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Engineering Design & Specifications of Cyclone Separator

Technical Report · June 2014

DOI: 10.13140/RG.2.2.30512.40966

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 Engineering Design & Specifications of
Cyclone Separator
Nelson Pynadathu, Paul Thomas, Arjun P
MTech (Energy & Environmental Engineering)
SMBS, VIT-University, Vellore-632014. India.

Abstract—Cyclone Separator is a device used to separate sized to provide the maximum inlet velocity possible for
particular matter from the air or gas stream. The design and high separation without excessive turbulence. Multiple-
performance of a cyclone separator is based on the various
parameters such as pressure drop, collection efficiency and cut cyclone separators consist of a number of small-diameter
size diameter. The study about the above mentioned parameters cyclones, operating in parallel and having a common gas inlet
has been made for designing the cyclone separator. This paper and outlet. Multiclones operate on the same principle as
also discusses the other related parameters and specifications, cyclones–creating a main downward vortex and an ascending
operating costs and applications. inner vortex.
In general, a cyclone consists of an upper cylindrical part
Index Terms—Cyclone separator, design, specification, referred to as the barrel and a lower conical part referred to as
pressure drop, collection efficiency, cut size diameter. cone. The air stream enters tangentially at the top of the barrel
and travels downward into the cone forming an outer vortex.
I. INTRODUCTION The increasing air velocity in the outer vortex results in a
centrifugal force on the particles. Because of inertia, the
Chemical processes consist of reaction stages and/or particles resist the direction change as the gas turns, and they
separation stages in which the process streams are separated migrate toward the cylinder walls, separating them from the
and purified. Such separations involve physical principles air stream. When the air reaches the bottom of the cone, an
based on differences in the properties of the constituents in the inner vortex is created reversing direction and exiting out the
stream. These heterogeneous mixtures consist of components top as clean air while the particulates fall into the dust
that do not react chemically and have clearly visible collection chamber attached to the bottom of the cyclone. The
boundaries of separation between the different phases. collection efficiency of a cyclone separator improves as the
Components of such mixture can be separated using one or number of revolutions made by the gas and the gas velocity
more appropriate techniques using particulate removal increase. However, the overall performance depends on the
devices. particle size distribution of the incoming gas stream.
A preliminary selection of suitable particulate emission
control systems is generally based on knowledge of four
items: particulate concentration in the stream to be cleaned,
the size distribution of the particles to be removed, the gas
flow rate, and the final allowable particulate emission rate.
Cyclone separators provide a method of removing
particulate matter from air or other gas streams at low cost and
low maintenance. A cyclone separator is a mechanically aided
collector that uses inertia to separate PM from the gas stream
as it spirals through the cyclone. Cyclones are generally used
for collection of medium-sized and coarse particles. Cyclone
separator can be constructed of any material, metal or ceramic
that is capable of withstanding high temperatures, abrasive
particles or corrosive atmospheres. It is necessary that the
interior surface be smooth so that the collected particles may
slide easily down the wall to the hopper. The most common
types of centrifugal, or inertial, collectors in use today are
single-cyclone separators and multiple-cyclone separators
(multiclone).
Cyclones have a relatively simple construction and
generally have no moving parts. Simple cyclones consist of an Fig.1: Schematic diagram of Cyclone Separator
inlet cylindrical section, conical section, outlet gas duct, outlet
dust tube, and collection hopper; a cyclone uses an induced
draft fan to move the gas stream through the device. They are
 II. DESIGN CONSIDERATIONS
The basic shape and function of cyclones has not changed
much in over 100 years. The earliest type the-“pot-bellied”
or low-pressure design was soon joined by high efficiency
designs that were smaller in diameter relative to the inlet
volumetric gas flow. These high efficiency designs captured a
greater percentage of incoming particulate due to their higher
gas flow (and particle) velocities. Cyclone designs are
described by relating the height of the cylinder and cone
sections to the cylinder diameter.
