type 350 Through 850 Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 6B Van Tongeren Type 850 Cyclone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 7 Emtrol Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 7A Emtrol Type A, Type X Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 7B Emtrol Corp. Hauppauge, New York . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 7C Emtrol Corp. Hauppauge, New York . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 7D Emtrol Corp. Hauppauge, New York . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 7E Emtrol Model 1550 Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 8 General Electric Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 9 Cyclone Inlet, Outlet Sizes and Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 10 Performance Debit for Manifolding of Multiclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 11 Grade Efficiency Correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 12 Loading Correction Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 13A Gas Side Velocity Head Factors for Ducon Model 810 Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 13B Solid Side Velocity Head Factors for Ducon Model 810 Cyclone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 13C Gas Side Velocity Head Factors for Ducon Model 800 Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 13D Solid Side Velocity Head Factors for Ducon Model 800 Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 14A Gas Side Pressure Drop for Emtrol Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 14B Solid Side Pressure Drop for Emtrol Cyclones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 15 Cyclone Pressure Drop Factor for Dust Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 16 Trickle Valve – Unshrouded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 17 Trickle Valve – Open Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 18 Elbow Trickle Valve with Double Refractory Flapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 19 Cyclone Sample Calculation – Particle Size Distributions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Revision Memo
December 1995 Corrections and minor updates.

DESIGN PRACTICES
VI-C 3 of 67
Date
SCOPE
This subsection discusses removal and collection of particulate matter from gases. Cyclones are the principal solid, gas separation
devices described. References are given to descriptions of other solid, gas separation systems such as bag filters, scrubbers and
electrostatic precipitators.
This subsection also describes the methods used to estimate solids losses in the gases from a fluid solids process by means of
attrition, entrainment and loss through multistage cyclone systems.
REFERENCES
1. Design Practices, Section XVIII A-3, Cyclones.

2. Matsen, J. M., Calculation of Cyclone Efficiency, EE.2ERL.69.
3. Tao, L. L., R. C. Hoke, Revised Program T-3575, Fluidization and Particulate Emissions, EE.1FF.85 (March 1985).
4. Danielson, A. M., Improved Reactor Trickle Valve Design for Fluid Catalytic Cracking Units, EE.13E.88 (February 1988).
ADDITIONAL REFERENCES
1. Skouby, D. C., Rossetti, S. J., and Hoke, R. C., Improved Cyclone Performance Correlation. EE.76E.93 (November 1993).
CYCLONES
Cyclone design is also described in Design Practices Section XVIII(1). A cyclone is a static device which separates solids from a
gas (or from a liquid) by centrifugal force. A typical cyclone is shown in Figure 1. Gas and suspended solids enter the cyclone at
a relatively high velocity through a tangential inlet section. The tangential entry generates an inlet vortex as shown in Figure 1. The
centrifugal forces tend to drive the solids to the wall of the cyclone where they are separated from the vortex by impact with the wall.
The solids then drop to the bottom of the conical section of the cyclone from where they are discharged through a solids outlet line.
The cleaned gas forms a second (outlet) vortex which passes out through the gas outlet tube at the top of the cyclone.
The tangential inlet, axial dust outlet is the most common configuration used in Exxon installations. A variation of the standard
tangential inlet design is the scroll or wrap-around inlet as shown in Figure 2A. This variation is widely used in Exxon installations
including most primary cyclones. Scroll inlets are discussed in more detail in a subsequent paragraph. In addition to cyclones with
a tangential inlet and axial dust outlet, cyclones are also built with an axial inlet and outlet (Figure 2B). In this case, the vortex is
generated by inlet vanes. Clusters of small axial inlet cyclones, called multiclones, are used in some installations.
CYCLONE APPLICATIONS
Cyclones should be given first consideration for particulate removal due to their low cost and compact size. However, cyclones have
certain disadvantages, such as lower collection efficiency, compared to some other devices. Following is a listing of their advantages
and disadvantages.
Advantages
Compactness. Cyclones have a high capacity to size ratio. They are small enough to be placed inside process vessels and
can be used for internal recycle of collected solids.
Low installation and maintenance cost.
Ease of staging. The above advantages permit staging of cyclones to improve collection efficiency.
Operation at high inlet dust loading.
Operation at high pressure and high temperature, limited only by materials considerations.
Available in a wide range of efficiencies and gas handling capacities.
Mechanical reliability.
Flexibility. The outlet area can be decreased to increase efficiency at the price of increased pressure drop. The outlet area can
be increased to increase capacity without increasing pressure drop or lowering efficiency.

DESIGN PRACTICES
VI-C 4 of 67
Date
CYCLONES (Cont)
Disadvantages
Low collection efficiency for particles less than 5 m.
High pressure drop (although not as high as certain wet scrubbers).
Tendency to foul and plug when handling solids which are “sticky” or not free flowing.
Dependence of performance on inlet velocity. Collection efficiency decreases at inlet velocities less than 40 ft/s (12 m/s) due
to low centrifugal forces, and greater than 120 ft/s (35 m/s) due to re-entrainment of collected dust. In addition, cyclones are
prone to erosion at higher inlet velocities and the upper acceptable inlet velocity in a function of the inlet dust loading and particle
size. Particle attrition will also occur at higher velocities. These items are discussed further in subsequent paragraphs.
Multiclones
Multiclones, described previously and shown in Figure 2B, have been used in a small number of Exxon installations. The primary
advantage of multiclones compared to the standard tangential inlet cyclones is higher efficiency. This is due to the smaller diameter
of the individual multiclones. The higher efficiency can also be traded for lower pressure drop at the same efficiency.
The main disadvantage of multiclones is more costly installation and maintenance. This is due to the need to use a much larger
number of individual multiclone units for the same throughput. Smaller clearances in some models can also lead to plugging
problems, The efficiency advantage may also be decreased by gas recirculation as noted later.
A proprietary small cyclone system developed by Polutrol in Europe, claims the advantages of small cyclones without all the
disadvantages described above. It is currently used in some Non-Exxon FCC installations in place of conventional third stage
cyclone systems. When used in conjunction with a turbo expander, Polutrol claims improved blade life and longer expander run
lengths. One significant advantage of the Polutrol system is compactness. A smaller diameter tertiary cyclone vessel is possible
and expansion can occur by increasing the vessel straight side instead of diameter.
TYPICAL CYCLONE INSTALLATIONS

Cyclones are currently used within Exxon, where they are installed inside process vessels to retain and return collected solids. They
are also used in external tertiary collection systems, in solids transfer systems and in cleanup of incinerator stack gas.
Figure 3 shows a typical two-stage cyclone system installed within a process vessel. The cyclones return solids back to the fluid
bed through diplegs immersed in the fluid bed or a little above it.
Figure 4 shows a cyclone installation used in a solids transfer system.
CYCLONE DESIGN CONSIDERATIONS
The design of a cyclone system consists in the specification of a number of design parameters. This includes gas inlet and outlet
conditions, cyclone size and shape, the number of cyclones and number of stages. These parameters can be specified by the
designer, within certain limitations. Specification guidelines are given below. The design is also influenced by certain fixed conditions
such as gas and solid properties, required collection efficiency and possibly, required pressure drop. The fixed conditions are usually
specified in the DBS. The effects of the fixed conditions on cyclone design are also described below. Subsequent paragraphs detail
certain calculation procedures, and treat dipleg design and cyclone layout and placement.
Vendor contacts should be made early in the design of a cyclone system to allow inclusion of any desirable design features
suggested by the vendor.

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CYCLONE DESIGN CONSIDERATIONS (Cont)
DESIGN PARAMETERS
Certain key dimensions must be specified in designing a cyclone. Experience has indicated that the optimum cyclone geometry
is fairly consistent. A generalized picture of the geometry can be given by relating the key dimensions to the cyclone diameter. This
is shown in the following table:
CYCLONE GEOMETRY
Inlet
width (wi/db) 0.2 – 0.3
height (hi/db) 0.5 – 0.8
area (Ai /db2) 0.09 – 0.23
height/width (hi/wi) 2/1 – 3/1
Outlet
Diameter (do/db) 0.4 – 0.6
area (Ao/db 2) 0.13 – 0.25
Outlet/Inlet Area 0.5 – 1.5(1)
Length (/db) 3–5
where: db is the cyclone barrel diameter

wi is the inlet width
hi is the inlet height
Ai is the inlet area
do is the outlet tube diameter
Ao is the outlet area
is the cyclone length
Additional discussion of the specification of these dimensions is given in the following paragraphs. The exact dimensions are
obtained from vendors’ specifications modified as needed to conform to Exxon design practice. However, it is suggested that the
vendors be guided by specifying cyclone efficiency, inlet area, length, diameter, and other basic dimensions in a request for bid,
to assure that the cyclone designs provided by the vendors will meet performance requirements. Preliminary specifications for
Ducon, Van Tongeren, Emtrol and General Electric cyclones are given in Figures 5 through 8. Vendors should also be contacted
to confirm that the preliminary specifications shown in the figures are up to date.
Inlet Conditions
Inlet conditions to be specified in the design include inlet velocity, area of the inlet section (height, width) and inlet configuration
(tangential vs. scroll).
Inlet Velocity. Increasing inlet velocity increases collection efficiency up to a maximum value. At higher velocities, efficiency
decreases due to turbulence-induced re-entrainment. Erosion of the cyclone body will also occur at high velocity. The extent
of erosion is also dependent on the inlet particulate size,hardness and loading and the internal configuration of the cyclone.
The following table gives ranges of inlet velocities use d in various applications. Consult process documents for specific
acceptable ranges.
ALLOWABLE CYCLONE INLET VELOCITIES
ft/s
(m/s)
PRIMARY SECONDARY TERTIARY
STAGE STAGE STAGE
55 – 75 55 – 85 90 – 120
(17 – 23) (17 – 26) (27 – 37)
Note:
(1) Lower ratios have been used, but are not common due to outlet velocity limitations.

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In special cases, lower inlet velocities can be used, but the outlet area must be decreased to maintain collection efficiency.
Inlet Shape. The inlet to the cyclone has a rectangular cross section with a height to width ratio in the range of 2/1 to 3/1. This
range of ratios minimizes the width, thereby minimizing the lateral distance particles must travel before impacting on the wall
and being collected. The narrow width also minimizes the distance between the outlet gas tube OD and the cyclone wall needed
to prevent impact of inlet solids on the outlet gas tube and subsequent outlet tube erosion. See Figure 9.
Inlet Configuration. Two types of inlet configurations, the tangential and scroll (or volute) are used depending on the size of
the outlet tube diameter. The two types of inlet configurations are shown in Figure 9. The scroll inlet prevents impact of inlet
solids on the outlet gas tube in those cases where a large outlet tube diameter is required, for example, to reduce pressure drop
through the cyclones.
Tangential inlet configurations are used when scroll inlets are not required.
Gas Outlet Conditions
The gas outlet conditions to be specified in the design are outlet tube diameter (or outlet to inlet area ratio) and outlet tube
insertion length.
Gas Outlet Tube Diameter. Decreasing the gas outlet tube diameter increases the collection efficiency but also increases the
pressure drop through the cyclone. The increased efficiency is due primarily to a higher outlet vortex velocity. The outlet tube
diameter is often specified by specifying the outlet to inlet area ratio, Ao/Ai. Outlet to inlet area ratios for various applications are
given in the following table. Consult process documents for specific ratios.
GAS OUTLET TO INLET AREA RATIO (Ao/Ai)

PRIMARY SECONDARY TERTIARY
STAGE STAGE STAGE
1.0 – 1.5 0.5 – 1.0 0.5 – 0.7
Outlet tube diameter should be 24 in. (0.6 m) or more to permit inspection. Removable inserts have been used in some cases
to reduce the diameter and still permit inspection. However, removal is difficult and some compromises are usually made during
inspection to avoid insert removal. Removable inserts can also be used when expansion of the cyclone capacity is expected.
Outlet Tube Insertion. The outlet tube should extend into the cyclone from 0.8 to 1.0 the inlet height (hi). Shorter insertions
result in bypassing from the inlet to outlet. Long insertions interfere with the vortex, increase pressure drop, and reduce
collection efficiency.
Cyclone Size and Shape
Cyclone Diameter. Increasing the diameter of geometrically similar cyclones decreases collection efficiency due to lower
centrifugal forces and the effect of an increased inlet width. Since geometrically similar cyclones have the same ratio of inlet
area to cyclone diameter, the larger cyclones will have increased throughput capacity. However, if inlet area and gas flow rate
are held constant, increasing the cyclone diameter will increase collection efficiency. This is due to longer residence time in
the cyclone.
Grouping of small (6 to 10 inch (150 to 250 mm) diameter) cyclones in multiclone clusters does not yield the entire theoretical
advantage of their small size due to entrainment from the dust hopper. This is shown in Figure 10. Increasing the fraction of
the inlet gas which passes down the dipleg (gas underflow) will decrease dust entrainment and increase efficiency. However,
this will require more underflow gas to be handled along with the solids.
Minimum cyclone diameters are usually set by maintenance requirements. The cyclone diameter should be large enough to
permit internal inspection and repair. Since cyclone length increases with diameter, the maximum diameter is set by the overall
length of the cyclone and its dipleg which can be housed in the containing vessel, without excessively increasing the height
of the vessel. Maximum diameter is also affected by collection efficiency, since efficiency decreases with diameter for
geometrically similar cyclones. Cyclone diameters typically range from 42 to 100 in. (1.1 to 2.5 m).
Cyclone diameters less than the above have been used, but the small size may require early replacement due to maintenance
difficulties. The smaller cyclones are more efficient, are shorter, thereby allowing shorter vessel straight side, and may permit
increased capacity due to the ability to pack more of them into the top of the vessel. However, if greater efficiency is desired,
decreasing the cyclone outlet pipe diameter can have a more significant effect than decreasing cyclone diameter, assuming
the increased pressure drop can be tolerated.

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D Cyclone Length. Cyclones should be long enough to contain the natural vortex length. This maximizes the residence time of
the rotating gas and solids and increases collection efficiency. It also decreases erosion caused by the vortex. As the outlet tube
diameter is decreased, the velocity of the outlet vortex increases. This requires lengthening the cyclone to prevent erosion
caused by the higher vortex velocity. The relationship between outlet to inlet area and cyclone length to diameter ratio is shown
in the following table.
CYCLONE LENGTH
Ao/Ai MINIMUM LENGTH TO DIAMETER
1.35 + 3.0
1.0 – 1.35 3.5
0.75 – 1.0 4.0
0.65 – 0.75 4.4
0.5 – 0.65 4.7
0.5 or below 5.0
The ratio of the length of the conical section to the total length of a cyclone is not a critical factor and is set by the vendor. Longer
cones may be preferred in some cases to aid in drainage of the collected solids. The maximum included cone angle should
be 40_.
D Roof Configuration. The flat roof design is preferred over the helical roof design. The benefits of the helical roof design,
if any, do not justify the extra fabrication cost. Helical roofs may also be subject to higher erosion rates and poorer
cyclone performance.
Number of Cyclones, Number of Stages
The number of cyclones per stage is determined by balancing the effects of diameter, length, velocity, erosion, efficiency and
maintenance described above. Cyclone placement is another factor to consider.
The number of stages per installation depends on the required efficiency and pressure drop. In some installations, two stages are
used with an external tertiary stage to provide additional particulate control if needed.
OTHER DESIGN FACTORS

Additional design factors such as gas and solids properties are usually fixed prior to the design. The collection efficiency (or solid
losses) and cyclone pressure drop are factors which are determined in the course of the design.
Gas Properties
Gas density and viscosity influence design and performance. Increasing gas density increases pressure drop. Gas density has a
negligible effect on collection efficiency except at high pressure where gas density becomes significantly large when compared
to particle density. In this case, increasing gas density decreases collection efficiency. Increasing gas viscosity decreases
collection efficiency.
Solid Properties
D Particle Size. Larger particles are collected more efficiently than smaller particles.
D Particle Density. Denser particles are collected more efficiently. The significant density parameter is particle density rather than
bulk or skeletal density.
D Dust Loading. Increased dust loading increases collection efficiency.
Collection Efficiency
The cyclone system must be chosen to meet the required collection efficiency (or solids losses). The primary factors affecting
efficiency as described above are inlet velocity, outlet tube diameter, cyclone diameter and length, number of stages, gas properties,
particle size distribution, density and loading. The efficiency (or solids losses) of the cyclone system should be calculated to assure
that the specified efficiency is realistic. Comparison with available commercial experience is suggested to be sure that all factors
affecting collection efficiency have been considered in the efficiency calculation. Calculation of efficiency is described in a
subsequent paragraph.

