Powder Technology 356 (2019) 480–492

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Powder Technology

journal homepage: www.elsevier.com/locate/powtec

Removal of fine solid particles in aggressive gas flows in a newly designed

multi-channel cyclone
Pranas Baltrėnas, Aleksandras Chlebnikovas ⁎
Vilnius Gediminas Technical University, Saulėtekio ave. 11, 10223 Vilnius, Lithuania

a r t i c l e i n f o a b s t r a c t

Article history: A significant proportion of pollutants arise from the heat production equipment in private households. The pro-
Received 26 November 2018 cesses of combustion and product treatment (drying, adding chemical compounds) generate aggressive gas
Received in revised form 26 July 2019 flows containing solid particles (SPs). Common methods employ high-efficiency gas purification to remove
Accepted 12 August 2019
SPs, the most popular include electrostatic and sleeve-type filters. However, the operation of these types of filters
Available online 13 August 2019
is complex, and thus their application is very limited. This is especially evident when collecting adhesive and wet
Keywords:
FSPs or when purifying aggressive gas flows. New design multi-channel cyclone has a few principal elements of
Multi-channel cyclone the structure such as secondary inlets, inner slits and convex bottom. These improvements allow to avoid an ad-
Solid particles hesion of sticky and moist SPs on the inner surfaces of the cyclone. This study focuses on estimating the effect of
Aggressive gas flow separating wood and wood ash SPs. The obtained results are presented and the comparison of the advantages and
Adhesion disadvantages of two different design multi-channel cyclone are provided.
Acetone © 2019 Elsevier B.V. All rights reserved.

1. Introduction FSPs smaller than 10 μm in diameter are the most damaging to

Industrialization and the growing needs of humanity have increased
energy demands. Technological advancements contribute to energy
production and development of new products, but the resulting envi-
ronmental pollution renders many such processes unsustainable.
Many current technologies generate numerous pollutants that are con-
sidered environmentally harmful. For example, solid particles (SP) are
formed in various industrial processes and their emissions have differ-
ent dispersal properties (in all fractions, particulate matter up to 10
μm (PM10 or PM2.5) [1,2].
Similar to particles produced in the energy industries, SPs and
their fly ash are disseminated along with industrial gas flows. Ex-
tremely high concentrations of SPs are generated during combustion
of liquids, which is the most widely-employed energy recovery
method, especially where solid fuels are used in boilers installed in
boiler houses and combined heat and power (CHP) plants. A signifi-
cant proportion of pollutants arise from the heating equipment used
in homes. Additionally, the mechanical processes used to treat mate-
rials and other processes (e.g., convective drying, laser cutting) af-
fecting such materials in the work area result in hazardous
environmental pollution, including the production of extremely
harmful fine solid particles (FSPs) [3,4].
⁎ Corresponding author.
E-mail addresses: pranas.baltrenas@vgtu.lt (P. Baltrėnas),
aleksandras.chlebnikovas@vgtu.lt (A. Chlebnikovas).
human health, and their effective removal from industrial gases is an
important need [5].
The processes of combustion and product treatment (drying, adding
chemical compounds) generate aggressive gas flows containing SP.
Such processes modify the physical, chemical, and mechanical proper-
ties of FSPs [6].
Common methods employ high-efficiency gas (air) purification to
remove SPs, the most popular include electrostatic and sleeve-type fil-
ters [7]. However, the operation of these types of filters is complex,
and thus their application is very limited. This is especially evident
when collecting adhesives and wet FSPs or when purifying aggressive
gas flows [8].
Traditional cyclones have been effectively used for purifying dry and
dusty gas flows. Their action is from the use of centrifugal forces to sep-
arate SPs, and so, they are not very efficient in treating gas, especially
when the gas flow is polluted with small-sized pollutant particles (up
to 20 μm in diameter) [9]. Therefore, such equipment is commonly
used for removing dry, non-adhesive particles from the air [10]. This
equipment frequently operates with high resistance, which increases
power consumption and limits the performance of the unit [11].
Multi-channel cyclones with curvilinear channels create closed circuits,
and similar to conventional hollow-structure cyclones, these are con-
structed and installed easily, and are not complicated either to operate
or manufacture [12].
Multi-channel cyclones are used to purify non-aggressive gases by
collecting FSPs larger than 1 μm. The operating principle of these cy-
clones are based on the polluted dusty flow entering the 1st channel