Fig 2: Geometric dimensions of Cyclone Separator
In the agricultural processing industry, 2D2D [1] and
1D3D [2] cyclone designs are the most commonly used
abatement devices for particulate matter control. The D‟s in
the 2D2D designation refer to the barrel diameter of the
cyclone. The numbers preceding the D‟s relate to the length of
the barrel and cone sections, respectively. A 2D2D cyclone
has barrel and cone lengths of two times the barrel diameter,
whereas the 1D3D cyclone has a barrel length equal to the
barrel diameter and a cone length of three times the barrel
diameter. Previous research by Wang[3] indicated that,
compared to other cyclone designs, 1D3D and 2D2D are the
most efficient cyclone collectors for fine dust (particle
diameters less than 100μm).
Mihalski et al [4] reported “cycling lint” near the trash exit
for the 1D3D and 2D2D cyclone designs when the PM in the
inlet air stream contained lint fiber. Mihalski reported a
significant increase in the exit PM concentration for these high
efficiency cyclone designs and attributed this to small balls of
lint fiber “cycling” near the trash exit causing the fine PM that
would normally be collected to be diverted to the clean air exit
stream. Simpson and Parnell [5] introduced a new low-
pressure cyclone, called the 1D2D cyclone, for the cotton
ginning industry to solve the cycling-lint problem. The 1D2D
cyclone is a better design for high-lint content trash compared
with 1D3D and 2D2D cyclones [6].
The cyclone design procedure outlined in Cooper and
Alley [7], hereafter referred to as the classical cyclone design
(CCD) process, was developed by Lapple in the early 1950s.
The CCD process (the Lapple model) is perceived as a
standard method and has been considered by some engineers
to be acceptable. However, there are several problems
associated with this design procedure. First of all, the CCD
process does not consider the cyclone inlet velocity in
developing cyclone dimensions. It was reported (Parnell,
1996) that there is an “ideal” inlet velocity for the different
cyclone designs for optimum cyclone performance. Secondly,
the CCD does not predict the correct number of turns for
different type cyclones. The overall efficiency predicted by the
CCD process is incorrect because of the inaccurate fractional
efficiency curve generated by the CCD process [8].
In order to use the CCD process, it is assumed that the
design engineer will have knowledge of (1) flow conditions,
(2) particulate matter (PM) concentrations and particle size
distribution (PSD) and (3) the type of cyclone to be designed
(high efficiency, conventional, or high throughput). The PSD
must be in the form of mass fraction versus aerodynamic
equivalent diameter of the PM. The cyclone type will provide
all principle dimensions as a function of the cyclone barrel
diameter (D). The different proportional values are given in
Fig.3. With these given data, the CCD process is as follows:
The Number of Effective Turns (Ne): The first step of CCD
process is to calculate the number of effective turns. The
number of effective turns in a cyclone is the number of
revolutions the gas spins while passing through the cyclone
outer vortex. A higher number of turns of the air stream result
in a higher collection efficiency. The Lapple model for Ne
calculation is as follows
Ne = ( h + H / 2 ) / a (1)
Where “h” is the cylinder height, “H” is the cyclone height
and “a” is the inlet height which is calculated based on the
geometric dimensions from the Fig.3 shown below. Based on
equation 1, the predicted numbers of turns were calculated.
The three cyclone designs have the same inlet dimensions,
referred to as the 2D2D inlet. The 1D3Dt cyclone is a
traditional 1D3D cyclone design, which has the same design
dimensions as 1D3D. It has been observed that the Lapple
model for Ne produces an excellent estimation of the number
of turns for the 2D2D cyclone designs. However, this model
(equation 1) fails to give an accurate estimation of N e for the
cyclone design other than 2D2D design. This observation
indicates a limitation for the Lapple model to accurately
predict the number of effective turns. The 1D3Dt cyclone has
an inlet height equal to the barrel diameter (Hc = Dc) and an
inlet width of one eighth of the barrel diameter (Bc = Dc/8).
Cut-Point diameter (d50): The second step of the Cyclone
separator design process is the calculation of the cut-point
diameter. The cut diameter of the cyclone is defined as the size
of the particles collected with 50% collection efficiency. It is
an indicator of the size range of particles that can be collected.