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Pressure Drop
Factors affecting pressure drop include many of the factors affecting efficiency. In many cases, increasing pressure drop also
increases efficiency. When the pressure drop must be limited, the design must trade off pressure drop, efficiency and, possibly,
maintenance considerations. If a higher pressure drop is available, high efficiency can be obtained for a given flow rate with large
diameter cyclones by increasing inlet velocity, decreasing the outlet tube diameter or adding additional stages. If the pressure drop
is limiting, high efficiency for a given flow rate can be obtained by using a larger number of small cyclones in parallel, but at the
possible risk of making maintenance more difficult. Cyclones less than 42 in. (1.1 m) diameter may require disassembly for
maintenance, adding to cost and turnaround time. In certain circumstances, pressure drop limitations can be removed by increasing
the vessel straight side during turnaround, thereby permitting longer cyclone diplegs and higher allowable cyclone pressure drops.
Calculation of pressure drop is described in subsequent paragraphs.
Flexibility
Cyclone systems should not be designed to tight limits. Sufficient flexibility should be included to allow for future changes in
operations such as feed or catalyst changes, for pressure fluctuations, emergencies, etc.
CYCLONE CALCULATIONS
Computer program T-3575 can be used to calculate cyclone efficiency and pressure drop. This is a general purpose fluid solids
program described in Appendix A. The equations and correlations used to calculate cyclone performance in T-3575 are described
below. The equations and correlations can be used to make “hand” calculations of efficiency and pressure drop. Additional
background is given in references (2) and (3).
CYCLONE COLLECTION EFFICIENCY
Cyclone collection efficiency is based on the use of a generalized grade efficiency curve shown in Figure 11. In this figure, efficiency
is given as a function of a relative particle size, dp/dc where dp is the particle size and dc is the critical particle size. The critical particle
size is that size collected at 50% efficiency. It is given as:
ƪ ƫ ƪ ƫ
0.25 0.5
mw i d o
ƪ0.52 ƫ
hi 0.33
d c + 2.85 L f ρp Vȏ Vf (ft), (m) Eq. (1)
pd b z
where: dc is the critical particle diameter (ft), (m)

Lf is a particle loading factor
hi, wi, db, dp, do are as described above (ft), (m)
m is the gas viscosity (lbs/fts), (kg/ms)
ρp is the particle density (lbs/ft3), (kg/m3)
V is the inlet velocity (ft/s), (m/s)
ȏ is the effective cyclone length, defined below (ft), (m)
z is the Heywood shape factor (Table 1, Subsection E)
L is particle loading (lb/ft3) (kg/m3)
Lc is a corrected loading, (120/ρp)L (lb/ft3) (1923/ρp)L (kg/m3)
Vf is a velocity correction factor tabulated below for different values of Lc
Lc Vf
Lc t 0.1 1
0.1 t Lc t 1 (1 + log10Lc) (0.032 V0.9) – log10Lc (ft/s )
(1 + log10Lc) (0.093 V0.9) – log10Lc (m/s )
Lc u 1 0.032 V0.9 (ft/s)
0.093 V0.9 (ft/s)
More efficient cyclones have lower values of dc, i.e., the higher the efficiency, the smaller the particle size captured at 50% efficiency.
Equation (1) illustrates the effects of design variables described previously. For example, for geometrically similar cyclones, where all
dimensions remain in the same proportion to barrel diameter as barrel diameter changes, i.e., hi = k1 db, wi = k2 db, ȏ = k3 db, do = k4
db, dc is proportional to db. This indicates that efficiency decreases with increasing diameter for geometrically similar cyclones. However,
as cyclone diameter increases at a constant inlet area and cyclone length, dc decreases and efficiency increases.

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CYCLONE CALCULATIONS (Cont)
Cyclone length, ȏ, is the effective length, given as the smaller of:
ƪ ȏ
ȏ1 + ȏb ) c
3
ƫ (ft), (m) Eq. (2)
ȱ ȳ
ȏ 2 + ȏ b ) 1 ȧ2.3 d o ƪ b ƫ
1ń3
d2
) ȏ o * ȏ bȧ (ft), (m) Eq. (3)
Ȳ ȴ
3 hi wi
where: ȏb is the length of the barrel (ft), (m)

ȏc is the length of the cone (ft), (m)
ȏo is the length of the outlet tube insertion (ft), (m)
The loading factor, Lf, is given in Figure 12 for solids with ρp = 120 lbs/ft3 (1920 kg/m3). For other solids, the loading is corrected
by multiplying by 120/ρp (1920/ρp – metric) before using Figure 12.
To calculate cyclone performance for a given set of inlet conditions, including inlet particle size distribution, the following procedure is used:
1. Calculate dc from equation (1), (2) and (3) and Figure 12.
2. Divide a log normal probability plot of inlet particle size vs. cumulative weight percent into n equal segments. Ten segments are
suggested with midpoints of 5, 15, 25 – up to 95%.
3. Divide the particle diameter, d, of the midpoint of each segment by dc.
4. From Figure 11, determine collection efficiency for each value of d/dc. Plot efficiency vs. d to obtain the grade efficiency curve,
if desired.
5. Calculate the overall efficiency by summing values of efficiency for each segment and dividing the total by n:
Eff + S Effńn
6. Calculate the solids losses as:
(1 * Eff) (Inlet solids rate) Eq. (4)
7. Calculate the particle size distribution of the collected material by first calculating the ratio of the efficiency for each segment
divided by the sum of the efficiencies for all segments, or:
EffińS Eff
Effi is the efficiency of one segment. A cumulative particle size distribution is obtained by plotting the maximum
particle size in Segment 1 (5% mid particle size segment) against Eff1/SEff, the maximum particle size in Segment 2 against
Eff1/SEff + Eff2/SEff, etc., up to the tenth segment (95% mid particle size segment).
8. Calculate the particle size distribution of the material escaping the cyclone in a similar fashion. In this case, the term used is
(1 – Effi)/S (1-Eff). Use the maximum size of each segment to make the cumulative particle size distribution plot.
See the sample calculation for further illustration of the calculation procedure.
CYCLONE PRESSURE DROP
The procedure used to calculate cyclone pressure drop in program T-3575 is given below. If vendors’ calculation procedures are
available, they probably will give better estimates of pressure drop and should be used. Procedures recommended by three vendors
are discussed in a subsequent section.
Calculation Procedure
The pressure drop from the inlet of a primary cyclone to the gas outlet of the same cyclone is given by:
DP 1 + 1 V 2 (K Ȁ ρ ) K 2Ȁ K 4 ρg ) (psi) Eq. (5c)

144 (2g c) 1 1 f
–3
DP 1 + 10 V 21 (K 1Ȁ ρf ) K 2Ȁ K 4 ρg ) (kPa) Eq. (5m)
2

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where: DP1 is the pressure drop (psi), (kPa)

V1 is the inlet gas velocity (ft/s), (m/s)
K1 ´ is a velocity function equal to 1.1(1)
ρf is the density of gas/solids stream entering the cyclone (lbs/ft3), (kg/m3)
K2 ´ is the number of velocity heads on the gas side
K4 is a dust loading factor given in Figure 15
ρg is the gas density (lbs/ft3), (kg/m3)
gc is the gravitational conversion factor (32 ft lb mass/s2 lb force)
K2 ´ can be calculated by:
ǒ Ǔ ȧ n ȧƪdoƫ * 1ȧ) f ǒdoǓ ȳȧ

ȱ ȡ ȣ
2n 2n
Ai 1 * n db db
K 2Ȁ + 4.62 Eq. (6)
db do
Ȳ Ȣ Ȥ ȴ
where: n is a function of cyclone diameter and temperature given by:
n + 1 * ƪ (Tń520)0.3 ƪ
1 *
(d b)0.14
1.77
ƫƫ Eq. (7c)
n + 1 – ƪ (Tń290)0.3 ƪ
1 –
1.5
ƫƫ
(d b)0.14
Eq. (7m)
where: T = cyclone operating temperature (_R), (K) (2)

f is a function of n given by:
f = 0.88 n + 1.7 Eq. (8)
The pressure drop from the inlet of a primary cyclone to the gas outlet of a secondary cyclone is given by:
DP 1 ) 2 + 1 ƪV21 ǒK1Ȁ ρf ) K2Ȁ K4 ρgǓ ) V22 K2ȀȀ ρgƫ (psi) Eq. (9c)
144 (2g c)
DP 1 ) 2 + 10
–3
ƪV21 ǒK 1Ȁ ρf ) K2Ȁ K4 ρgǓ ) V22 K2ȀȀ ρgƫ (kPa) Eq. (9m)
2
where: V2 is inlet velocity to the secondary cyclone (ft/s), (m/s)
K2 I is the number of velocity heads on the gas side of the secondary cyclone.
K2I can also be obtained from Equation (6).
In a similar fashion, the pressure drop from the inlet of a primary cyclone to the gas outlet of a tertiary cyclone is given by:
DP 1 ) 2 ) 3 + 1 ƪV21 ǒK1Ȁ ρf ) K2Ȁ K4 ρgǓ ) V22 K2ȀȀ ρg ) V 23 K 2ȀȀȀ ρgƫ (psi) Eq. (10c)
144 (2g c)
DP 1 ) 2 ) 3 + 10
–3
ƪV21 ǒK1Ȁ ρf ) K2Ȁ K4 ρgǓ ) V22 K2ȀȀ ρg ) V23 K2ȀȀȀ ρg ƫ (kPa) Eq. (10m)
2
where: K2I is the number of velocity heads on the gas side of the tertiary cyclone.
K2I can also be obtained from Equation (6).
Notes:
(1) This is the factor which will give the pressure drop required to accelerate the gas solids to the primary cyclone inlet velocity.
(2) For FCC reactor conditions, use T as the temperature at which the viscosity of air equals the viscosity of the reactor gases.
This will increase the calculated pressure drop by about 20%.

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Pressure drop from the primary cyclone inlet to the top of the primary, secondary or tertiary cyclone diplegs (solids outlet) can be
calculated from the above equations by making the following substitutions:
Primary cyclone: Use K3i in place of K2i in Eq. (5)
Primary + secondary cyclones: Use K3I in place of K2I in Eq. (9)
Primary + secondary +
Tertiary cyclones: Use K3Ii in place of K2iI in Eq. (10)
where: K3i, K3I, K3Iiare velocity heads on the solids sides of the primary, secondary and tertiary cyclones respectively.
These constants can be calculated from:
ǒ Ǔ ȧǒddǓ * 1ȳȧ
ȱ 2n
Ai db
4.62 Eq. (11)
db do n
Ȳ ȴ
where: dd is the effective dipleg diameter (ft), (m) equal to the diameter of the bottom of the main cyclone cone
or dust pot at the elevation of the apex of the projected cone, whichever is smaller. See reference (10).
Vendor Procedures
Information obtained from Ducon, Emtrol and General Electric (formerly Buell) allows calculation of pressure drops using methods
suggested by the vendors. The procedures used by Ducon and General Electric are similar to those given previously but use
different values for the number of velocity heads. Emtrol uses an empirical approach as discussed below.
D Ducon. For Model 810 cyclones, use Equations (5), (9), and (10).
Use Figure 13A for K2i, K2I, and K2Ii for the gas side pressure drop (gas inlet to gas outlet). Use Figure 13B for K3i, K3I,
and K3Ii for solids side pressure drop (gas inlet to solids outlet). For model 800 cyclones (L/D=5), Ducon recommends the
following equation for gas side pressure drop for a primary cyclone:
DP 1 + 1 V 2 ǒK Ȁ ρ ) K 5Ȁ ρgǓ (psi) Eq. (12c)

144 (2g c) 1 1 f
V 21 ǒK 1Ȁ ρf ) K 5Ȁ ρg )
–3
DP 1 + 10 (kPa) Eq. (12m)
2
Equation (12) can be modified to calculate the gas side pressure drop from the inlet of a primary cyclone to the gas outlet of
a secondary cyclone by adding a term for the secondary cyclone pressure drop:
DP 1 ) 2 + 1 ƪV21 ǒK1Ȁ ρf ) K5Ȁ ρgǓ ) V22 K5ȀȀ ρgƫ (psi) Eq. (13c)
144 (2g c)
DP 1 ) 2 + 10
–3
ƪV21 ǒK 1Ȁ ρf ) K5Ȁ ρgǓ ) V22 K5ȀȀ ρgƫ (kPa) Eq. (13m)
2
The equation can be modified further to include a tertiary cyclone:
DP 1 ) 2 ) 3 + 1 ƪV21 ǒK1Ȁ ρf ) K5Ȁ ρg Ǔ ) V22 K5ȀȀ ρg ) V 23 K 5ȀȀȀ ρgƫ (psi) Eq. (14c)
144 (2g c)
DP 1 ) 2 ) 3 + 10
–3
ƪV21 ǒK1Ȁ ρf ) K5Ȁ ρgǓ ) V22 K5ȀȀ ρg ) V23 K5ȀȀȀ ρgƫ (kPa) Eq. (14m)
2
Velocity head factors K5i, K5I, and K5Ii are obtained from Figure 13C. Ducon does not recommend use of a dust loading factor
in equations (12), (13), and (14).
For the solids side pressure drop for model 800 cyclones, Ducon recommends the following equation for a primary cyclone:
DP 1 + 1 ƪV21 (K1Ȁ ρf ) 0.92 K6Ȁ ρg )ƫ (psi) Eq. (15c)

144 (2g c)
DP 1 + 10
–3
ƪV21 (K1Ȁ ρf ) 0.92 K6Ȁ ρg )ƫ (kPa) Eq. (15m)
2

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The pressure drop from the gas inlet of a primary to solids outlet of a secondary cyclone is:
DP 1 ) 2 + 1 ƪV21 ǒK1Ȁ ρf ) K5Ȁ ρgǓ ) 0.92 V22 K6ȀȀ ρgƫ (psi) Eq. (16c)
144 (2g c)
DP 1 ) 2 + 10
–3
ƪV21 ǒK 1Ȁ ρf ) K5Ȁ ρg Ǔ ) 0.92 V22 K6ȀȀ ρgƫ (kPa) Eq. (16m)
2
Pressure drop from the gas inlet of a primary to solids outlet of a tertiary cyclone is:
DP 1 ) 2 ) 3 + 1 ƪV21 ǒK1Ȁ ρf ) K5Ȁ ρg Ǔ ) V22 K5ȀȀ ρg ) 0.92 V23 K6ȀȀȀ ρgƫ (psi) Eq. (17c)
144 (2g c)
DP 1 ) 2 ) 3 + 10
–3
ƪV21 ǒK1Ȁ ρf ) K5Ȁ ρg Ǔ ) V22 K5ȀȀ ρg ) 0.92 V23 K6ȀȀȀ ρgƫ (kPa) Eq. (17m)
2
Figure 13D gives K6i, K6I, or K6Ii for Ducon Model 800 cyclones.
D Emtrol. Emtrol uses the empirical relationship shown in Figure 14A for gas side pressure drop. In this figure, the ratio of the
gas side pressure drop to gas density is given as a function of:
2
ǒViǓ
2.3
M ǒd ońd bǓ
for various values of solids entrainment, e.