https://doi.org/10.1016/j.powtec.2019.08.018
0032-5910/© 2019 Elsevier B.V. All rights reserved.
 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492
(transitioning to the 2nd and 3rd channels) where it is filtered while the
peripheral flow reverts to the previous channel [13]. Closed circuits
made up of curved elements with slits between adjacent curved ele-
ments allow gas flow in and out of the channels. The gas flow passing
through these closed-type circuits in the cyclone are purified by remov-
ing the pollutant particles through centrifugation; and additionally by
capturing a portion of the particles using the resulting ‘gas flow curtains’
that redirects the pollutants to the slits in the separation chamber and
deposits in the cyclone hopper [14].
Theoretical mathematical modelling [15,16] of the distribution of gas
flows in the cyclone channels have derived the motion equations involved.
These studies estimate the rate components in each direction of the axis
coordinates within the cyclone channels. It is assumed that the maximum
airflow rate in a rectangular channel is reached in the symmetrical axis
(centre of the cross-section). A longitudinal symmetry arc oriented to-
wards the mid-point of the channel is considered as the symmetry axis
of the arc in the curvilinear channel [8]. The length of such an arc is the geo-
metric mean of the interior and exterior curvilinear surfaces (peripheral
wall, half-rings), and the radius of this arc in each of the cyclone channels
determines the maximum circular rate. Thus, the trajectory radius of the
maximum circular rate, for instance, the geometric mean of the radii of
the interior and exterior walls of the channel can be expressed [17] as:
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Rwall:0 ¼ Rwall:1 Rwall:2 ;
where, Rwall.1 and Rwall.2 are the radii of the interior and exterior walls of the
channel, m, respectively.
Thus, in the coordinate system, the circular rate equation at the point
of the cyclone channel is:
Q
 