It is a convenient way of defining as it provides information
on the effectiveness for a particle size range. As the cut-point
diameter increases, the collection efficiency decreases. The
Lapple cut-point model was developed based upon force
balance theory. The Lapple model for cut-point (d50) is as
follows
dpc = [9µW/((2πNeVi(ρp-ρg))]1/2 (2)

Fig 3: Standard Cyclone Dimensions
where µ is the viscosity, W is the inlet width, Ne is the
effective number of turns, Vi is the inlet gas velocity, ρp is the
particle density and ρ is the gas density. In the process to
develop this cut-point model, it was assumed that the particle
terminal velocity was achieved when the opposing drag force
equaled the centrifugal force, and the drag force on every
single particle was determined by Stokes law. As a result, the
cut-point (dpc, or d50) determined by the Lapple model
(equation 2) is an equivalent spherical diameter (ESD), or in
other words, it is a Stokes diameter. The following equation
can be used to convert ESD to AED for the spherical particles
AED = (ρp)1/2 * ESD (3)
Since ρ >> ρ , it could be considered that (ρ -ρ ) ≈ ρ .
p g p g p
Combining equations 2 & 3, the Lapple model for cut-point
could be modified as follows:
dpc = [9µW/(2πNeVi)]1/2 (in AED) (4)
Equation 4 is the Lapple model for cut-point in AED. This
model indicates that the cut-point is totally independent of
characteristics of the inlet PM. However, It has been reported
(Wang et al. 2000) that the cyclone fractional efficiency
curves are significantly affected by the particle size
distribution of particulate matter entering. The cut-point
shifted with the change of inlet PSD. The Lapple model for
cut-point needs to be corrected for particle characteristics of
inlet PM.
Fractional Efficiency Curve (FEC - ηi) The third step of the
design process is to determine the fractional efficiency. Based
upon the cut-point, Lapple then developed an empirical model
(equation 5) for the prediction of the collection efficiency for
any particle size, which is also known as fractional efficiency
curve:
η = 1/(1+(dpc + dpj))2 (5)
It is observed that cyclone efficiency correlates in a general
way with cut diameter ratio. For a typical cyclone, efficiency
will increase as the ratio increases. The preceding correlation
has been found to agree well with experimental data.
Collection efficiency: The collection or separation
efficiency is most properly defined for a given particle size.
As mentioned, fractional efficiency is defined as the fraction
of particles of a given size collected in the cyclone, compared
to those of that size going into the cyclone. Experience shows
that collection efficiency of cyclone separator increases with
increasing particle mean diameter and density; increasing gas
tangential velocity; decreasing cyclone diameter; increasing
cyclone length; extraction of gas along with solids through the
cyclone legs.
If a size distribution of the inlet particles is known, the
overall collection efficiency of a cyclone can be calculated
based on the cyclone fractional efficiency. The overall
collection efficiency of a cyclone is the weighted average of
the collection efficiencies for the various size ranges. It is
given by:
η0 = Σ njmj (6)
Pressure Drop (ΔP): Cyclone pressure drop is another major
parameter to be considered in the process of designing a
cyclone system. The pressure drop significantly affects the
performance parameters of a cyclone. The total pressure drop
in a cyclone will be due to the entry and exit losses, and
friction and kinetic energy losses in the cyclone. Normally
most significant pressure drop occurs in the body due to swirl
and energy dissipation. There have been many attempts to
predict pressure drops from design variables. The idea is that
having such an equation, one could work back and optimize
the design of new cyclones. The empirical equation given by
Stairmand (1949) can be used to estimate the pressure drop.

(7)
Where ΔP is the cyclone pressure drop, ρf is the gas
density; u1 is the inlet duct velocity; u2 is the exit duct velocity
rt is the radius of circle to which the center line of the inlet is
tangential; re is the radius of exit pipe, φ is the cyclone
pressure drop factor,
Ψ = fc (As/A1) (8)
Fc is the friction factor, taken as 0.005 for gases, and As the
surface area of cyclone exposed to the spinning fluid. For
design purposes this can be taken as equal to the surface area
of a cylinder with the same diameter as the cyclone and length
equal to the total height of the cyclone.
At is the area of inlet duct.
Above equation is for the gas flowing alone, containing no
solids. The presence of solid will increase the pressure drop
over that calculated using equation (9), depending on the
solids loading. Alternative design equation for cyclones
occasionally used is:
(9)
Where q is volumetric flow rate, Bc is the inlet width, Hc is
the inlet height, Dc is the outlet diameter, Zc is the cone
length, Lc is the cylinder length.