where: Vi is the inlet gas velocity (ft/s)
M is the cyclone model number e.g., 800 or 1550 (also equal to the ratio d 2b (in.2)/Ai (ft2))
do is the gas outlet tube diameter (in.)
db is the barrel diameter (in.)
Pressure drop due to acceleration of the solids at the inlet to a primary cyclone, DPa, is taken as one velocity head, or
DP a + 1 V2
144 (2g c) 1 ρf
(psi) Eq. (18c)
–3
DP a + 10 V 21 ρf (kPa) Eq. (18m)
2
For secondary and tertiary cyclones, the entrainment used in Figure 14A is 0. The total gas side pressure drop through a series
of cyclones, e.g., a tertiary set, then consists of acceleration loss into the primary, DP in the primary plus DP in the secondary
plus DP in the tertiary cyclones.
For solid side pressure loss, Figure 14B is used. In this figure, DP/ρg is given as a function of (Vi)2/Y for various values of
entrainment, e,
where: Y = (M)0.6 (doL/ d 2b)0.74
L is the cyclone length from roof to the projected cone apex (in)
For primary cyclones, inlet acceleration loss must be included as given in Equation (18) Entrainment is taken as 0 for secondary
and tertiary cyclones. Solid side pressure drop through a series of cyclones is calculated as shown previously. This is
summarized as follows:
DP 1 + DP a ) DP 1(ss) (psi), (kPa) Eq. (19)
DP 1 ) 2 + DP a ) DP 1(gs) ) DP 2(ss) (psi), (kPa) Eq. (20)
DP 1 ) 2 ) 3 + DP a ) DP 1(gs) ) DP 2(gs) ) DP 3(ss) (psi), (kPa) Eq. (21)

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where: 1, 2 and 3 refer to primary, secondary and tertiary cyclones

DPa is given by Equation (18)
subscripts gs refer to gas side (gas inlet to gas outlet)
subscripts ss refer to solid side (gas inlet to solids outlet)
General Electric. The method used by General Electric is similar to that used in program 3575 and by Ducon. Pressure loss
due to solids acceleration at the primary cyclone inlet is taken as 1 velocity head Equation (18). For Model CG-435 S and
CG-375 S cyclones, gas side pressure drop is given as:
DP + 6.6 V2 ρ (psi) Eq. (22c)

144 (2g c) i g
DP + 6.6 10 –3 V 2 ρ (kPa) Eq. (22m)

i g
2
Gas side pressure drop through a tertiary cyclone system is obtained as before by summing the acceleration loss into the
primary cyclone, primary cyclone gas side DP, secondary cyclone gas side DP, and tertiary cyclone gas side DP.
Solid side pressure drop for CG-4355 cyclones is given as:
DP + 7.6 V2 ρ (psi) Eq. (23c)

144 (2g c) i g
DP + 7.6 10 –3 V 2 ρ (kPa) Eq. (23m)

2 i g
For CG-3755 cyclones, the equation is:
DP + 9.3 V2 ρ (psi) Eq. (24c)

144 (2g c) i g
DP + 9.3 10 –3 V 2
i ρg
(kPa) Eq. (24m)
2
Solid side pressure loss through a series of cyclones is as given in Equations (19), (20), and (21).
RELIABILITY OF CYCLONE CALCULATION METHODS
The reliability of the predicted efficiency and solids losses using program T-3575 depends on how accurately the solids size
distribution and concentration entering the cyclones are known. In many cases, these solids inlet conditions are calculated using
the entrainment portion of T-3575. The reliability of the entrainment calculations, in turn, depends on how well the fines portion of
the solids size distribution in the bed is know. Obtaining a good measure of fines distribution is very difficult due to measurement
technique limitations.
Before the use of the newer catalysts, the FCC bed fines content could be fairly well estimated by extrapolating a measured
log-normal size distribution of the bed catalyst. In those cases, T-3575 gave reasonably good estimates of catalyst losses. For
example, calculated losses from two stage regenerator cyclone systems gave a standard error of about "30% when compared
to measured losses. These comparisons were based on the results of nine plant tests conducted over a period from 1970 to 1979.
However, since the advent of the newer FCC catalysts, the fines size distribution can no longer be obtained by extrapolating the
bed size distribution. Fines from the new catalysts tend to be smaller in size, showing bimodal distributions. Calculations using
T-3575 based on the measured bed solids size distribution, or even worse, on the fresh catalyst size distribution of the new FCC
catalysts can be very inaccurate. Some adjustments to the inlet size distribution can be made which will give better estimates of
losses if operating data are available upon which such adjustments could be based (12). However, solids losses for these situations
can be better estimated using the DYNAMOD program described later.
Calculated losses from tertiary cyclone systems are subject to the limitations described above to an even greater degree. Most of
the solids captured in a tertiary cyclone are finer than the smallest size normally reported in size distributions of bed solids. The
uncertainty in the losses calculated from a tertiary cyclone are compounded by uncertainties in the starting bed size, entrainment,
and primary and secondary cyclone efficiency calculations.
Calculations of cyclone pressure drop agree well with measured results.

DESIGN PRACTICES
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DIPLEG DESIGN
Dipleg diameter, length and sealing method must be specified. Diameter is based on solids flow rate, size and density. Length is
determined by the static head needed to allow the solids to flow from the dipleg. It is calculated from a pressure balance. Sealing
methods must assure that excessive gas does not flow up the dipleg and the affect cyclone performance. Each of these is described
below.
DIPLEG DIAMETER
The diameter of a primary cyclone dipleg can be calculated, from:
0.4
d d + 0.623 ƪWńρd ƫ ) 1.5 d p (ft) Eq. (25c)
0.4
d d + 0.790 ƪWń ρdƫ ) 1.5 d p (m) Eq. (25m)
where: dd is the dipleg diameter (ft), (m)

W is the solids flow rate (equal to inlet solids rate) (lbs/s), (kg/s)
dp is the weight mean particle size in the dipleg (ft), (m)
ρd is the density of the material in the dipleg (lbs/ft3), (kg/m3)
For most applications, the second term in Equation (25) can be dropped.
Mass velocities in diplegs on primary cyclones are in the range of 100 – 150 lbs/ft2s (490 to 730 kg/m2s). Diplegs on secondary
cyclones are usually 8 inches (200 mm). Tertiary cyclone diplegs are usually 6 inches (150 mm). Minimum diameter for all diplegs
on commercial units is 6 inches (150 mm). For close coupled reactor cyclones, catalyst maldistribution often occurs and must be
taken into account in sizing diplegs.
DIPLEG LENGTH
In order for solids captured by an internal cyclone to flow down the dipleg back into the vessel, the dipleg must be long enough to
build the required static head. The static head must be sufficient to overcome the cyclone solids side pressure drop, the dilute phase
and dense bed pressure drops and the trickle valve pressure drop (if used). Therefore, for a primary cyclone:
Lρd + Cyclone solids side DP ) dilute phase DP ) dense bed DP Eq. (26c)
144
) trickle valve DP (psi)
10 –3 g L ρd+ Cyclone solids side DP ) dilute phase DP ) dense bed DP Eq. (26m)
) trickle valve DP (kPa)
where: L is the minimum dipleg length (ft), (m)

ρd is the density of solids in the dipleg (lbs/ft3), (kg/m3)
g is the gravity constant (9.8 m/s2)
Cyclone solids side DP is obtained at maximum operating cyclone velocity from Equation (5) using K3i in place
of K2i
Dilute phase DP = dilute phase holdup (lbs)/dilute phase area (in2)
= dilute phase holdup (kg) x 10–3g/dilute phase area (m2)
Dense bed DP = height of dense bed above dipleg outlet (ft) x rB/144 (lb/ft3)
= height of dense bed above dipleg (m) x rB (kg/m3) x 10–3g
ρB is the dense bed density (lbs/ft3), (kg/m3)
Trickle valve DP = 0.05 psi (0.3 kPa)
For a secondary cyclone, the solids side DP in Equation (26) is replaced by the DP from the primary cyclone inlet to the top of the
secondary dipleg. Use Equation (9) for the DP calculation, replacing K2I by K3I. The dense bed DP is calculated based on the
height of the dense bed above the secondary cyclone dipleg outlet.
The dipleg design length is obtained by adding 3 ft (0.9 m) or an additional 35%, whichever is greater, to the minimum dipleg length.
The added length will allow for variations in operating conditions. The minimum length for tertiary cyclone diplegs is 4 ft (1.2m).
Considerations should also be given to allowing a greater length to accommodate future expansions or bed level variations during
startup or upset conditions.

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DIPLEG DESIGN (Cont)
Density of the solids in the dipleg used in the pressure balance should be based on measured densities. If such data are not available
from design notes, the following ratios of dipleg solids density to density at minimum fluidization should be used.
PRIMARY CYCLONE SECONDARY, TERTIARY,

DIPLEG – ρd/ρmf CYCLONE DIPLEG – ρd/ρmf
0.70 0.55
DIPLEG SEALING
Diplegs must be sealed to prevent the backflow of gas up the diplegs which will adversely affect performance. This is done by the
use of trickle valves (Figures 16, 17) or by assuring that the dipleg terminates below the level of the dense bed. If trickle valves are
not used, the dipleg should terminate in a 90_ elbow cut at a slant or a splash plate. Trickle valves are flapper valves which seal
the dipleg until the static head is sufficient to force the trickle valve open and allow some solids to flow out. For dilute phase operation,
a modified trickle valve design (Figure 18) should be used. This design minimizes flapper plate erosion and also improves the
process performance by providing a more stable (less turbulent) dipleg solids level, particularly in the secondary dipleg operating
range. The design incorporates a 1/2” (12 mm) thick steel flapper with hexmesh and erosion resistant refractory on both faces
installed on an “elbow” type valve body. The refractory lined flapper minimizes thermal distortion as well as providing improved
erosion resistance. “Elbow” type configurations provide more uniform solids discharge and less gas upflow compared to
conventional miter body trickle valves. See reference (4) for further details. Diplegs which are immersed in a bed should terminate
2 ft (0.6 m) below the bed level and 5 ft (1.5 m) above grids to prevent erosion and to minimize the chance for gas backflow. If this
is not possible, the grid holes below the dipleg should be blanked. Diplegs should also be located away from other potential sources
of erosion. It may be necessary to slope diplegs for process reasons. If so, the maximum slope is 20_ from the vertical. This slope
should be minimized.
CYCLONE LAYOUT
The cyclones should be arranged in a symmetrical fashion with primary cyclone inlets drawing gas as evenly as possible over the
vessel cross section. The cyclones are usually arranged in a circle (looking at a top plan view of the vessel). In larger vessels, the
cyclone sets are arranged in two concentric circles with the smaller circle of cyclones occupying the center portion of the vessel.
The rotation of the gas in all the cyclones in a vessel should be in the same direction, all clockwise or all counter clockwise.
TERTIARY CYCLONE SYSTEMS
Tertiary cyclones are often used to protect flue gas expander turbines or to meet environmental limits. Tertiary cyclones are installed
external to the process vessels to prevent recycling the captured fines back to the process. This arrangement requires a vessel
to contain the cyclones, a fines hopper and cyclone to handle the fines prior to disposal, and a fines transport system connecting
the tertiary cyclone vessel and the fines hopper. This arrangement is shown in Design Practices Section XVIII - A3.
INSTRUMENTATION
Differential pressure instruments to determine primary and secondary cyclone dipleg density, level and cyclone pressure drop
should be considered for inclusion in the design, especially in a new service in which cyclone performance and solids properties
such as dipleg density have not been characterized. It is sufficient to instrument only one cyclone in a set.
OTHER GAS, SOLIDS SEPARATION SYSTEMS
Other gas, solid separation systems may be used in conjunction with cyclones to meet particulate removal requirements in effect
at the site of a fluid solids unit. If needed, systems would be installed downstream of the cyclones at lower temperatures and
pressures. Bag filters, wet scrubbers and electrostatic precipitators can be used for this service. The design bases for these are
described in Design Practices Sections XVIII A4, A5, and A6.

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SOLIDS LOSSES
Loss of solids from a fluid solids process is given by:
Loss + Entrainment Gas Rate ǒ1 – Collector100EfficiencyǓ

where the loss is given in lbs/hr (kg/hr), entrainment in lbs/ft3 (kg/m3) gas, gas rate in ft3/hr (m3/hr), and collector efficiency in
percent. If the particle size distribution in the fluid bed is know, the losses can be calculated by direct application of program T-3575.
However, in many cases, the equilibrium bed particle size distribution is not sufficiently defined, especially in the –20 m size range.
In those cases, bed equilibrium particle size distribution, entrainment and fines losses can be calculated using DYNAMOD, a particle
population balance model. Application of DYNAMOD requires information on the attrition rate and particle breakage pattern for the
bed solids. This information can be obtained through jet and impact attrition tests described in Subsection E, as well as from other
pilot plant or commercial plant operations. DYNAMOD calculates the bed particle size distribution over a series of time intervals as
a result of particle attrition, reaction, entrainment and solids feeding and withdrawal. Entrainment rates, particle collection rates, and
overhead solids recycle rates and size distributions are then calculated for each time interval based on the bed particle size
distributions. The calculation is repeated for a number of cycles until the change in particle size distributions and solid stream rates
with succeeding cycles is less than an acceptable level. In this way, a steady state estimate for the system is calculated. DYNAMOD
may also be used to analyze transient as well as steady state results, as for example, from batch attrition tests.
DYNAMOD has the capability of including the effect of chemical reaction on the solids balance for reacting solids such as in char
gasification or oil shale retorting. DYNAMOD has been applied to a number of fluid solids processes, including those under
development. It permits estimates of the performance of integrated fluid solids processes based on small scale measurements of
fundamental particle properties. It has been successfully applied to a few specific commercial operations, primarily FCC units.
SAMPLE CALCULATIONS
CYCLONE EFFICIENCY, PARTICLE SIZE DISTRIBUTIONS

Calculate overall collection efficiency, size distribution of collected and escaping material
Given: Cyclone dimensions
db = 3.0 ft
wi = 0.75 ft
hi = 1.5 ft
do = 0.75 ft
ȏb = 2.0 ft
ȏc = 3.0 ft
ȏo = 1.5 ft
Operating conditions
v = 67 ft/s
= 1.21 x 10–5 lbs/ft s
ρp = 120 lbs/ft3
z = 0.52
dustloading = 3.2 x 10–3 lbs/ft3 gas
inlet solids size distribution – see Figure 21
inlet gas rate = 4500 ACFM
1. Calculate effective cyclone length, ȏ, using equations (2) and (3)
ȏ1 = ƪȏ b
ȏ
) c
3
ƫ
= 2.0 ) 3.0
3.0
= 3 ft

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SAMPLE CALCULATIONS (Cont)
ȱ ȳ
ȧ2.3 do ƪhi wiƫ ) ȏo * ȏbȧ
1ń3
d2
ȏ2 = ȏb ) 1 b
Ȳ ȴ
3
ȏ2 = 2.0 ) 1
3
ƪ 2.3 (0.75) ƪ1.5 32
0.75
ƫ
1ń3
) 1.5 * 2.0 ƫ
= 2.98 ft
ȏ = lesser of ȏ 1, ȏ 2
= 2.98 ft
2. Determine dust loading factor, Lf, using Figure 14
log dust loading = log (3.2 x 10–3)
= –2.50
hf = 0.28 (Figure 14)
3. Calculate critical particle diameter, dc, using Equation (1)
ƪ ƫ ƪ ƫ
0.25 0.5
m wi do
ƪ0.52 ƫ
hi 0.33
dc = 2.85 L f ρp Vȏ
p db z
ƪ1.21 ƫ
0.5
ƪp ƫ ƪ0.52 ƫ
0.25 0.33
= 2.85 0.28 1.5 10 *5 0.75 0.75
3.0 120 67 2.98 0.52
= 0.85 10 *5 ft (2.6 microns)

4. Divide log normal probability plot of inlet solids size distribution into 10 equal segments. Obtain particle diameters at midpoints
of each segment. See Figure 21, Table 1.
5. Divide the midpoint diameter of each segment by dc. See Table 1.
6. Obtain collection efficiency for each value of d/dc using Figure 13. See Table 1. If desired, plot efficiency of each segment vs.
d to obtain grade efficiency curve.
7. Calculate the overall efficiency by summing the efficiencies for each segment and dividing by the number of segments (10).
Overall efficiency = 96,2% See Table 1
8. Calculate the solids losses using Equation (4)
Losses = (1 * Eff) (Inlet solids rate)
3
= 0.0383 4500 ft 3.2 10 *3 lbs 60 min
min ft 3 hr
= 33 lbsńhr
9. Calculate the ratio of Eff/SEff for each segment. See Table 1.
10. Calculate the cumulative weight % for the collected solids by obtaining 100 (Eff1/SEff) for Segment 1, 100 (Eff1/SEff + Eff2/SEff)
for Segment 2, etc. See Table 1. Plot cumulative weight % for each segment against the maximum particle size for each
segment, e.g., 7.2 microns for Segment 1. See Figure 21.
11. Calculate 1-Eff for each segment and sum to obtain S(1-Eff). See Table 1.
12. Calculate the ratio (1-Eff)/S(1-Eff) for each segment. See Table 1.
13. Calculate the cumulative weight % for the escaping solids by obtaining 100 (1-Eff1)/S(1-Eff) for segment 1, 100 [(1-Eff1)/S(1-Eff)
+ (1-Eff2)/S(1-Eff)] for segment 2, etc. See Table 1. Plot cumulative weight % for each segment against the maximum particle
size for each segment. See Figure 21.