Schan: ∂u U ax:
þ ¼ F ðV circ: Þ;
Rchan: ∂r rp:
where, Q is the air flow passing through the channel (m3/s), Schan. is the
cross-sectional area of the cyclone channel (m2), Rchan is the radius of
the cyclone channel (m), Uax is the axial gas flow rate (m/s), rp is the ra-
dial point coordinate, and Vcirc. is the circular rate (rad/s).
The gas flow motion through the cyclone channel splits the flow into
the peripheral (reversible) and transitional (moving to the next chan-
nel) flows. The distribution is defined by the following gas flow recircu-
lation coefficient:
q The dimensions of the multi-channel cyclone were as follows: the
Q rec: ¼ ; ð3Þ
Q tot
where, q is the reversible gas flow in the cyclone (m3/s), and Qtot is the
total gas flow in the channel (m3/s).
The gas flow distribution in the cyclone channels is described by the
following equations:
Q 1 ¼ Q tot þ ð1−β2 Þ  Q 2 ;
Q 2 ¼ Q 1 þ ð1−β3 Þ  Q 3 ;
β3 Q 3 ¼ Q tot þ ð1−β3 Þ  Q 2 ;
where, Q1, Q2, Q3 are the gas traffic flows through channels 1, 2, and 3,
respectively (m3/s), and β2, β3 are the share of transitional gas flows
at the 2nd and 3rd channels, respectively.
Serebryanskyy [17] conducted a mathematical analysis that yielded
the following integral expression:
Z i ΔRi
Ri þβ
. Ziþ2
R
βi ¼ ϑ φi ðr Þdr ϑ φi ðr Þdr;
Ri Ri
where, ϑϕi(r) is the circular rate in the outlet of the ith channel (rad/s); Ri
andRi+2are the radii of the interior and exterior walls of the ith channel
481
(m); ΔRiis the width of the ith channel (m); ΔRi = Ri − Ri+2; and βi is a
share of the transitional flow at the outlet of the ith channel.
Multi-channel cyclones are more appropriate for removing adhesive
solids from gas flows. However, clogging occurs under specific climatic
conditions (such as high humidity and temperature) and due to the
presence of factors leading to the formation of certain chemical com-
pounds in the gas flow. Consequently, this results in longer cleaning
time [18]. Regeneration is impossible, and so, exploitation under such
conditions requires investigation of other treatment processes [19].
By creating a new multi-channel cyclone structure and applying
constructive solutions, such as the treatment of aggressive gas flow
with non-abrasive SPs, it is possible to reduce the aerodynamic resis-
tance (drop in pressure) needed to deposit the SPs and avoid clogging
the cyclone channels [20]. Previously studied cyclones were designed
with tangential air inflow. The aerodynamic cyclones have higher per-
formance and efficiency than the conventional cyclones. Such structures
are much more advanced than the conventional cyclonic equipment,
and therefore are intended for separating dry SPs from the gas-air
flow. To apply multi-channel cyclones in the industry, different struc-
tures have been created and have national patents [12,21,22] and a Eu-
ropean patent application [23].
In this study, we investigated the adhesion properties of a multi-
channel cyclone and a newly designed model. Furthermore, we defined
ð1Þ smoothness, aerodynamic parameters, and the efficiency of the interior
surface structural elements encountered when removing FSPs found in
wood ash from aggressive gas flows. This study focuses on understand-
ing the effect of separating wood particles when the gas flow is addi-
tionally polluted with an acetone steam.
2. Materials and methods
ð2Þ The experimental multi-channel cyclone used in this study is pre-
sented in Fig. 1. The apparatus is installed in the Laboratory of Environ-
mental Protection Technologies, Department of Environmental
Protection and Water Engineering, Vilnius Gediminas Technical
University.
During the experiments, gas (air) generated by a 3-kW centrifugal
blower was blown through the duct system. Measurements were
made in the ducts 5–6 Dort. from the inlet to the cyclone at a distance
of 3–4 Dort. (where Dort. is the duct diameter = 160 mm). During mea-
surement, no gas flow disturbances from the blower, valve, toggle
switch, duct narrowing or expansion, or other structures were observed.
diameter of the cylindrical casing was 0.53 m, the total height of the cy-
clone (including a two-piece conical hopper) was 1.1 m, the diameter of
the flow inlet and outlet was 0.16 m, and the dimensions of both the pri-
mary and secondary gas inlets were 0.038 m × 0.29 m, respectively.
Curved elements with the same radius were arranged in the interior
of the separation chamber. The first element was in-built such that its
outlet (without considering the overlap with the adjacent curvilinear el-
ement) would correspond to the primary gas inlet and the length of the
ð4Þ element arc would form a turn angle of π/2. The other elements were
similarly selected to form a four-exterior-channel cyclone with an inte-
rior central channel. In cases where the cyclone had more than four
channels, the curved elements were arranged according to the turn
angle. The newly designed multi-channel cyclone contained gas flow
inlet and outlet ducts, primary and secondary gas inlets, a separation
chamber with curved elements, exterior and interior slits, and a two-
piece conical hopper to collect the FSPs.
Based on previous studies and by analysing multi-channel cyclones
[24], an optimal 50/50 flow distribution ratio in the separation zones
ð5Þ was determined by adjusting the position of the curved elements [25].
In general, the intrinsic geometry of multi-channel cyclones can be ad-
justed by altering the flow distribution ratios in the flow separation
zones along each edge of the curved element where the inflow passing
through the channel is divided into peripheral (back to the previous
482 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492

Fig. 1. The experimental multi-channel cyclone used in this study. 1 – autoclave; 2 – measurement point for the rate and solid particles concentration in the air duct ahead of the cyclone; 3
– rate measurement points in the primary and secondary air inlet; 4 – rate measurement points in the channels of the cyclone; 5 – blower; 6 – measurement point for the rate and SP
concentration in the air duct following the cyclone; 7, 8 – pressure measurement points ahead of and following the cyclone; 9 – injection of solid particles (simulation of a pollution source).