In this equation Kc is a dimensionless factor express of
cyclone inlet vanes. Kc = 0.5 for cyclones without vanes; Kc =
1.0 for cyclone vanes that do not expand the entering gas or
touch the outer wall; however Kc = 2.0 for cyclone vanes that
expand and touch the outlet all. The above equation when
compared with experimental data shows poor correlation
coefficient (Theodore, 2008). Another form of the empirical
pressure drop an equation which is being widely used:
ΔP = Kc ρVi2 (10)
Kc is a proportionality factor, if it is measured in inches; it
varies from 0.013 to 0.024, with 0.024 the norm.
In short, the design considerations that can be followed are
 Select either the high efficiency or high throughput
design, depending on the performance required.
 Obtain an estimate of the particle size distribution of
the solids in the stream to be treated.
 Calculate the number of cyclone needed in parallel.
 Estimate the cyclone diameter for an inlet velocity of
say 15 m/s. Then obtain the other cyclone dimensions
from the graphs.
 Then estimate the scale up factor for the transposition
of the figure.
 Estimate the cyclone performance and overall
efficiency, if the results are not satisfactory try small
diameter.
III. SPECIFYING A CYCLONE
Selecting the proper cyclone to provide a desired level of
performance requires accurate and reliable operating data. In
addition, information about construction materials, equipment
features and accessories is needed. Operating conditions can
be divided into gas and particulate conditions at the cyclone
inlet. Gas data should include analysis, flow rate, temperature
and pressure.
Particulate data should include particle density, size
distribution and explanation of how density and size
distribution data are determined. A particle behavior is
affected by its mass, shape geometric dimensions and surface
texture. Thus, to have any validity in predicting cyclone
performance, the data must define the dusts aerodynamic
properties. Density and size distribution are best determined
by measuring terminal or settling velocities in still air.
Performance requirements can be established by specifying
the operating pressure drop and the desired collection
efficiency. If the particle size distribution is unknown,
efficiency may be expressed as the desired weight percent
collection at one or more particle sizes. If the distribution is
known, performance may be specified as a desired total
collected weight percent or maximum allowable emissions to
meet federal, state or local needs.
Another specification to be mentioned is the data
pertaining to construction materials, equipment features and
accessories. With reliable and accurate information,
manufactures can design and construct cyclones precisely
tailored to the user needs.
IV. CYCLONE SEPARATOR COSTS
Equipment cost depends on performance requirements,
construction materials, special features and accessories needed
for the application. In general, a single, large cyclone designed
for a particular level of performance is less expensive than two
or more smaller units operating in series or parallel providing
the same efficiencies and pressure drops.
V.ADVANTAGES, DISADVANTAGES & APPLICATIONS
Compared with the other separation devices, the cyclone
separators advantages are:
 The collected product remains dry and, normally
useful.
 Low capital investment and maintenance costs in
most applications.
 Very compact in most applications.
 Can be used under extreme processing conditions, in
particular at high temperatures and pressures and with
chemically aggressive feeds.
 No moving parts very robust.
 Can be constructed from most any material suitable
for the intended service including plate steel, casting
metals, alloys, aluminum, plastics, ceramics, etc.
 Can be equipped with erosion or corrosion resistant
or „particle repelling type liners, such as Teflon.
Internal surfaces may be electro polished to help
combat fouling.
 Can be fabricated from plate metal or, in the case of
smaller units, cast in molds.
  Can, in some processes, handle sticky or tacky solids
with proper liquid irrigation.
 Can separate either solids or liquid particulates;
sometimes both in combination with proper design.
Some disadvantages of cyclones are:
 Low efficiency for particle sizes below their „cut-off
diameter when operated under low solids-loading
conditions.
 Usually higher pressure loss than other separator
types, including bag filters and low pressure drop
scrubbers.
 Subject to erosive wear and fouling if solids being
processed are abrasive or „sticky.
 Can operate below expectations if not designed and
operated properly.
 Although this problem, as well as the erosion and
fouling problem mentioned above, is not unique to
cyclones.
Due to the mentioned advantages, cyclones have found
application in virtually every industry where there is a need to
remove particles from a gas stream. Figure 1.4 presents some
examples of cyclones industrial applications with wide range
of sizes, locations and applications. Today, cyclone separators
are found in:
• Ship unloading installations
• Power stations
• Spray dryers
• Fluidized bed and reactor riser systems.