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CYCLONE PRESSURE DROP

D Calculate the pressure drop from the inlet to the gas outlet of a primary cyclone.
Given: Cyclone dimensions from previous sample calculation
Operating conditions from previous sample calculation
ρg = 0.07 lb/ft3 (flue gas)
T = 1760_R
1. Calculate ρf, the inlet mixture density as the sum of the gas density and dust loading
ρf = 0.07 ) 0.0032
= 0.0732 lbsńft 3
2. Calculate the number of velocity heads on the gas side, K2i, using Equation (6).
ȱ
K ’ = 4.62 ȧƪ ƫ ȱ ƪ ƫ
2n
ȳ ƪ db ȳ
ƫ
2n
ȧ n do * 1ȧ ) f do ȧ
Ai 1 * n db
Ȳ db do Ȳ ȴ ȴ
2
n= 1 * ƪ (Tń520)0.3 ƪ
1 *
(d b)0.14
1.77
ƫƫ Eq. (7)
n= 1 * ƪƪ 1760
520
ƫ
0.3
ƪ 1 *
(3)0.14
1.77
ƫƫ
= 0.51
f = 0.88 n ) 1.7 Eq. (8)
= 0.88 0.51 ) 1.7
= 2.15
K2’ = 4.62 ƪƪ0.75

3.0
1.5
0.75
ƫ ƪ 1 * 0.51 3.0
0.51 0.75
ƪ ƫ
2 0.51
* 1 ƫ ) 2.15 ƪ0.75
3.0 ƫ
2
ƫ
0.51
= 27.3
3. Obtain the dust loading factor, K4, from Figure 17.

K4 = 0.9
4. Calculate the primary cyclone gas side pressure drop, DP1, using Equation (5).
DP1 = 1 V 2 (K Ȁ ) K 2Ȁ K 4 ρg )
144 (2g c) 1 1 ρf
DP1 = 1 (67)2 (1.1 0.073 ) 27.3 0.9 0.07)

144 (2 32)
= 0.88 psi

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D Calculate the pressure drop from the inlet to the top of the cyclone dipleg of a primary cyclone.
Given: Cyclone dimensions from previous sample calculation
dd = 1 ft
Operating conditions from previous sample calculation
1. Calculate the number of velocity heads on the solids side, K3i, using Equation (11)
ƪ ƫ ȧƪddƫ * 1ȳȧ
ȱ 2n
Ai db
K3 ’ = 4.62
db do n
Ȳ ȴ
= 4.62 ƪ3.0 1.50.750.750.51ƫ ƪ3.0
1.0
ƪ
ƫ
1.02
* 1 ƫ
= 9.36
2. Calculate the primary cyclone solids side pressure drop, DP1, using Equation (5) with K3i substituted for K2i
DP1 = 1 V 2 (K Ȁ ρ ) K 3Ȁ K 4 ρg )
144 (2g c) 1 1 f
DP1 = 1 (67)2 (1.1 0.073 ) 9.36 0.9 0.07)

144 (2 32)
= 0.33 psi

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NOMENCLATURE
Ai = Cyclone inlet area, ft2 (m2)
Ao = Cyclone outlet area, ft2 (m2)
db = Cyclone barrel diameter, ft (m)
dc = Critical particle diameter, ft (m)
dd = Dipleg diameter, ft (m)
do = Outlet tube diameter, ft (m)
dp = Particle diameter, ft (m)
dp50 = Weight mean particle size, ft (m)
f = Cyclone parameter, Eq. 8
g = Gravity constant, 32 ft/s2 (9.8 m/s2)
gc = Gravitational conversion factor (ft lb mass/s2 lb force)
gs = Gas side
hi = Cyclone inlet height, ft (m)
i = Segment number
K1 i = Velocity function
K2 i = Number of velocity heads on gas side – primary cyclone
K2 I = Number of velocity heads on gas side – secondary cyclone
K2Ii = Number of velocity heads on gas side – tertiary cyclone
K3 i = Number of velocity heads on solid side – primary cyclone
K3 I = Number of velocity heads on solids side – secondary cyclone
K3Ii = Number of velocity heads on solid side – tertiary cyclone
K4 = Dust loading factor
K5i, K5I, K5Ii = Pressure drop factors – Ducon cyclones, Eq. 12, 13, 14
K6i, K6ii, K6iii = Pressure drop factors – Ducon cyclones, Eq. 15, 16, 17
k = Cyclone dimension ration
Lf = Particle loading factor
= Effective cyclone length, ft (m)
b = Barrel length, ft (m)
c = Cone length, ft (m)
o = Outlet tube insertion, ft (m)
M = Emtrol cyclone model number
n = Total number of particle size segments for cyclone efficiency calculation

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NOMENCLATURE (Cont)
n = Cyclone parameter, Eq. 7
ss = Solid side
T = Temperature, _R (K)
V, Vi = Inlet gas velocity, ft/s (m/s)
V1 = Inlet gas velocity, primary cyclone, ft/s (m/s)
V2 = Inlet gas velocity, secondary cyclone, ft/s (m/s)
V3 = Inlet gas velocity, tertiary cyclone, ft/s (m/s)
W = Solids flow rate through dipleg, lbs/s (kg/s)
wi = Cyclone inlet width, ft (m)
z = Heywood shape factor
DP = Pressure difference, lb/in.2 (kPa)
DPa = Pressure difference due to acceleration, lb/in.2 (kPa)
DP1 = Cyclone pressure difference, inlet to gas outlet in primary, lb/in.2 (kPa)
DP2 = Cyclone pressure difference, inlet to gas outlet in secondary, lb/in.2 (kPa)
DP3 = Cyclone pressure difference, inlet to gas outlet in tertiary, lb/in.2 (kPa)
m = Gas viscosity, lb/ft s (kg/ms)
ρB = Dense bed density, lb/ft3 (kg/m3)
ρd = Density of mixture in dipleg, lb/ft3 (kg/m3)
ρf = Density of gas, solids stream entering cyclone, lb/ft3 (kg/m3)
ρg = Gas density, lb/ft3 (kg/m3)
ρp = Particle density, lb/ft3 (kg/m3)

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APPENDIX A
PROGRAM T-3575, FLUIDIZATION AND PARTICULATE EMISSION
Computer program T-3575, Fluidization and Particulate Emissions, is a general purpose fluidization program first developed in 1976
and revised in 1985. The major fluidization and particulate emission parameters calculated by T-3575 are entrainment rates and
entrained particle size distribution, dilute phase holdup, performance of up to three cyclone stages, electrostatic precipitator (ESP)
performance and particle size distributions in streams entering and leaving the cyclone states and the ESP.
ENTRAINMENT
Solids entrainment is defined as the weight of solids per volume of gas flowing past a point in the dilute phase region above a fluidized
bed. Entrainment is usually calculated at the vessel outlet or at the inlet to internal cyclones. Entrainment decreases with height
above the fluidized bed up to a point, referred to as the Transport Disengaging Height (TDH), above which entrainment becomes
constant. The TDH is calculated by T-3575 as a subroutine in the entrainment calculation. Other fluidization parameters calculated
by T-3575 as part of the entrainment calculation include:
Minimum fluidization velocity

Terminal velocity
Bubble size
Volume surface mean particle diameter
Program T-3575 calculates both the total entrainment rates and the particle size distribution of the entrained solids.
DILUTE PHASE HOLDUP

Dilute phase holdup is the total weight of solids contained in the dilute phase above the fluidized bed and is obtained by integrating
the dilute phase density over the dilute phase region. Calculation of dilute phase holdup entails the use of many of the same
fluidization parameters used in the entrainment calculation.
Several options are provided by T-3575 in the calculation of entrainment and dilute phase holdup. These include a deep bed versus
a shallow bed option and a return of solids from cyclones to the bed versus not returning the solids. The program modifies the
calculation methods based on the selected options.
CYCLONE PERFORMANCE
Cyclone efficiency, pressure drop and particle size distribution of the solids escaping and collected by the cyclones are calculated.
Calculations can be made for up to two stages of internal cyclones and one external stage. Efficiency calculations are based on
cyclone geometry, gas and solids properties, cyclone inlet velocity and loading. Unless specified otherwise, T-3575 bases the inlet
conditions to the first stage cyclone on the entrained gas/solids stream, the second stage on the material escaping the first stage,
and the third stage on the material escaping the second stage. The user also has the option to specify inlet conditions.
Pressure drops are also calculated for up to three stages of cyclones. Pressure drops from the cyclone inlets to both the gas outlet
tubes and the dipleg entrances can be calculated.
ESP PERFORMANCE
Efficiency and particle size distribution of the solids escaping an ESP can be calculated by T-3575. The efficiency calculation is
based on ESP geometry, gas and solid physical properties and also includes a correction for solids entrainment.

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APPENDIX A (Cont)
PROGRAM INPUT
The program has twenty-nine input blocks, some of which are optional. The following is a list of the input blocks with a brief
description of each block.
BLOCK DESCRIPTION
*TITLE Contains all descriptive information on the problem.
*UNITS Indicates the selected units (US or SI) and must precede all numerical data.
*CALCOPT Indicates the calculation options desired by the user.
*PHYSPRP Contains physical properties of the vessel.
*CYCLONO Contains the number of cyclones in each stage.
*SIZEDIS Contains the number of input sets from the particle size distribution data.
Cumulative Weight Percents and Particle Sizes – Contain the cumulative weight percents less than the
corresponding particle size in microns.
*DIFFCUT Contains the number of different cuts for the particle size distribution.
*CUTSIZE Contains the particle sizes for each cut.
*CUTRANGE Contains the maximum particle size (in microns) for each cut size.
*ENTDVSL Contains the vessel and cyclone dimensions for entrainment.
*ENTOUTG Contains the outage information for entrainment.
*ENTVELO Contains the velocity information for entrainment.
*ENTSLBD Contains the solids return and bed depth options for entrainment.
*DPHDVSL Contains the vessel and cyclone dimensions for dilute phase holdup.
*DPHOUTG Contains the outage information for dilute phase holdup.
*DPHVELO Contains the velocity information for dilute phase holdup.
*DPHSLBD Contains the solids return and bed depth options for dilute phase holdup
*DIMPRCY Contains primary cyclone dimensions.
*CONPRCY Contains the primary cyclone operating conditions.
*DIMSECY Contains the secondary cyclone dimensions.
*CONSECY Contains the secondary cyclone operating conditions.
*DIMXTCY Contains the external cyclone dimensions.
*CONXTCY Contains the external cyclone operation conditions.
*SHAPEFACT Contains the shape factor.
*DCADJUST Adjusts cyclone performance to match losses under known conditions
*BAFFLEVAL Contains the baffle information.
*ESPDIM Contains the precipitator chamber dimensions.
*ESPCOND Contains the precipitator operating conditions.
*ENDCASE Last card of each use.
*STOP Last card of the total dataset.

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APPENDIX A (Cont)
PROGRAM OUTPUT
A listing of all input block values and choices is given. Output for each of the calculation procedures appears on a separate page
and includes the title, date of run, and input and calculated variables. The calculation options are as follows:
1. Entrainment information
2. Cyclone efficiency information
3. Dilute phase holdup information
4. Electrostatic precipitator information
Each input card is printed exactly as received. The printed input is a permanent record of the input data. It also helps to find any
improperly typed data. The data on each card are immediately checked to detect any possible errors. T-3575 prints a message when
an error is found. The message explains what is wrong and the action that is being taken. In most cases, the program will revert
to default values.
A users’ guide to the current version of T-3575 is given in EE.1FF.85 (10).

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TABLE 1
CYCLONE SAMPLE CALCULATION – EFFICIENCY, PARTICLE SIZE DISTRIBUTION

" "

"

! !

Overall efficiency = 961.9/10 = 96.2%

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FIGURE 1
TYPICAL CYCLONE
Eddy
Outlet Vortex
Inlet (Main) Vortex

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FIGURE 2
VARIATIONS OF CYCLONIC INLET AND DISCHARGE
Gas Out
Gas Out
Gas In
Gas In
Dust Out
B. Axial Inlet and

Discharge
Dust Out
A. Scroll Inlet,
Axial Discharge

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FIGURE 3
TWO STAGE CYCLONE SYSTEM INSTALLED IN PROCESS VESSEL
Primary Secondary
Cyclone Cyclone
Max. Bed Level
Trickle Valve
Norm. Bed Level
Min. Bed Level
Grid

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FIGURE 4
INTERNALLY MOUNTED CYCLONE USED IN SOLIDS TRANSFER SYSTEM
Carrier Air Outlet
Cyclone
Solids Inlet
(Tangential)
Wear Plate
Aeration Taps (3)
Solids Outlet

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Note:
Figures 5A through 8 contain vendor information not available in metric units. Use following conversion factors:
in x 25.4 = mm
ft x 0.305 = m
ft 2 x 0.0929 = m 2
ft 3 x 0.0283 = m 3
lb x 0.454 = kg