channel) and transitional (flow to the other channel towards the axis of
the cyclone) flows.
2.1. Determination of surface smoothness
Smoothness, or alternatively, surface roughness is described as the
cleanliness or unevenness of the surface. Wherever the smoothness of
the interior surfaces of the multi-channel cyclone affects the adhesion
of the FSPs, the structure was constructed of metallic elements. The
most common metal surfaces, such as galvanized sheet (brand
S350GD + Z275 MA), stainless steel (brand AISI 304 (EN 1.4306)),
and black (plain) metal (brand S235) were selected for their surface
smoothness.
The surface smoothness of the treated metals was measured using a
digital profilometer with an inductive diamond needle sensor (TR-200
(USA)) (error ± 10%). Its operating principle is based on the induction
coil installed within the device for recording variations that occur due
to the displacement of the sensor by the unevenness of the surface. Var-
iations in the inductivity generate an analogue signal proportional to
unevenness.
To define the surface smoothness, the surfaces of the different metal
preparations were investigated in five different sections. The points
were selected by considering the dimensions of the sample surface
(120 × 60 mm) arranged symmetrically and uniformly at 20-mm
longitudinal and 15-mm transverse distances (Fig. 2a). The profile pa-
rameters were measured at each point, and finally, to estimate the pa-
rameters for each profile, an average was calculated. The methodology
was developed in accordance with ISO 8503-1:2012 standard guidelines
[26] for determining the roughness of steel surfaces using abrasive flow
treatment. The sample metal surface dimensions were selected accord-
ing to standard recommendations. Therefore, to determine the smooth-
ness of the different metals at an average profile deviation of 0.02–0.32
μm, the total length of the section exceeded 1.6 mm at a deviation of
0.32–2.5 μm, where the total length of the section was 4 mm [26].
The Ra and Rq measurements ranged from 0.005–16 μm, and the Rz,
Rt, and Rp measurements ranged from 0.02–160 μm. The TS100
profilometer sensor settings were automatically selected by the device;
which ranged from 0.25–2.5 mm, depending on the surface smooth-
ness. The measurements were used to create the digital surface profile.
Prior to these tests, the surfaces of the samples were cleaned to remove
any possible dirt and grease.
2.2. Generating aggressive gas flow
We investigated cyclone clogging by treating high-humidity and
high-temperature dusty gas-vapour flow without fine wood ash solid
particles. Similar conditions occur in industrial boilers with condensing
economisers, various types of raw material drying equipment, and wet

Fig. 2. Surface smoothness measurements. The surface profile characteristics were determined using a profilometer. 1 –metal surface; 2 – measurement point; 3 – sample surface
treatment; 4 – profilometer; 5 – profilometer sensor.
 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492 483