• Synthetic detergent production units
• Food processing plants
• Crushing, separation, grinding
• Chemical industries
• Fossil and wood-waste fired combustion units vacuum
cleaning machines
• Dust sampling equipment
Cyclones have also been used to classify solids on the
basis of their characteristic such as their mass, density, size, or
shape. Because of their simple construction and high
reliability, cyclones are also used very effectively to separate
two-phase gas-liquid mixtures, such as the entrained droplets
exiting a venturi scrubber or other types of scrubber. Other
examples include the removal of water droplets from steam
generators and coolers and oil-mist from the discharge of air
compressors. Likewise, they have been widely applied in
process machinery to remove entrained oil and hydrocarbon
droplets generated from spraying, injection, distillation, or
most any process that results in the production of entrained
droplets or a two-phase mixture. They have even been used as
inlet devices to prevent foaming in gravity separation drums.
VI. CONCLUSION
The cyclone separator is one of the simplest and cheapest
particulate matter removal devices. It works on the basis of the
vortex motion occurring inside the device. The design of a
separator is dependent on the pressure drop, collection
efficiency and the cut size diameter of the equipment. Cyclone
separators with proper specifications are required for specific
applications.
VI.REFERENCES
[1] Shepherd, C. B. and C. E. Lapple, “Flow pattern and
pressure drop in cyclone dust collectors”, Industrial
and Engineering Chemistry,(1939) 31(8): 972-984.
[2] Parnell, C.B. Jr. and D.D. Davis, “Predicted effects of
the use of new cyclone designs on agricultural
processing particle emissions” ASAE Paper No.
SWR-79-040 (1979), Presented at Southwest Region
Meeting of the ASAE, Hot Springs, Ark.
[3] Wang, L., C. B. Parnell and B. W. Shaw, “1D2D,
1D3D, 2D2D cyclone fractional efficiency curves for
fine dust”. In Proc. 2000 Beltwide Cotton Production
Conferences. San Antonio, Tex.: National Cotton
Council.
[4] Mihalski, K., P. Kaspar and C. B. Parnell,” Design of
pre-separators for cyclone collectors”. In Proc. 1993
Beltwide Cotton Production Conferences, 1561-1568.
Memphis, Tenn.: National Cotton Council.
[5] Simpson, S. and C.B. Parnell, Jr., “New low-pressure
cyclone design for cotton gins”. In Proc. 1995
Beltwide Cotton Production Conferences, Memphis,
Tenn.: National Cotton Council.
[6] Wang, L., C. B. Parnell and B. W. Shaw,
“Performance characteristics for the 1D2D, 2D2D,
1D3D and barrel cyclones”. ASAE Paper No. 99-
4195. Presented at the 1999 ASAE Annual Meeting.
Toronto, Canada.
[7] Cooper, C.C. and G.C Alley. “Air Pollution Control;
A Design Approach”. Prospect Heights, Ill.:
Waveland Press, Inc.(1994)
[8] Kaspar, P., K.D. Mihalski and C.B. Parnell, Jr.
Evaluation and development of cyclone design
theory. In Proc. 1993 Beltwide Cotton Production
Conferences. New Orleans, La. National Cotton
Council.
[9] C.J. Stairmand, The design and performance of
cyclone separators, Trans. Inst. Chem. Eng.
(1951).29. 356–383.
[10] H.S. Bryant, R.W. Silverman, F.A. Zenz, How dust
in gas affects cyclone pressure drop, Hydrocarbon
Process. 62(1983) 87–90.
[11] S.H. Rongbiao, K.W. Xiang, K.W. Park, K.W. Lee,
Effects of cone dimension on cyclone performance,
Aerosol Sci. 32 (2001) 549–561.
[12] Casal, J. M., Martinez, A., A better way to calculate
cyclone pressure drop. Chemical engineering.(1983)
90, 99.
 [13] Ji, Z., Xiong, Z., Chen, H., Wu, H. “Experimental [16] Gimbun J, Chuah TG, Choong TSY, Fakhr‟ul-Razi
investigations on a cyclone separator Performance at A.: “Prediction of the effects of cone tip diameter on
an extremely low particle concentration”. Powder the cyclone performance”. J. Aerosol Sci. 36,(2006)
Tech. (1983)(191), 254-259. pp.1056-1065

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[15] Qian, F., Huang, Z., Chen, G., Zhang, M. (2006)
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