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FIGURE 5A
DUCON MODEL 810 CYCLONES
SIZE D G H A B P F K K1 d1 d2 V SIZE
70 24 15Ć1/2 6Ć1/2 6 - 11 32 9Ć1/2 15Ć1/2 19 33 14 11Ć1/2 12 70
80 25Ć1/2 16Ć1/2 7 7-5 34 10Ć1/4 16Ć1/2 21 34Ć1/2 14Ć3/4 12 12Ć3/4 80
90 27 17Ć1/4 7Ć1/2 7 - 9Ć1/2 36 10Ć3/4 17Ć1/2 21Ć1/2 36 15Ć3/4 12Ć3/4 13Ć1/2 90
100 28Ć1/2 18 8 8-3 38 11Ć1/2 18Ć1/2 23 37 16Ć1/2 13Ć1/2 14Ć1/4 100
110 30 19 8Ć3/8 8-8 40 12 19Ć1/2 24 38Ć1/2 17Ć1/2 14Ć1/4 15 110
120 31Ć1/4 19Ć3/4 8Ć3/4 9 - 0Ć1/2 41Ć3/4 12Ć1/2 20Ć1/4 25 40 18 14Ć1/2 15Ć1/2 120
130 32Ć1/2 20Ć3/4 9 9 - 4Ć1/2 43Ć1/4 13 21 26 41 19 15Ć1/2 16 130
140 33 Ć3/4 21Ć1/4 9Ć1/2 9-9 45 13Ć1/2 22 27 42 19Ć1/2 16 17 140
150 35 22 9Ć3/4 10 - 1 46Ć1/2 14 22Ć3/4 28 43 20Ć1/4 16Ć1/2 17Ć1/2 150
160 36 23 10 10 - 5 48 14Ć1/2 23Ć1/4 29 44 21 17 18 160
170 37 24 10Ć1/4 10 - 8Ć1/2 49Ć1/4 15 24 30 45 21Ć1/2 17Ć1/2 18Ć1/2 170
180 38 24Ć3/4 10Ć1/2 10 - 11Ć1/2 50Ć1/2 15Ć1/4 24Ć3/4 30Ć1/2 46 22 18 19 180
190 39 25Ć1/2 10Ć3/4 11 - 3 52 15Ć1/2 25Ć1/4 31 47 22Ć1/2 18Ć1/2 19Ć1/2 190
200 40 26 11Ć1/8 11 - 7 53Ć1/2 16 26 32 47Ć1/2 23Ć1/4 19 20 200
210 41 26Ć1/4 11Ć1/2 11 - 10 54Ć1/2 16Ć1/2 26Ć1/2 33 48 23Ć3/4 19Ć1/2 20Ć1/2 210
220 42 27 11Ć3/4 12 - 1Ć1/2 56 16Ć3/4 27Ć1/4 33Ć1/2 49 24Ć1/2 20 21 220
230 43 27Ć1/2 12 12 - 5Ć1/2 57Ć1/2 17Ć1/4 28 34Ć1/2 50 25 20Ć1/2 21Ć1/2 230
240 44 28Ć1/4 12Ć1/4 12 - 8 58Ć1/2 17Ć1/2 28Ć1/2 35 51 25Ć1/2 21 22 240
250 45 28Ć3/4 12Ć1/2 13 - 0 60 18 29Ć1/4 36 52 26 21Ć1/2 22Ć1/2 250
260 46 29Ć1/4 12Ć3/4 13 - 4 61Ć1/2 18Ć1/2 30 37 53 26Ć3/4 22 23 260
270 47 30 13 13 - 7 62Ć1/2 19 30Ć1/2 38 54 27Ć1/4 22Ć1/4 23Ć1/2 270
280 47 Ć3/4 30Ć1/2 13Ć1/4 13 - 9Ć1/2 63Ć1/2 19Ć1/4 31 38Ć1/2 54Ć1/2 27Ć3/4 22Ć1/2 24 280
290 48Ć1/2 31 13Ć1/2 14 - 0 64Ć1/2 19Ć1/2 31Ć1/2 39 55 28Ć1/4 23 24Ć1/4 290
300 49Ć1/4 31Ć1/2 13Ć3/4 14 - 2Ć1/2 65Ć1/2 19Ć3/4 32 39Ć1/2 55Ć1/2 28Ć1/2 23Ć1/4 24Ć1/2 300
Reprinted by permission of the DUCON Company.

To Suit
G
B
M
“D” ID K 1 is for Elongated Dust Trap where

Apex Intersects 1 ft. above Dipleg.
M
V
d1 d2 Cyclone Inlet Area = Size / 100

A
ID ID
Approx. Weight of Cyclones:
B
“P” ID Type – VM W = 10.7 x D 2 x LB / Ft. 2

Type – M W = 10.4 x D 2 x LB / Ft. 2
Type – VM Type – M “W” is Less Reinfocing & Brackets
K or K 1
“F” ID
6”
To Suit
Note:
The cyclone design is patented. Therefore, cyclones cannot be fabricated from the above. These dimensions are to be used for
preliminary layouts only. The drawing above is the property of the DUCON Company. It is not to be communicated or disclosed to
others or to be copied in whole or in part except by written permission of the DUCON Company, Inc.

DESIGN PRACTICES
VI-C 32 of 67
Date
FIGURE 5A (Cont)
DUCON MODEL 810 CYCLONES
SIZE D G H A B P F K K1 d1 d2 V SIZE
310 50 32 14 14 - 5 66Ć1/2 20 32Ć1/2 40 56 29 23Ć3/4 25 310
320 51 32Ć1/4 14Ć1/4 14 - 9 68 20Ć1/2 33 41 57 29Ć1/2 24Ć1/4 25Ć1/2 320
330 51Ć3/4 32Ć3/4 14Ć1/2 14 - 1Ć1/2 69 20Ć3/4 33Ć1/2 41Ć1/2 58 30 24Ć1/2 26 330
340 52Ć1/2 33Ć3/4 14Ć1/2 15 - 2 70 21 34 42 58Ć1/2 30Ć1/2 25 26Ć1/4 340
350 53Ć1/4 34Ć1/4 14Ć3/4 15 - 4Ć1/2 71 21Ć1/4 34Ć1/2 42Ć1/2 59 31 25Ć1/4 26Ć1/2 350
360 54 34Ć1/2 15 15 - 7 72 21Ć1/2 35 43 60 31Ć1/2 25Ć1/2 27 360
370 54Ć3/4 35 15Ć1/4 15 - 10 73 22 35Ć1/2 44 61 31Ć3/4 26 27Ć1/4 370
380 55Ć1/2 35Ć1/4 15Ć1/2 16 - 0Ć1/2 74 22Ć1/4 36 44 Ć1/2 61Ć1/2 32Ć1/4 26Ć1/4 27Ć3/4 380
390 56Ć1/4 35Ć3/4 15Ć3/4 16 - 3 75 22Ć1/2 36Ć1/2 45 62 32Ć3/4 26Ć7/8 28 390
400 57 36 16 16 - 5Ć1/2 76 22Ć3/4 37 45Ć1/2 62Ć1/2 33 27 29 400
410 57Ć3/4 36Ć1/4 16Ć1/4 16 - 8 77 23 37Ć1/2 46 63Ć1/2 30Ć1/2 27 29 410
420 58Ć1/2 37Ć1/4 16Ć1/4 16 - 11 78 23Ć1/2 38 47 64 34 27Ć3/4 29Ć1/4 420
430 59Ć1/4 37Ć1/2 16Ć1/2 17 - 1Ć1/2 79 23Ć3/4 38Ć1/2 47Ć1/2 64Ć1/2 34Ć1/2 28 29Ć1/2 430
440 60 37 3/4 16 3/4 17 - 4 80 24 39 48 65 35 28Ć1/2 30 440
450 60Ć1/2 38 17 17 - 6Ć1/2 81 24Ć1/4 39Ć1/4 48Ć1/2 65Ć1/2 35Ć1/4 28Ć3/4 30Ć1/4 450
460 61 39 17 17 - 8 81Ć1/2 24Ć1/2 39Ć1/2 49 66 35Ć1/2 29 30Ć1/2 460
470 61Ć3/4 39Ć1/4 17Ć1/4 17 - 10Ć1/2 82Ć1/2 24Ć3/4 40 49Ć1/2 67 36 29Ć1/4 31 470
480 62Ć1/2 39Ć1/2 17Ć1/2 18 - 1 83 1/2 25 40Ć1/2 50 67Ć1/2 36Ć1/4 29Ć1/2 31Ć1/4 480
490 63 40Ć1/4 17Ć1/2 18 - 2Ć1/2 84 25Ć1/4 41 50Ć1/2 68 36Ć1/2 30 31Ć1/2 490
500 62Ć1/2 40Ć1/2 17Ć3/4 18 - 4 84Ć1/2 25Ć1/2 41Ć1/4 51 68Ć1/2 37 30Ć1/4 31Ć3/4 500
510 64Ć1/2 40Ć3/4 18 18 - 6Ć1/2 85Ć1/2 25Ć3/4 41Ć3/4 51Ć1/2 69 37Ć1/4 30Ć1/2 32Ć1/4 510
520 65 41Ć1/2 18 18 - 9 86Ć1/2 26 42Ć1/4 52 69Ć1/2 37Ć3/4 30Ć3/4 32Ć1/2 520
530 65Ć1/2 41Ć3/4 18Ć1/4 18 - 11Ć1/2 87Ć1/2 26Ć1/4 42Ć1/2 52Ć1/2 70 38 31 32Ć3/4 530
540 66 42 18Ć1/2 19 - 1 88 26Ć1/2 43 53 70Ć1/2 38Ć1/2 31Ć1/4 33 540
Reprinted by permission of the DUCON Company.
To Suit
G
B
M
“D” ID K 1 is for Elongated Dust Trap where

Apex Intersects 1 ft. above Dipleg.
M
V
d1 d2 Cyclone Inlet Area = Size / 100

A
ID ID
B
Approx. Weight of Cyclones:

“P” ID Type – VM W = 10.7 x D 2 x LB / Ft. 2
Type – M W = 10.4 x D 2 x LB / Ft. 2
Type – VM Type – M “W” is Less Reinfocing & Brackets
K or K 1
“F” ID
6”
To Suit
Note:
The cyclone design is patented. Therefore, cyclones cannot be fabricated from the above. These dimensions are to be used for
preliminary layouts only. The drawing above is the property of the DUCON Company. It is not to be communicated or disclosed to
others or to be copied in whole or in part except by written permission of the DUCON Company, Inc.

DESIGN PRACTICES
VI-C 33 of 67
Date
FIGURE 5B
DUCON MODEL 800 CYCLONE L / D = 5
See DWG. No. S – 4511
Typical Designation
Size 288 VMEE 800 / 120
1 2 3 4
288
1 = Inlet Area, Sq. Ft. = 2.88
100
2 VMEE = Volute Inlet
3 Model
120
4 = Outlet to Inlet Area Ratio, 0/1 = 1.2
100
Size 288 MEE 800 / 50
1 5 3 6
1 and 3 Same as Above.
5 MEE = Tangential Inlet.
50
6 = Outlet to Inlet Area Ratio, 0/1 = 0.5
100
Cyclone Diameter, Inches = Inlet Area, Sq. Ft. (800)
Cyclone Diameter, Inches = 2.88 (800) = 48

DESIGN PRACTICES
VI-C 34 of 67
Date
FIGURE 5B (Cont)
M
Type – VMEE M
(Volute Inlet) Type – MEE
G
G
Typical for 1st and 2nd Stage
Reactor & 1st Stage Regenerator. (Tangential Inlet.)
P
N
Typical of 2nd Stage Regenerator.

Inlet Bell Not Used for 2nd Stage.
D3 DIMENSIONS
R
Dimensions in Inches and are Inside Lining where Applicable –
for Preliminary Use Only – Not for Construction.
D4
K
H
D3, Diameter Gas Outlet Pipe for VMEE with Outlet to Inlet Area
Ratio (0/1) = 1.2 – Also External Outlet Neck for Type MEE.
D4, Diameter Internal Gas Outlet Pipe for MEE with Outlet to Inlet Area
Detail A
Ratio (0/1) = 0.5
B
D
D3 and D4 Can be Varied to Suit.
K, as Shown, Based on Outlet Tube Penetration of 0.8 Inlet Height

as a Minimum. Penetration May, on Occasion, be Greater.
Inlet Area – Square Feet.

C
A
L
D1
APPROXIMATE WEIGHT
Approximate Weight for Type VMEE

D2 W, Lb = 3.3 (D 2)
C1
with D in Inches.
Above Based on 1/4” Plate and
1” Lining at 165 Lb/Ft 3
Detail B Weight for Type – MEE Slightly Less
E
F
12”
Dia. Variable
Detail A Detail B

DESIGN PRACTICES
VI-C 35 of 67
Date
FIGURE 5B (Cont)


DESIGN PRACTICES
VI-C 36 of 67
Date
FIGURE 6A
VAN TONGEREN TYPE 350 THROUGH 850 CYCLONES
F Dia F Dia
D Dia.
B
C
D Dia.
L
C
L C Dia.
H
(Min.)
P
C Dia. *
H
(Min.)
8” J
Centre-Line
of Inlet A
E A
Ratios as Function of D
TYPE A B C D E F G H J
AC 350 0.320 0.700 2.67 1.00 0.617 0.63 0.60 1.00 0.54
AC 400 0.295 0.665 2.67 1.00 0.610 0.58 0.60 1.00 0.54
AC 430 0.284 0.643 2.67 1.00 0.600 0.56 0.60 1.00 0.54
AC 435 0.282 0.640 3.38 1.00 0.600 0.56 0.60 1.00 0.54
AC 500 0.264 0.594 2.67 1.00 0.590 0.56 0.60 1.00 0.54
AC 550 0.250 0.570 2.67 1.00 0.580 0.56 0.60 1.00 0.54
Van Togeren Cyclone Proportions

Type AC – for FCC Units

DESIGN PRACTICES
VI-C 37 of 67
Date
FIGURE 6A (Cont)
VAN TONGEREN TYPE 350 THROUGH 850 CYCLONES
Notes:
(1) Inlet dimensions A and B and all diameters are measured inside the refractory lining.
(2) Length of refractory lined stub marked * can be made to suit individual requirements.
(3) First stage inlet horn can be orientated as required.
(4) Dimensions L and P to be specified by EXXON. Dimensions C and H to be modified to suit.
(5) It is preferred that tabulated E is used. If space is limited E may be reduced to 0.5 minimum.

DESIGN PRACTICES
VI-C 38 of 67
Date
FIGURE 6B
VAN TONGEREN TYPE 850 CYCLONE
0.428
0.457
1.0 1.5
5.452
0.6
12”
0.6
0.203
0.564

DESIGN PRACTICES
VI-C 39 of 67
Date
FIGURE 7
EMTROL CYCLONES
Notes:
(1) Model 800 Emtrol Cyclones with L/D = 5.0 are used in FCC Regenerators and Reactors. Normally, first stage cyclones are
provided with inlet volutes, i.e, Type A cyclone in both Regenerator and Reactor. Second stage cyclones in Regenerator are
normally tangential, i.e., Type X cyclone. Second stage cyclones in Reactor are normally provided with inlet volutes, i.e., Type A
cyclones.
(2) Model 800 Emtrol Cyclones with L/D = 3.6 (standard length) are used in certain existing FCC Reactors and Regenerators which
cannot utilize the longer cyclones because of vessel headroom considerations.
(3) Model 800 Emtrol Cyclones with L/D = 3.6 (standard length) are also used in coker burners, heaters and reactors. Normally, the
single stage reactor and first stage heater and burner cyclones are provided with inlet volutes, i.e., Type A cyclones. Second
stage heater and burner cyclones are normally tangential, i.e., Type X cyclones.
(4) Model 1550 Emtrol Cyclones with L/D = 5.0 are utilized in tertiary cyclone systems where maximum catalyst recovery is
desired. Note that ratio of cylindrical area to inlet area is 8.67, double this ratio in the 800 type cyclones. Tertiary cyclones are
normally provided with inlet volutes.
(5) Model 1550 Emtrol Cyclones Type SP with L/D = 5.0 are utilized for Tertiary Fines Hopper applications and are designed as
pressure vessels.
Notes:
(1) All dimensions are inside plate or inside lining if linings are used.
(2) The diameter of dust outlet and length of lined section (*) can be made to suit individual requirments. Recommended
minimum outlet diameter is 6”
(3) All dimensions are multiples of barrel diameter except as noted.