material evaporators. To simulate these conditions, an average-power
autoclave with a 40-L closed cylindrical tank and a 3-kW heating ele-
ment was used. The autoclave cylinder was filled with water and the
valves were tightly closed. The automatic safety and manual valves
were closed prior to switching on. As the water in the autoclave cham-
ber reached a pressure of 6 bar and a temperature of 145 °C, the auto-
matic gas-vapour discharge valve became functional. The operating
parameters were monitored. The heated, wet gas-vapour flow was sup-
plied to the multi-channel cyclone experiment table through a robust
hose.
The relative humidity and temperature of the aggressive gas flow
were determined using a KIMO AMI 300 multifunctional measuring in-
strument (relative humidity measuring range, 5–95%; resolution, 0.1%;
accuracy, 0.1%; temperature, 20–180 °C: resolution, 0.1 °C; relative
error, 0.3%).
Long-term multi-channel cyclone clogging studies were carried out
to evaluate the adhesion of wood ash particles with diameter below
20 μm as the treated aggressive gas flows that passed through the cy-
clone reached volumes of 30, 50, 100, and 150 thousand m3. These
amounts also determined the corresponding period of operational
hours, e.g., 50 thousand m3 of gas flow was treated for 50 h.
2.3. Aggressive gas flow rate in the multi-channel cyclone
Fig. 3 shows the arrangement of rate measurement points (r.m.p.) in
the multi-channel cyclone with a single inlet and in the newly designed
multi-channel cyclone secondary inlets. To determine the flow rate at
the measurement points, the cyclone lid was perforated with the possi-
bility of resealing the holes. The points located at the beginning of the
channel (perpendicular to the flow inlet) and in the lines with displace-
ment angles of 45° and 90° perpendicular to the flow inlet were se-
lected. To obtain an average cross-sectional rate, the gas flow rates
were set at a height equal to half the height of the channel at a distance
of 5 mm from the lower base of the channel (lowest level) and the same
distance from the upper base of the channel (highest level).
Previous studies examined variations in gas flow rates by changing
the number of revolutions of the blower and the gas flow rate entering
the cyclone. They found that the optimal multi-channel cyclone param-
eters for the efficient treatment of polluted gas flow were achieved at an
average gas flow rate of 12 m/s [24]. Here, we explored the gas flow rate
distribution in a multi-channel cyclone with a single inlet and in a newly
designed multi-channel cyclone with secondary inlets.
For the experiments, a Pitot tube with a dynamic probe and multi-
functional gauge (Testo–350; temperature measurement limits, 20–
700 °C, error, ±0.2 °C; rate measurement limits, 1–30 m/s error, ±
0.05 m/s) was connected to the hose.
2.4. Efficiency of the multi-channel cyclone treatment
Wood-ash fine SPs were used to estimate the efficiency of the four-
channel cylindrical cyclone for purifying the polluted gas flow. The SPs
were screened through MORIS sieves (900, 200, 50, and 20 μm) using
a Rotoshake RS 12 sample shaker.
SP concentrations were determined by weighing the particles col-
lected on AFA-VP–20 filters under isokinetic conditions. The FSPs were
fed through a nozzle under constant 6-bar pressure flow generated by
a compressor. Measurements for ensuring the stability of the supplied
SP values were repeated at least three times. The observed values

Fig. 3. Measurement point scheme for the multi-channel single-inlet cyclone (a) and the newly designed multi-channel cyclone with secondary inlets (b). 1 – polluted air flow duct; 2, 3 –
primary and secondary gas inlets; 4 – separation chamber; 5 – measurement points; 6 –configured curved elements; 7 – exterior cyclone channels; 8 – exterior integral circular slit; 9
– interior segmental circular overlapping slits in the channels; 10 – segmental slits; 11 – purified gas flow exhaust duct; 12, 13 – peripheral and transitional distribution flows; 14, 15
– openings made in the curved elements and slots folded at 5° angle; 16 – fasteners; 17 – secondary flow trajectory lines; 18 – interior central channel.
484 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492
Fig. 4. Scanning electron microscope images of wood ash solid particles. a – unmagnified image of the wood ash particles (x1); b – cohesion of the wood-ash solid particles with fine
particles (x1500); c – structure of the wood ash solid particles entrained with the fine particles (x2700).
were only analysed if the results from similar studies differed by no
more than by 5% (confidence interval, 95%).
Experiments to evaluate the purification efficiency of the multi-
channel cyclone used aggressive, chemically polluted gas flows. A simu-
lated volatile organic compound (VOC) source was used by placing
evenly evaporating VOCs (acetone, C3H6O) in a water-heated chemical
bath. Our experimental FSPs were released from the wood treatment
process (including varnished wooden products). The chemical com-
pound concentrations were selected by considering VOC emissions
(e.g. varnishing vapours) generated during the production processes.
Mass concentration in the gas flow volume were approximately equal
to 4000 mg/Nm3 or 4 g/Nm3, corresponding to 1560 ppm. We aimed
to determine the effect of the chemically polluted flow of aggressive
gas on the performance and efficiency of the multi-channel cyclone. A
MiniRAE 2000 portable VOC gas analyser (model PGM 7600) was used
to measure the concentration of organic compounds. The measurement
range varied from 0 to 7000 mg/m3. The measurement accuracy for pol-
lutants was within the range of 0–2000 ppm, with ±2 ppm margin.
When the concentration was N2000 ppm, the accuracy was ±20%. The
pollutant pumping rate of the device was 450–550 cm3/min.
Wood ash and FSPs were used in the multi-channel cyclone studies
(Fig. 4) and the basic physical parameters for the particles are defined in
Table 1.
Particle size was measured using a laser granulometer (CILAS 1090).
The repeatability errors were b1% and the accuracy errors was below 3%.
In liquids, particles ranging in size from 0.04–500 μm were measured;
and for dry measurements, particles ranging in size from 0.1–500 μm
were measured (CILAS 1090, 2016). To measure their sizes, particles
were dispersed in water, and the suspension was transmitted through
a glass measurement cell. Due to diffraction, the laser beam passing
through the cell is diffused and partially reflected. The finer the material,
the larger the angle of the diffused laser beam.
The diameter of the sample particles was calculated based on
measurements of the diffused light intensity and by referring to the
Fraunhofer diffraction theory and the Mie scattering theory. The Mie
theory is applied when the material contains an abundance of parti-
cles smaller than 1 μm. When a substance reacts with a dispersing
medium or is soluble, the pneumatic measuring method is used. In
this case, a vibrating dispenser was used to feed the powdered mate-
rial to the compressed air flow that intersects the measurement cell
Table 1
Physical properties of fine solid particles' physical properties.
Solid particles Physical parameter for the solid particles
Skeletal density of the sample, kg/m3 Density of the saturated sample, kg/m3
Wood ash 624 2238
Wood 184 1184
and the laser beam. The diffused light intensity was measured as pre-
viously described [27].
Particle shapes and surface characteristics were investigated using a
JEOL JSM-7600F scanning electron microscope. A Quorum Q150R ES was
used to coat the samples with metal and carbon. Low-aberration zoom
lenses allowed for a stable high-definition image even at high light
beam induced current (N200 nA at 15 kV). With these, highly precise
analyses of nanostructures could be performed. The device magnifica-
tion ranged from 25 to 106 times, at a spatial resolution of up to 1 nm
at 15 kV.
The pre-scan samples were treated with liquid nitrogen and coated
with carbon. The samples were fixed to a microscope holder with car-
bon labels and placed between plates that were previously coated
with a conductive gold layer in vacuum [28,29]. The wood ash and FSP
images are presented in Figs. 4 and 5.
The dispersive wood ash FSPs are composed of particle sizes ranging
from 0.1–20 μm. Analysis of the data shows the following distribution of
diameter sizes: 2.4% of the particles were from 0.1–1 μm in diameter;
5.6% were from 1 to 2.5 μm; 33.3% were from 2.5–10 μm; 33.9% were
from 10 to 15 μm; and 24.8% were from 15 to 20 μm in diameter. The av-
erage diameter was 10.8 μm.
3. Results and discussion
3.1. Determining the surface smoothness
A profilometer was used to determine the basic smoothness indica-
tors of the examined metals. Three types of metal surfaces were inves-
tigated: galvanized sheet, stainless steel, and black metal.
The average arithmetic deviation of the galvanized sheet surface
profile (Ra) (Fig. 6) was 1.302 μm and the total uneven height (Rt)
was 7.389 μm. The sizes of the largest bumps and pits differed slightly
and ranged from 3.6–3.8 μm. The surface profile analysis showed un-
even manufactured surface with recurring pits and bumps occurring
across a large surface area.
Such uneven surfaces pose an obstruction that attracts FSPs, and
forms an FSP layer and accelerating adhesion. The advantages of using
galvanized sheet metal for the structural components of the cyclone
are their relatively low cost and easy mechanical handling.
Overall porosity Overall density, kg/m3 Bulk sample, kg/m3
25–35 80–900 710
65–80 500–800 455
 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492 485

Fig. 5. Scanning electron microscope images of wood ash solid particles: a – unmagnified image of the wood particles (x1); b – agglomerated wood particles (x300); c – structure of the
agglomerated wood particles (x3000).