DESIGN PRACTICES
VI-C 40 of 67
Date
FIGURE 7A
EMTROL TYPE A, TYPE X CYCLONES
Q Type-A Cyclone Type-X Cyclone

Gas Inlet Volute Gas Tangential Inlet
B
N B
Cyclone Numbering Code: 50A530

Cyclone Diameter: 50
PLAN VIEW
Cyclone Type: A D4
Cyclone L / D Ratio: 5 12” or to Suit
Cyclone Do / D Ratio: .30
P
R C
D3
P To Suit
C
E
D
D3
E
D1 F L A
A L F D1
G
D2
S
G
D2 H
S 12”
H 30
12”
To Suit To Suit
ELEVATION
Note:
All dimensions are inside metal or lining

DESIGN PRACTICES
VI-C 41 of 67
Date
FIGURE 7B
EMTROL CORP.
HAUPPAUGE, NEW YORK
DIMENSION CHART FOR MODEL 800 CYCLONE

TYPE-A&X WITH L/D RATIO OF 5.00
INLET BARREL CONE DUST TRAP
TOTAL APEX
DIA. INLET HT. WIDTH HT. HT. HT. CYL. CONE DIA. DIA.
D AREA A B C E F G H D2 D1
36 1.63 192.0 10.00 23.50 72.0 43.5 43.0 33.5 21.5 14.50
37 1.73 197.0 10.25 24.25 74.0 45.0 44.0 34.0 22.0 14.75
38 1.80 202.0 10.50 24.75 76.0 45.0 46.0 35.0 23.0 15.25
39 1.90 207.0 10.75 25.50 78.0 46.5 47.0 35.5 23.5 15.50
40 2.01 212.0 11.00 26.25 80.0 48.0 48.0 36.0 24.0 16.00
41 2.09 217.0 11.25 26.75 82.0 49.5 49.0 36.5 24.5 16.50
42 2.20 222.0 11.50 27.50 84.0 51.0 50.0 37.0 25.0 16.75
43 2.28 227.0 11.75 28.00 86.0 51.0 52.0 38.0 26.0 17.25
44 2.40 232.0 12.00 28.75 88.0 52.5 53.0 38.5 26.5 17.50
45 2.56 237.0 12.50 29.50 90.0 54.0 54.0 39.0 27.0 18.00
46 2.66 242.0 12.75 30.00 92.0 55.5 55.0 39.5 27.5 18.50
47 2.78 247.0 13.00 30.75 94.0 57.0 56.0 40.0 28.0 18.75
48 2.90 252.0 13.25 31.50 96.0 57.0 58.0 41.0 29.0 19.25
49 3.00 257.0 13.50 32.00 98.0 58.5 59.0 41.5 29.5 19.50
50 3.13 262.0 13.75 32.75 100.0 60.0 60.0 42.0 30.0 20.00
51 3.23 267.0 14.00 33.25 102.0 61.5 61.0 42.5 30.5 20.50
52 3.36 272.0 14.25 34.00 104.0 63.0 62.0 43.0 31.0 20.75
53 3.50 277.0 14.50 34.75 106.0 63.0 64.0 44.0 32.0 21.25
54 3.61 282.0 14.75 35.25 108.0 64.5 65.0 44.5 32.5 21.50
55 3.81 287.0 15.25 36.00 110.0 66.0 66.0 45.0 33.0 22.00
56 3.93 292.0 15.50 36.50 112.0 67.5 67.0 45.5 33.5 22.50
57 4.07 297.0 15.75 37.25 114.0 69.0 68.0 46.0 34.0 22.75
58 4.22 302.0 16.00 38.00 116.0 69.0 70.0 47.0 35.0 23.25
59 4.34 307.0 16.25 38.50 118.0 70.5 71.0 47.5 35.5 23.50
60 4.50 312.0 16.50 39.25 120.0 72.0 72.0 48.0 36.0 24.00
61 4.65 317.0 16.75 40.00 122.0 73.5 73.0 48.5 36.5 24.50
62 4.78 322.0 17.00 40.50 124.0 75.0 74.0 49.0 37.0 24.75
63 4.94 327.0 17.25 41.25 126.0 75.0 76.0 50.0 38.0 25.25
64 5.07 332.0 17.50 41.75 128.0 76.5 77.0 50.5 38.5 25.50
65 5.31 337.0 18.00 42.50 130.0 78.0 78.0 51.0 39.0 26.00
Note: Inlet Area is in sq. ft.

All Dimension Are in Inches.

DESIGN PRACTICES
VI-C 42 of 67
Date
FIGURE 7B (Cont)
EMTROL CORP.
HAUPPAUGE, NEW YORK

TOTAL APEX
66 5.48 342.0 18.25 43.25 132 79.5 79.0 51.5 39.5 26.50
67 5.62 347.0 18.50 43.75 134 81.0 80.0 52.0 40.0 26.75
68 5.79 352.0 18.75 44.50 136 81.0 82.0 53.0 41.0 27.25
69 5.97 357.0 19.00 45.25 138 82.5 83.0 53.5 41.5 27.50
70 6.12 362.0 19.25 45.75 140 84.0 84.0 54.0 42.0 28.00
71 6.30 367.0 19.50 46.50 142 85.5 85.0 54.5 42.5 28.50
72 6.45 372.0 19.75 47.00 144 87.0 86.0 55.0 43.0 28.75
73 6.63 377.0 20.00 47.75 146 87.0 88.0 56.0 44.0 29.25
74 6.82 382.0 20.25 48.50 148 88.5 89.0 56.5 44.5 29.50
75 7.06 387.0 20.75 49.00 150 90.0 90.0 57.0 45.0 30.00
76 7.26 392.0 21.00 49.75 152 91.5 91.0 57.5 45.5 30.50
77 7.42 397.0 21.25 50.25 154 93.0 92.0 58.0 46.0 30.75
78 7.61 402.0 21.50 51.00 156 93.0 94.0 59.0 47.0 31.25
79 7.82 407.0 21.75 51.75 158 94.5 95.0 59.5 47.5 31.50
80 7.98 412.0 22.00 52.25 160 96.0 96.0 60.0 48.0 32.00
81 8.19 417.0 22.25 53.00 162 97.5 97.0 60.5 48.5 32.50
82 8.40 422.0 22.50 53.75 164 99.0 98.0 61.0 49.0 32.75
83 8.57 427.0 22.75 54.25 166 99.0 100.0 62.0 50.0 33.25
84 8.78 432.0 23.00 55.00 168 100.5 101.0 62.5 50.5 33.50
85 9.06 437.0 23.50 55.50 170 102.0 102.0 63.0 51.0 34.00
86 9.28 442.0 23.75 56.25 172 103.5 103.0 63.5 51.5 34.50
87 9.50 447.0 24.00 57.00 174 105.0 104.0 64.0 52.0 34.75
88 9.68 452.0 24.25 57.50 176 105.0 106.0 65.0 53.0 35.25
89 9.91 457.0 24.50 58.25 178 106.5 107.0 65.5 53.5 35.50
90 10.10 462.0 24.75 58.75 180 108.0 108.0 66.0 54.0 36.00
91 10.33 467.0 25.00 59.50 182 109.5 109.0 66.5 54.5 36.50
92 10.56 472.0 25.25 60.25 184 111.0 110.0 67.0 55.0 36.75
93 10.76 477.0 25.50 60.75 186 111.0 112.0 68.0 56.0 37.25
94 11.00 482.0 25.75 61.50 188 112.5 113.0 68.5 56.5 37.50
95 11.35 487.0 26.25 62.25 190 114.0 114.0 69.0 57.0 38.00
96 11.55 492.0 26.50 62.75 192 115.5 115.0 69.5 57.5 38.50
97 11.80 497.0 26.75 63.50 194 117.0 116.0 70.0 58.0 38.75
98 12.00 502.0 27.00 64.00 196 117.0 118.0 71.0 59.0 39.25
99 12.25 507.0 27.25 64.75 198 118.5 119.0 71.5 59.5 39.50
100 12.51 512.0 27.50 65.50 200 120.0 120.0 72.0 60.0 40.00
101 12.72 517.0 27.75 66.00 202 121.5 121.0 72.5 60.5 40.50
102 12.98 522.0 28.00 66.75 204 123.0 122.0 73.0 61.0 40.75
103 13.19 527.0 28.25 67.25 206 123.0 124.0 74.0 62.0 41.25
104 13.46 532.0 28.50 68.00 208 124.5 125.0 74.5 62.5 41.50
105 13.85 537.0 29.00 68.75 210 126.0 126.0 75.0 63.0 42.00

All Dimension Are in Inches.

DESIGN PRACTICES
VI-C 43 of 67
Date
FIGURE 7B (Cont)
EMTROL CORP.
HAUPPAUGE, NEW YORK

APPROXIMATE VOLUTE OUTLET INLET INLET APEX

DIA. OUTLET DIA. WGT. (1) INLET LENGTH LENGTH BELL LENGTH
D D3 D4 FIRST SECOND N P Q R S
36 19.75 14 4.1 3.3 19.75 19.5 19.5 4.5 43.25

37 20.25 15 4.4 3.5 20.25 20.0 20.0 4.5 44.50
38 21.00 15 4.6 3.6 21.00 20.5 20.5 5.0 45.50
39 21.50 16 4.8 3.8 21.50 21.0 21.0 5.0 46.75
40 22.00 16 5.1 4.0 22.00 22.0 21.5 5.0 48.00
41 22.50 16 5.3 4.2 22.50 22.5 22.0 5.0 49.25

42 23.00 17 5.6 4.4 23.00 23.0 22.5 5.5 50.50
43 23.75 17 5.8 4.6 23.75 23.5 23.0 5.5 51.50
44 24.25 18 6.1 4.8 24.25 24.0 23.5 5.5 52.75
45 24.75 18 6.4 5.1 24.75 24.5 24.0 5.5 54.00
46 25.25 18 6.6 5.3 25.25 25.0 24.5 6.0 55.25

47 25.75 19 6.9 5.5 25.75 25.5 25.0 6.0 56.50
48 26.50 19 7.2 5.7 26.50 26.0 25.5 6.0 57.50
49 27.00 20 7.5 6.0 27.00 26.5 26.0 6.0 58.75
50 27.50 20 7.8 6.2 27.50 27.0 26.5 6.5 60.00
51 28.00 20 8.1 6.5 28.00 27.5 27.0 6.5 61.25

52 28.50 21 8.4 6.7 28.50 28.5 27.5 6.5 62.50
53 29.25 21 8.8 7.0 29.25 29.0 28.0 6.5 63.50
54 29.75 22 9.1 7.2 29.75 29.5 28.5 7.0 64.75
55 30.25 22 9.4 7.5 30.25 30.0 29.0 7.0 66.00
56 30.75 22 9.8 7.7 30.75 30.5 29.5 7.0 67.25

57 31.25 23 10.1 8.0 31.25 31.0 30.0 7.0 68.50
58 32.00 23 10.5 8.3 32.00 31.5 30.5 7.5 69.50
59 32.50 24 10.8 8.6 32.50 32.0 31.0 7.5 70.75
60 33.00 24 11.2 8.9 33.00 32.5 31.5 7.5 72.00
61 33.50 24 11.5 9.2 33.50 33.0 32.0 7.5 73.25

62 34.00 25 11.9 9.5 34.00 33.5 32.5 8.0 74.50
63 34.75 25 12.3 9.8 34.75 34.5 33.0 8.0 75.50
64 35.25 26 12.7 10.1 35.25 35.0 33.5 8.0 76.75
65 35.75 26 13.1 10.4 35.75 35.5 34.0 8.0 78.00
Note: All Dimension Are in Inches.

(1) Approximate Weight Are in Kips Based on 1/4 in. Thick Plate and 1 in. Thick Lining at 160 lbs/sq. ft..
For 3/8 Thick Plate Add 2 Percent.

DESIGN PRACTICES
VI-C 44 of 67
Date
FIGURE 7B (Cont)
EMTROL CORP.
HAUPPAUGE, NEW YORK


66 36.25 26 13.5 10.7 36.25 36.0 34.5 8.5 79.25

67 36.75 27 13.9 11.0 36.75 36.5 35.0 8.5 80.50
68 37.50 27 14.3 11.3 37.50 37.0 35.5 8.5 81.50
69 38.00 28 14.7 11.7 38.00 37.5 36.0 8.5 82.75
70 38.50 28 15.1 12.0 38.50 38.0 36.5 9.0 84.00
71 39.00 28 15.6 12.3 39.00 38.5 37.0 9.0 85.25

72 39.50 29 16.0 12.7 39.50 39.0 37.5 9.0 86.50
73 40.25 29 16.4 13.0 40.25 39.5 38.0 9.0 87.50
74 40.75 30 16.9 13.4 40.75 40.5 38.5 9.5 88.75
75 41.25 30 17.3 13.7 41.25 41.0 39.0 9.5 90.00
76 41.75 30 17.8 14.1 41.75 41.5 39.5 9.5 91.25

77 42.25 31 18.3 14.5 42.25 42.0 40.0 9.5 92.50
78 43.00 31 18.7 14.9 43.00 42.5 40.5 10.0 93.50
79 43.50 32 19.2 15.2 43.50 43.0 41.0 10.0 94.75
80 44.00 32 19.7 15.6 44.00 43.5 41.5 10.0 96.00
81 44.50 32 20.2 16.0 44.50 44.0 42.0 10.0 97.25

82 45.00 33 20.7 16.4 45.00 44.5 42.5 10.5 98.50
83 45.75 33 21.2 16.8 45.75 45.0 43.0 10.5 99.50
84 46.25 34 21.7 17.2 46.25 45.5 43.5 10.5 100.75
85 46.75 34 22.2 17.6 46.75 46.0 44.0 10.5 102.00
86 47.25 34 22.7 18.0 47.25 47.0 44.5 11.0 103.25

87 47.75 35 23.2 18.4 47.75 47.5 45.0 11.0 104.50
88 48.50 35 23.8 18.8 48.50 48.0 45.5 11.0 105.50
89 49.00 36 24.3 19.3 49.00 48.5 46.0 11.0 106.75
90 49.50 36 24.8 19.7 49.50 49.0 46.5 11.5 108.00
91 50.00 36 25.4 20.1 50.00 49.5 47.0 11.5 109.25

92 50.50 37 25.9 20.6 50.50 50.0 47.5 11.5 110.50
93 51.25 37 26.5 21.0 51.25 50.5 48.0 11.5 111.50
94 51.75 38 27.1 21.5 51.75 51.0 48.5 12.0 112.75
95 52.25 38 27.6 21.9 52.25 51.5 49.0 12.0 114.00
96 52.75 38 28.2 22.4 52.75 52.0 49.5 12.0 115.25

97 53.25 39 28.8 22.8 53.25 53.0 50.0 12.0 116.50
98 54.00 39 29.4 23.3 54.00 53.5 50.5 12.5 117.50
99 54.50 40 30.0 23.8 54.50 54.0 51.0 12.5 118.75
100 55.00 40 30.6 24.3 55.00 54.5 51.5 12.5 120.00
101 55.50 40 31.2 24.7 55.50 55.0 52.0 12.5 121.25

102 56.00 41 31.8 25.2 56.00 55.5 52.5 13.0 122.50
103 56.75 41 32.4 25.7 56.75 56.0 53.0 13.0 123.50
104 57.25 42 33.0 26.2 57.25 56.5 53.5 13.0 124.75
105 57.75 42 33.7 26.7 57.75 57.0 54.0 13.0 126.00
Note: All Dimension Are In Inches.

For 3/8 Thick Plate Add 2 Percent.

DESIGN PRACTICES
VI-C 45 of 67
Date
FIGURE 7C
EMTROL CORP.
HAUPPAUGE, NEW YORK

TOTAL APEX
36 1.63 141.5 10.00 23.50 48.5 32.5 27.0 33.5 21.5 14.50
37 1.73 145.5 10.25 24.25 50.0 34.0 27.5 34.0 22.0 14.75
38 1.80 149.0 10.50 24.75 51.0 33.5 29.0 35.0 23.0 15.25
39 1.90 152.5 10.75 25.50 52.5 35.0 29.5 35.5 23.5 15.50
40 2.01 156.0 11.00 26.25 54.0 36.0 30.0 36.0 24.0 16.00
41 2.09 160.0 11.25 26.75 55.5 37.5 30.5 36.5 24.5 16.50
42 2.20 163.0 11.50 27.50 56.5 38.5 31.0 37.0 25.0 16.75
43 2.28 167.0 11.75 28.00 58.0 38.5 32.5 38.0 26.0 17.25
44 2.40 170.5 12.00 28.75 59.5 39.5 33.0 38.5 26.5 17.50
45 2.56 174.5 12.50 29.50 61.0 40.5 34.0 39.0 27.0 18.00
46 2.66 177.5 12.75 30.00 62.0 41.5 34.5 39.5 27.5 18.50
47 2.78 181.5 13.00 30.75 63.5 43.0 35.0 40.0 28.0 18.75
48 2.90 185.0 13.25 31.50 65.0 42.5 36.5 41.0 29.0 19.25
49 3.00 188.5 13.50 32.00 66.0 44.0 37.0 41.5 29.5 19.50
50 3.13 192.0 13.75 32.75 67.5 45.0 37.5 42.0 30.0 20.00
51 3.23 196.0 14.00 33.25 69.0 46.5 38.0 42.5 30.5 20.50
52 3.36 199.0 14.25 34.00 70.0 47.5 38.5 43.0 31.0 20.75
53 3.50 203.0 14.50 34.75 71.5 47.5 40.0 44.0 32.0 21.25
54 3.61 206.5 14.75 35.25 73.0 48.5 40.5 44.5 32.5 21.50
55 3.81 210.5 15.25 36.00 74.5 49.5 41.5 45.0 33.0 22.00
56 3.93 213.5 15.50 36.50 75.5 50.5 42.0 45.5 33.5 22.50
57 4.07 217.5 15.75 37.25 77.0 52.0 42.5 46.0 34.0 22.75
58 4.22 221.0 16.00 38.00 78.5 51.5 44.0 47.0 35.0 23.25
59 4.34 224.5 16.25 38.50 79.5 53.0 44.5 47.5 35.5 23.50
60 4.50 228.0 16.50 39.25 81.0 54.0 45.0 48.0 36.0 24.00
61 4.65 232.0 16.75 40.00 82.5 55.5 45.5 48.5 36.5 24.50
62 4.78 235.0 17.00 40.50 83.5 56.5 46.0 49.0 37.0 24.75
63 4.94 239.0 17.25 41.25 85.0 56.5 47.5 50.0 38.0 25.25
64 5.07 242.5 17.50 41.75 86.5 57.5 48.0 50.5 38.5 25.50
65 5.31 246.5 18.00 42.50 88.0 58.5 49.0 51.0 39.0 26.00

All Dimension Are in Inches

DESIGN PRACTICES
VI-C 46 of 67
Date
FIGURE 7C (Cont)
EMTROL CORP.
HAUPPAUGE, NEW YORK

TOTAL APEX
66 5.48 249.5 18.25 43.25 89.0 59.5 49.5 51.5 39.5 26.50
67 5.62 253.5 18.50 43.75 90.5 61.0 50.0 52.0 40.0 26.75
68 5.79 257.0 18.75 44.50 92.0 60.5 51.5 53.0 41.0 27.25
69 5.97 260.5 19.00 45.25 93.0 62.0 52.0 53.5 41.5 27.50
70 6.12 264.0 19.25 45.75 94.5 63.0 52.5 54.0 42.0 28.00
71 6.30 268.0 19.50 46.50 96.0 64.5 53.0 54.5 42.5 28.50
72 6.45 271.0 19.75 47.00 97.0 65.5 53.5 55.0 43.0 28.75
73 6.63 275.0 20.00 47.75 98.5 65.5 55.0 56.0 44.0 29.25
74 6.82 278.5 20.25 48.50 100.0 65.5 55.5 56.5 44.5 29.50
75 7.06 282.5 20.75 49.00 101.5 67.5 56.5 57.0 45.0 30.00
76 7.26 285.5 21.00 49.75 102.5 68.5 57.0 57.5 45.5 30.50
77 7.42 289.5 21.25 50.25 104.0 70.0 57.5 58.0 46.0 30.75
78 7.61 293.0 21.50 51.00 105.5 69.5 59.0 59.0 47.0 31.25
79 7.82 296.5 21.75 51.75 106.5 71.0 59.5 59.5 47.5 31.50
80 7.98 300.0 22.00 52.25 108.0 72.0 60.0 60.0 48.0 32.00
81 8.19 304.0 22.25 53.00 109.5 73.5 60.5 60.5 48.5 32.50
82 8.40 307.0 22.50 53.75 110.5 74.5 61.0 61.0 49.0 32.75
83 8.57 311.0 22.75 54.25 112.0 74.5 62.5 62.0 50.0 33.25
84 8.78 314.5 23.00 55.00 113.5 75.5 63.0 62.5 50.5 33.50
85 9.06 318.5 23.50 55.50 115.0 76.5 64.0 63.0 51.0 34.00
86 9.28 321.5 23.75 56.25 116.0 77.5 64.5 63.5 51.5 34.50
87 9.50 325.5 24.00 57.00 117.5 79.0 65.0 64.0 52.0 34.75
88 9.68 329.0 24.25 57.50 119.0 78.5 66.5 65.0 53.0 35.25
89 9.91 332.5 24.50 58.25 120.0 80.0 67.0 65.5 53.5 35.50
90 10.10 336.0 24.75 58.75 121.5 81.0 67.5 66.0 54.0 36.00
91 10.33 340.0 25.00 59.50 123.0 82.5 68.0 66.5 54.5 36.50
92 10.56 343.0 25.25 60.25 124.0 83.5 68.5 67.0 55.0 36.75
93 10.76 347.0 25.50 60.75 125.5 83.5 70.0 68.0 56.0 37.25
94 11.00 350.5 25.75 61.50 127.0 84.5 70.5 68.5 56.5 37.50
95 11.35 354.5 26.25 62.25 128.5 85.5 71.5 69.0 57.0 38.00
96 11.55 357.5 26.50 62.75 129.5 86.5 72.0 69.5 57.5 38.50
97 11.80 361.5 26.75 63.50 131.0 88.0 72.5 70.0 58.0 38.75
98 12.00 365.0 27.00 64.00 132.5 87.5 74.0 71.0 59.0 39.25
99 12.25 368.5 27.25 64.75 133.5 89.0 74.5 71.5 59.5 39.50
100 12.51 372.0 27.50 65.50 135.0 90.0 75.0 72.0 60.0 40.00
101 12.72 376.0 27.75 66.00 136.5 91.5 75.5 72.5 60.5 40.50
102 12.98 379.0 28.00 66.75 137.5 92.5 76.0 73.0 61.0 40.75
103 13.19 383.0 28.25 67.25 139.0 92.5 77.5 74.0 62.0 41.25
104 13.46 386.5 28.50 68.00 140.5 93.5 78.0 74.5 62.5 41.50
105 13.85 390.5 29.00 68.75 142.0 94.5 79.0 75.0 63.0 42.00

All Dimension Are in Inches

DESIGN PRACTICES
VI-C 47 of 67
Date
FIGURE 7C (Cont)
EMTROL CORP.
HAUPPAUGE, NEW YORK


36 19.75 14 3.0 2.4 19.75 19.5 19.5 4.5 32.50

37 20.25 15 3.2 2.5 20.25 20.0 20.0 4.5 33.25
38 21.00 15 3.4 2.7 21.00 20.5 20.5 5.0 34.25
39 21.50 16 3.5 2.8 21.50 21.0 21.0 5.0 35.00
40 22.00 16 3.7 3.0 22.00 22.0 21.5 5.0 36.00
41 22.50 16 3.9 3.1 22.50 22.5 22.0 5.0 37.00

42 23.00 17 4.1 3.2 23.00 23.0 22.5 5.5 37.75
43 23.75 17 4.3 3.4 23.75 23.5 23.0 5.5 38.75
44 24.25 18 4.5 3.6 24.25 24.0 23.5 5.5 39.50
45 24.75 18 4.7 3.7 24.75 24.5 24.0 5.5 40.50
46 25.25 18 4.9 3.9 25.25 25.0 24.5 6.0 41.50

47 25.75 19 5.1 4.0 25.75 25.5 25.0 6.0 42.25
48 26.50 19 5.3 4.2 26.50 26.0 25.5 6.0 43.25
49 27.00 20 5.5 4.4 27.00 26.5 26.0 6.0 44.00
50 27.50 20 5.7 4.5 27.50 27.0 26.5 6.5 45.00
51 28.00 20 6.0 4.7 28.00 27.5 27.0 6.5 46.00

52 28.50 21 6.2 4.9 28.50 28.5 27.5 6.5 46.75
53 29.25 21 6.4 5.1 29.25 29.0 28.0 6.5 47.75
54 29.75 22 6.7 5.3 29.75 29.5 28.5 7.0 48.50
55 30.25 22 6.9 5.5 30.25 30.0 29.0 7.0 49.50
56 30.75 22 7.1 5.7 30.75 30.5 29.5 7.0 50.50

57 31.25 23 7.4 5.9 31.25 31.0 30.0 7.0 51.25
58 32.00 23 7.6 6.1 32.00 31.5 30.5 7.5 52.25
59 32.50 24 7.9 6.3 32.50 32.0 31.0 7.5 53.00
60 33.00 24 8.2 6.5 33.00 32.5 31.5 7.5 54.00
61 33.50 24 8.4 6.7 33.50 33.0 32.0 7.5 55.00

62 34.00 25 8.7 6.9 34.00 33.5 32.5 8.0 55.75
63 34.75 25 9.0 7.1 34.75 34.5 33.0 8.0 56.75
64 35.25 26 9.3 7.3 35.25 35.0 33.5 8.0 57.50
65 35.75 26 9.6 7.6 35.75 35.5 34.0 8.0 58.50
Note: All Dimension Are in Inches

For 3/8 Thick Plate Add 2 Percent

DESIGN PRACTICES
VI-C 48 of 67
Date
FIGURE 7C (Cont)
EMTROL CORP.
HAUPPAUGE, NEW YORK


66 36.25 26 9.8 7.8 36.25 36.0 34.5 8.5 59.50

67 36.75 27 10.1 8.0 36.75 36.5 35.0 8.5 60.25
68 37.50 27 10.4 8.3 37.50 37.0 35.5 8.5 61.25
69 38.00 28 10.7 8.5 38.00 37.5 36.0 8.5 62.00
70 38.50 28 11.0 8.8 38.50 38.0 36.5 9.0 63.00
71 39.00 28 11.3 9.0 39.00 38.5 37.0 9.0 64.00

72 39.50 29 11.7 9.2 39.50 39.0 37.5 9.0 64.75
73 40.25 29 12.0 9.5 40.25 39.5 38.0 9.0 65.75
74 40.75 30 12.3 9.8 40.75 40.5 38.5 9.5 66.50
75 41.25 30 12.6 10.0 41.25 41.0 39.0 9.5 67.50
76 41.75 30 13.0 10.3 41.75 41.5 39.5 9.5 68.50

77 42.25 31 13.3 10.5 42.25 42.0 40.0 9.5 69.25
78 43.00 31 13.6 10.8 43.00 42.5 40.5 10.0 70.25
79 43.50 32 14.0 11.1 43.50 43.0 41.0 10.0 71.00
80 44.00 32 14.3 11.4 44.00 43.5 41.5 10.0 72.00
81 44.50 32 14.7 11.6 44.50 44.0 42.0 10.0 73.00

82 45.00 33 15.0 11.9 45.00 44.5 42.5 10.5 73.75
83 45.75 33 15.4 12.2 45.75 45.0 43.0 10.5 74.75
84 46.25 34 15.8 12.5 46.25 45.5 43.5 10.5 75.50
85 46.75 34 16.1 12.8 46.75 46.0 44.0 10.5 76.50
86 47.25 34 16.5 13.1 47.25 47.0 44.5 11.0 77.50

87 47.75 35 16.9 13.4 47.75 47.5 45.0 11.0 78.25
88 48.50 35 17.3 13.7 48.50 48.0 45.5 11.0 79.25
89 49.00 36 17.7 14.0 49.00 48.5 46.0 11.0 80.00
90 49.50 36 18.1 14.3 49.50 49.0 46.5 11.5 81.00
91 50.00 36 18.5 14.6 50.00 49.5 47.0 11.5 82.00

92 50.50 37 18.9 15.0 50.50 50.0 47.5 11.5 82.75
93 51.25 37 19.3 15.3 51.25 50.5 48.0 11.5 83.75
94 51.75 38 19.7 15.6 51.25 51.0 48.5 12.0 84.50
95 52.25 38 20.1 15.9 52.25 51.5 49.0 12.0 85.50
96 52.75 38 20.5 16.3 52.75 52.0 49.5 12.0 86.50

97 53.25 39 20.9 16.6 53.25 53.0 50.0 12.0 87.25
98 54.00 39 21.4 16.9 54.00 53.5 50.5 12.5 88.25
99 54.50 40 21.8 17.3 54.50 54.0 51.0 12.5 89.00
100 55.00 40 22.2 17.6 55.00 54.5 51.5 12.5 90.00
101 55.50 40 22.7 18.0 55.50 55.0 52.0 12.5 91.00

102 56.00 41 23.1 18.3 56.00 55.5 52.5 13.0 91.75
103 56.75 41 23.5 18.7 56.75 56.0 53.0 13.0 92.75
104 57.25 42 24.0 19.0 57.25 56.5 53.5 13.0 93.50
105 57.75 42 24.5 19.4 57.75 57.0 54.0 13.0 94.50

(1) Approximate Weight Are in Kips Based on 1/4 in. Thick Plate And 1 in. Thick Lining at 160 lbs/sq. ft..

DESIGN PRACTICES
VI-C 49 of 67
Date
FIGURE 7D
EMTROL CORP.
HAUPPAUGE, NEW YORK

TOTAL APEX
31 .60 167.0 6.00 14.50 62.0 37.5 37.0 30.5 18.5 12.50
32 .65 172.0 6.25 15.00 64.0 39.0 38.0 31.0 19.0 12.75
33 .70 177.0 6.50 15.50 66.0 39.0 40.0 32.0 20.0 13.25
34 .75 182.0 6.75 16.00 68.0 40.5 41.0 32.5 20.5 13.50
35 .80 187.0 7.00 16.50 70.0 42.0 42.0 33.0 21.0 14.00
36 .83 192.0 7.00 17.00 72.0 43.5 43.0 33.5 21.5 14.50
37 .88 197.0 7.25 17.50 74.0 45.0 44.0 34.0 22.0 14.75
38 .92 202.0 7.50 17.75 76.0 45.0 46.0 35.0 23.0 15.25
39 .98 207.0 7.75 18.25 78.0 46.5 47.0 35.5 23.5 15.50
40 1.04 212.0 8.00 18.75 80.0 48.0 48.0 36.0 24.0 16.00
41 1.07 217.0 8.00 19.25 82.0 49.5 49.0 36.5 24.5 16.50
42 1.13 222.0 8.25 19.75 84.0 51.0 50.0 37.0 25.0 16.75
43 1.20 227.0 8.50 20.25 86.0 51.0 52.0 38.0 26.0 17.25
44 1.26 232.0 8.75 20.75 88.0 52.5 53.0 38.5 26.5 17.50
45 1.33 237.0 9.00 21.25 90.0 54.0 54.0 39.0 27.0 18.00

31 17.00 12 3.1 2.5 17.00 14.5 17.0 4.0 37.25

32 17.50 13 3.3 2.6 17.50 15.0 17.5 4.0 38.50
33 18.25 13 3.5 2.8 18.25 15.5 18.0 4.0 39.50
34 18.75 14 3.7 2.9 18.75 16.0 18.5 4.5 40.75
35 19.25 14 3.9 3.1 19.25 16.5 19.0 4.5 42.00
36 19.75 14 4.1 3.3 19.75 17.0 19.5 4.5 43.25

37 20.25 15 4.4 3.5 20.25 17.5 20.0 4.5 44.50
38 21.00 15 4.6 3.6 21.00 18.0 20.5 5.0 45.50
39 21.50 16 4.8 3.8 21.50 18.5 21.0 5.0 46.75
40 22.00 16 5.1 4.0 22.00 19.0 21.5 5.0 48.00
41 22.50 16 5.3 4.2 22.50 19.5 22.0 5.0 49.25

42 23.00 17 5.6 4.4 23.00 19.5 22.5 5.5 50.50
43 23.75 17 5.8 4.6 23.75 20.0 23.0 5.5 51.50
44 24.25 18 6.1 4.8 24.25 20.5 23.5 5.5 52.75
45 24.75 18 6.4 5.1 24.75 21.0 24.0 5.5 54.00

Inlet Area is in Sq. Ft.