The stainless-steel surface profile (Fig. 7) has a low degree of rough-
ness compared to the galvanized sheet metal. The surface smoothness
parameters showed no significant signs for surface roughness. The max-
imum profile bump was higher than the pit by 16.9%, which is equal to
1.086 μm, indicating that the stainless-steel surface was approximately
3.2 times less rough than the galvanized sheet metal surface.
The stainless-steel surface Ra value was 4.7 times lower than that of
the galvanized sheet metal, and the value of the height of profile un-
evenness according to 10 points (Rz) varied by N1.7 points. Thus, com-
pared to the galvanized sheet metal surface, the stainless-steel
roughness is many folds lower and individual points of unevenness
are negligible.
Black metal may also be considered as an acceptable material for
producing the interior components of a multi-channel cyclone. Black
metal surface smoothness was intermediate between those of stainless
steel and galvanized sheet metal. Moreover, the results show that the
black metal surface is sufficiently smooth (Fig. 8).
The black metal surface has several areas with sharp surface devia-
tions. However, the overall surface unevenness and pits were negligible,
with a maximum value not exceeding 2.5 μm.
Another important point is that the black metal surface profile is, on
an average, two times smaller, than that of galvanized sheet metal, and
therefore, its surface roughness is twice as low. Meanwhile, compared
to stainless steel, only the Ra value of black metal was 2.2 times higher.

Fig. 6. Galvanized sheet metal surface profile.

Fig. 7. Stainless steel surface profile.

Fig. 8. Black metal surface profile.