DESIGN PRACTICES
VI-C 50 of 67
Date
FIGURE 7E
EMTROL MODEL 1550 CYCLONES
Q
B
To Suit
To Suit
L
C
E
D
A
F
D2
G
H
12”
To Suit
To Suit
DIMENSION CHART FOR MODEL 1550 CYCLONES
TYPE S P WITH L / D RATIO OF 5.00
INLET TOTAL INLET BARREL CONE DUST TRAP

DIA. D AREA HGT. A WIDTH B HGT. C HGT. E HGT. F CYL G CONE H DIA. D2 L Q
10 .07 77.00 2.00 4.75 20.00 12.00 12.00 18.00 6.00 15.00 14.00
12 .09 88.00 2.25 5.75 24.00 15.00 14.00 19.00 7.00 16.00 16.00
14 .12 98.00 2.75 6.50 28.00 16.50 17.00 20.50 8.50 16.00 18.00
16 .17 108.00 3.25 7.50 32.00 19.50 19.00 21.50 9.50 16.00 20.00
18 .21 118.00 3.50 8.50 36.00 21.00 22.00 23.00 11.00 16.00 22.00
20 .26 128.00 4.00 9.50 40.00 24.00 24.00 24.00 12.00 16.00 24.00
22 .30 138.00 4.25 10.25 44.00 27.00 26.00 25.00 13.00 16.00 26.00
24 .37 148.00 4.75 11.25 48.00 28.50 29.00 26.50 14.50 16.00 28.00
26 .45 161.00 5.25 12.25 52.00 31.50 31.00 27.50 15.50 19.00 30.00
28 .51 172.00 5.50 13.25 56.00 33.00 34.00 29.00 17.00 20.00 32.00
30 .58 182.00 6.00 14.00 60.00 36.00 36.00 30.00 18.00 20.00 34.00
32 .65 193.00 6.25 15.00 64.00 39.00 38.00 31.00 19.00 21.00 36.00
34 .75 203.00 6.75 16.00 68.00 40.50 41.00 32.50 20.50 21.00 38.00
Note:
Inlet area is in sq. ft. all dimensions are in inches.

DESIGN PRACTICES
VI-C 51 of 67
Date
FIGURE 8
GENERAL ELECTRIC CYCLONES
S A
F To Suit
B G
To Suit
B G M
D
M F
D
T L H P
P H L
T
C
N
C 70_
N 12”
2’
70_
12” To Suit 6”
6” To Suit

Date
Section
VI-C
FIGURE 8 (Cont)
GENERAL ELECTRIC CYCLONES
Page
December, 1995

52 of 67
DESIGN PRACTICES

A B F A B F C D G H I L M N P S T U

I.S. I.S. I.D. I.S. I.S. I.D. I.D. I.D. I.S. O.S. I.S. O.S. O.S. I.R. I.D.

FLUID SOLIDS

PARTICLE COLLECTION


PROPRIETARY INFORMATION — For Authorized Company Use Only

EXXON
ENGINEERING
DESIGN PRACTICES
VI-C 53 of 67
Date
FIGURE 9
CYCLONE INLET, OUTLET SIZES AND SHAPES
Tangential Inlet – Inlet Too Wide
Tangential Inlet – Proper Inlet Width
Scroll Inlet

DESIGN PRACTICES
VI-C 54 of 67
Date
FIGURE 10
PERFORMANCE DEBIT FOR MANIFOLDING OF MULTICLONES
100
Typical Efficiency of
Single Element
80
Typical Efficiency of
Multiple Array
Collection Efficiency, %
60
40
20
0
0 5 10 15 20 25
Particle Diameter, Microns

DESIGN PRACTICES
VI-C 55 of 67
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FIGURE 11
GRADE EFFICIENCY CORRELATION
99.99
99.9
99
95
90
Collection Efficiency, %
80
70
60
50
40
30
20
10
0.1
0.01
1 10 100
Relative Particle Size, d / dc

DESIGN PRACTICES
VI-C 56 of 67
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FIGURE 12
LOADING CORRECTION FACTOR
1.00
Loading Factor, Lf
kg /m 3
lb / ft 3
0.10
0.00 0 0.01 0.10 1.00 10.00
Loading, lb / ft 3 (kg / m3)

DESIGN PRACTICES
VI-C 57 of 67
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FIGURE 13A
GAS SIDE VELOCITY HEAD FACTORS FOR DUCON MODEL 810 CYCLONES
Outlet Area
Inlet Area
0.2 0.3 0.4 0.5 0.75 1.0 1.5 2.0

70
60
50
Gas Side Velocity Head Factor, K’2 , K’’2 , K’’’ 2
40
30
25
20
15
10
9
7
0.1 0.2 0.3 0.4 0.5 0.6 0.8 1.0
Outlet Tube Diameter, do

Barrel Diameter, db
Redrawn from DUCON Drawing C-4/67-1, by permission.

Note: This drawing is the property of the Ducon Company and is for confidential use only. It is not to be communicated or disclosed to
others or to be copied in whole or in part except by written permission of the Ducon Company, Inc.

DESIGN PRACTICES
VI-C 58 of 67
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FIGURE 13B
SOLID SIDE VELOCITY HEAD FACTORS FOR DUCON MODEL 810 CYCLONES
1.5
Solid Side Vel, Head Factor

1.0
Gas Side Vel Head Factor

Ao / Ai = 1.50
1.25
0.8
1.00 1.00 0.6

Ao / Ai = 1.50 0.5
0.75 0.75 0.4
1.25
0.50 0.50 0.3
0.30
0.2
0.30
Solid Side Velocity Head
Factor K’3, K’’3, K’’’3 4 3
1 2 3 4 5 6 7 8 10 20 30 40 60 80
1.0 0.1
Proceed from Chart 1 1 2 dd = Dip Leg Dia = 10”
to Chart 4 by arrows
3” 4” 5” 6” 8” 12” 14” 16”
0.9
18”
Exponent “x”
0.8 20”
22”
0.7
24”
0.6
Cyclone Barrel Diameter db (dd / db)x
10” 20” 30” 40” 50” 60” 70” 0.1 0.2 0.3 0.4 0.5 0.6
CYCLONE BARREL CYCLONE BARREL CYCLONE BARREL CYCLONE BARREL

SIZE DIA. “D” SIZE DIA. “D” SIZE DIA. “D” SIZE DIA. “D”
20 12.75” 120 31.25 320 51.0 520 65.0

25 14.25 140 33.75 340 52.5 540 66.0
30 15.75 160 36.0 360 54.0 560 67.5
35 17.0 180 38.0 380 55.5 580 68.5
40 18.0 200 40.0 400 57.0 600 69.75
50 20.0 220 42.0 420 58.5 620 71.0
60 22.0 240 44.0 440 60.0 640 72.0
70 24.0 260 46.0 460 61.0 660 73.0
80 25.5 280 47.75 480 62.5 680 74.25
90 27.0 300 49.25 500 63.5 700 75.25
100 28.5
Reprinted from Ducon Drawing C-34/68-0, by permission.

Information is this Figure is from a vendor drawing not avilable in metric units.
Dimensions shown are in inches. Use the conversion factor: in x 25.4 = mm

DESIGN PRACTICES
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FIGURE 13C
GAS SIDE VELOCITY HEAD FACTORS FOR DUCON MODEL 800 CYCLONES
50
40
30
20
15
10
5
0.3 0.4 0.6 0.8 1.0 1.5 2.0
Outlet Area
Inlet Area
Redrawn from DUCON Drawing S-4512, by permission.


DESIGN PRACTICES
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FIGURE 13D
SOLID SIDE VELOCITY HEAD FACTORS FOR DUCON MODEL 800 CYCLONES
Gas Outlet Tube Diameter Plus Dipleg Diameter (m)
0.3 0.4 0.6 0.8 1.0 1.5 2.0

30
20
15
Ao/Ai
10 0.4
0.5
0.75
8
1.0
2.0
6
10 15 20 30 40 60 80
Gas Outlet Tube Diameter Plus Dipleg Diameter (in.)
Redrawn from DUCON Drawing S-4513, by permission.


DESIGN PRACTICES
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FIGURE 14A
GAS SIDE PRESSURE DROP FOR EMTROL CYCLONES
300
250
200
150
100
80
]
2.3
(V i ) /{M(d o /d b )
60
0.75 0.25
(lbs Solids / ft 3 gas)
2
e = 1.0 0.5
e=0
40
30
20
15
10
30 40 60 80 100 150 200 300 400 600 800 1000
DP / ρg (in W.G. / lbs / ft 3)
Information in this Figure is from a vendor drawing not available in Metric units. Use following conversion factors:
Vi (ft / s) = Vi (m / s) x 3.28
DP (in W.G.) = DP (kPa) x 4.02
ρg (lbs / ft 3) = DP (kg / m3) x 0.0625
e (lbs / ft 3) = e (kg / m3) x 0.0625

DESIGN PRACTICES
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FIGURE 14B
SOLID SIDE PRESSURE DROP FOR EMTROL CYCLONES
200
150
100
90
80
70
]
0.74
60
( d o L/d b )
2
50
0.6
40
(V i ) /[(M)
0.75
2
30
0.5 (lbs solids / ft 3 gas)
0.25 e=0
e = 1.0
20
15
10
10 15 20 25 30 40 50 60 80 100 150 200 300
DP / ρg (in W.G. / lbs / ft 3)
Information in this Figure is from a vendor drawing not available in Metric units. Use following conversion factors:
Vi (ft / s) = Vi (m / s) x 3.28
DP (in W.G.) = DP (kPa) x 4.02
ρg (lbs / ft 3) = DP (kg / m3) x 0.0625
e (lbs / ft 3) = e (kg/m 3) x 0.0625

DESIGN PRACTICES
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FIGURE 15
CYCLONE PRESSURE DROP FACTOR FOR DUST LOADING
0.9
0.8
kg / m3
0.7
lbs / ft 3
Pressure Drop Factor K 4
0.6
0.5
0.4
0.3
0.2
5 6 7 8 9 2 3 4 5 6 7 8 9 2 3 4 5 6 7 8 9 2
0.01 0.1 1
Solids Loading at Cyclone Inlet (lbs / ft 3)
0.1 1.0 10
Solids Loading at Cyclone Inlet (kg / m3)

DESIGN PRACTICES
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FIGURE 16
TRICKLE VALVE – UNSHROUDED
Cyclone
Dipleg
Support Rings
Flapper
Flapper Stop
Flapper Plate
Opening
Dipleg

DESIGN PRACTICES
VI-C 65 of 67
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FIGURE 17
TRICKLE VALVE – OPEN SHROUD
Cyclone
Dipleg
Support
Ring
Flapper
Flapper Stop
New Type
Baffle Plate
Opening
Dipleg
Flapper Plate
Gusset

DESIGN PRACTICES
VI-C 66 of 67
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FIGURE 18
ELBOW TRICKLE VALVE WITH DOUBLE REFRACTORY FLAPPER
Schematic Support
CL (Vender to Design an
actual support for CL
Commercial Unit)
Dipleg
Trickle Valve
R = 2D
3D / 8
2”
(50 mm)
3D / 8
2”
(50 mm)
D + 2”
3” + 1”
– 0”
3/4” (20 mm) Hexmesh and
D = Dipleg NPS (In.) RESCO AA-22 Refractory

DESIGN PRACTICES
VI-C 67 of 67
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FIGURE 19
CYCLONE SAMPLE CALCULATION – PARTICLE SIZE DISTRIBUTIONS
100
80
60
50
40
30
20
Particle Size (Microns)
Collected Solids Inlet Solids Escaping Solids
10
6
5
1
0.2 0.5 1 2 5 10 20 30 40 50 60 70 80 90 95 98 99 99.5 99.9
Cumulative Weight % Less than Stated Size

Design Practices for Fluid Solids Particle Collection Cyclones

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Design Practices for Fluid Solids Particle Collection Cyclones

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DESIGN PRACTICES

FLUID SOLIDS Section Page

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

December 1995 Corrections and minor updates.

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

1. Design Practices, Section XVIII A-3, Cyclones.

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

TYPICAL CYCLONE INSTALLATIONS

Figure 4 shows a cyclone installation used in a solids transfer system.

CYCLONE DESIGN CONSIDERATIONS

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

CYCLONE DESIGN CONSIDERATIONS (Cont)

where: db is the cyclone barrel diameter

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

CYCLONE DESIGN CONSIDERATIONS (Cont)

GAS OUTLET TO INLET AREA RATIO (Ao/Ai)

1.0 – 1.5 0.5 – 1.0 0.5 – 0.7

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

CYCLONE DESIGN CONSIDERATIONS (Cont)

Ao/Ai MINIMUM LENGTH TO DIAMETER

OTHER DESIGN FACTORS

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

CYCLONE DESIGN CONSIDERATIONS (Cont)

where: dc is the critical particle diameter (ft), (m)

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

CYCLONE CALCULATIONS (Cont)

Cyclone length, ȏ, is the effective length, given as the smaller of:

where: ȏb is the length of the barrel (ft), (m)

6. Calculate the solids losses as:

(1 * Eff) (Inlet solids rate) Eq. (4)

DP 1 + 1 V 2 (K Ȁ ρ ) K 2Ȁ K 4 ρg ) (psi) Eq. (5c)

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

CYCLONE CALCULATIONS (Cont)

where: DP1 is the pressure drop (psi), (kPa)

ǒ Ǔ ȧ n ȧƪdoƫ * 1ȧ) f ǒdoǓ ȳȧ

where: T = cyclone operating temperature (_R), (K) (2)

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

CYCLONE CALCULATIONS (Cont)

DP 1 + 1 V 2 ǒK Ȁ ρ ) K 5Ȁ ρgǓ (psi) Eq. (12c)

DP 1 + 1 ƪV21 (K1Ȁ ρf ) 0.92 K6Ȁ ρg )ƫ (psi) Eq. (15c)

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

CYCLONE CALCULATIONS (Cont)

for various values of solids entrainment, e.

DP 1 ) 2 + DP a ) DP 1(gs) ) DP 2(ss) (psi), (kPa) Eq. (20)

DP 1 ) 2 ) 3 + DP a ) DP 1(gs) ) DP 2(gs) ) DP 3(ss) (psi), (kPa) Eq. (21)

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

CYCLONE CALCULATIONS (Cont)

where: 1, 2 and 3 refer to primary, secondary and tertiary cyclones

DP + 6.6 V2 ρ (psi) Eq. (22c)

DP + 6.6 10 –3 V 2 ρ (kPa) Eq. (22m)

DP + 7.6 V2 ρ (psi) Eq. (23c)

DP + 7.6 10 –3 V 2 ρ (kPa) Eq. (23m)

For CG-3755 cyclones, the equation is:

DP + 9.3 V2 ρ (psi) Eq. (24c)

Calculations of cyclone pressure drop agree well with measured results.

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

where: dd is the dipleg diameter (ft), (m)

where: L is the minimum dipleg length (ft), (m)

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.

DIPLEG DESIGN (Cont)

PRIMARY CYCLONE SECONDARY, TERTIARY,

TERTIARY CYCLONE SYSTEMS