486 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492
The black metal surface profile contained pits reaching 2.379 μm, which
may have arisen during the preparation stage.
Based on these comparisons, we conclude that the surface of the
newly designed multi-channel cyclone should be manufactured using
stainless steel. The black metal surface indices indicate that it is slightly
rougher than stainless steel, with a minimum overall unevenness height
profile of 1.989 μm. The smallest average arithmetic deviation from the
profile belongs to stainless steel, at 0.273 μm.
3.2. Aggressive gas flow experiments
The aggressive gas flow within the experimental multi-channel cy-
clone bench was investigated under various temperatures (Fig. 1). The
relative humidity in all cases was ≥95% (above the maximum limit
established by the unit) (Table 2).
The ability to purify a dusty flow of aggressive gas under high hu-
midity and temperature is considered one of the main advantages of
the newly designed multi-channel cyclone with secondary gas inlets.
An experimental multi-channel cyclone structure requiring no addi-
tional structural solutions to reduce adhesion was investigated to iden-
tify potential obstructions prior to the final design step. In conventional
cyclones, the adhesion problem is not evident due to the lack of complex
structures. However, this type of cyclone cannot attain high cleaning ef-
ficiencies against fine-dispersed particulate matter with size up to 5 μm.
In contrast, multi-channel cyclones may be applied to purify non-ag-
gressive gas by collecting particles larger than 1 μm size.
Our experiments show that wood ash particles can be used to assist
in defining the structure of a cyclone under a flow of aggressive gas of up
to 150,000 m3, corresponding to approximately 150 cyclone working
hours at a temperature of 145 °C and a relative humidity of ≥95%. The
average FSP concentration reached 5 g/m3.
The newly designed multi-channel cyclone has secondary gas inlets
and other structural features that allow for reduced FSP adhesion. This
prevents the unit from clogging during the process of removing the
FSPs from the flow of aggressive gas.
The properties of solid particle adhesion in the newly designed
multi-channel cyclone with secondary gas inlets are presented in Fig.
5. The adhesion of wood ash FSPs was most pronounced on the wall of
the separation chamber at the second inlet (secondary flow), where
the particle layer reached 1–2 mm and occupied an area of approxi-
mately 50 × 50 mm (Fig. 9). Such a large accumulation of particles can
be explained by the fact that the aggressive gas flow trajectory makes
the first turn at an angle of 90° and enters the separation chamber at a
wider angle than that of the tangent with the interior surface of the
chamber. Meanwhile, the traditional multi-channel cyclone structure
accumulated a large amount of the particles in the 1st channel of the cy-
clone at the gas flow inlet, and in the 2nd channel, thus forming a gap of
1–2 cm between the adhesion zones (Fig. 10a).
At the 1st gas inlet, a small amount of wood ash FSPs were present,
and formed about 1 mm thick layer. The particles covered the metal sur-
face over the entire length of the cyclone channel, but the length of the
zone was 1.5–2 cm. Particle layers were thinner for the other inlets, and
was below 0.5 mm.
Table 2
Variations in the parameters for the flow of aggressive gas within the experimental multi-
channel cyclone bench.
Measurement point No. Gas flow temperature (°C) when the average
rate in the cyclone
16 m/s 12 m/s
1 (Autoclave) 145 145
2 (Inlet duct) 110 110
3 (Inlet to the cyclone) 70 80
4 (Inside the cyclone) 60 70
6 (Outlet duct) 50 55
The newly designed multi-channel cyclone has its interior chan-
nel segmented, circular, and with overlapping slits installed at the
convex bottom of the separation chamber. This resulted in a reduc-
tion in particle accumulation in the interior central channel. The
accumulation of wood ash FSPs was only observed along the exterior
edge of the curved element at the bottom, in a zone approximately
5 mm wide, and the particle layer did not exceed 0.5 mm (Fig. 5b).
The wood ash particles at the bottom accumulated in the interior
central channel of the cyclone along the axis of the device towards
the 4th curved element along the interior edge where the thickness
of the layer reached 0.5–1 mm (Fig. 9).
In the traditional multi-channel cyclone, a 4–5 cm particle layer ac-
cumulated at the bottom of the separation chamber close to the exterior
continuous slit. These particles could neither be deposited through the
slit nor enter the cyclone hopper due to their higher mass and high hu-
midity (Fig. 10c). In a previous study, 10 mm-wide segmental circular
slits were used, and in this case, the width was sufficient, but the addi-
tional interior segmental, circular, and overlapping slits of the channel
were necessary to allow the particles to accumulate in the interior cen-
tral channel at the bottom of the separation chamber.
As shown in Fig. 5b, in the newly designed, multi-channel cyclone,
FSP adhesion to the curved elements was not significant, and the largest
resulting layer formed on the element that forms the 4th channel. The
particles covered 70% of the surface area of this element (with slots
folded at an angle of 5°) and the thickness of the layer reached 0.5–
1 mm. The particles mostly covered the 4th curved element and its
exterior side, where the particle layer was one of the thickest, with 1–
3 mm thickness. Such adhesion can be explained by the fact that the ag-
gressive gas flow rate is reduced in the 4th channel, so that the particles
adhere to the surface rather than bounce off. A higher degree of adhe-
sion was avoided due to the introduction of the 4th gas inlet that com-
plements the moving gas flow from the previous channels. At the same
time, it increases the average rate in the 4th channel. On the surface of
the remaining components, no N30% of the area was covered by FSPs.
On the other hand, a 1–1.5 cm-thick wood ash FSP layer was noticed
on the walls of all curved elements making up all the 4 channels of the
traditional multi-channel cyclone structure (Fig. 10a). FSP adhesion was
observed in all channels, on both the exterior and interior sides of the
curved elements. This can be explained by the fact that the wood ash
has a higher density, and therefore the particles are more hydrophobic
(even though the structure is more porous) [30]. Hence, the moisture
in the aggressive gas flow has a minor effect on the particles because
they do not absorb moisture. However, particle adhesion to the surfaces
of the cyclone was evident.
The interior components of the newly designed multi-channel cy-
clone were made of stainless steel possessing the optimum smoothness
characteristics. This factor, together with the above-mentioned solu-
tions, further reduces FSP adhesion, thus preventing blockage in the
newly designed elements of the multi-channel cyclone. This allows for
long-term operation of the purification of dusty aggressive gas flow.
Based on previous studies [24], the continuous, circular slit of the
multi-channel cyclone was 30 mm wide (those with 10- and 20-mm
widths were further analysed). Thus, particle accumulation at the bot-
tom of the separation chamber at the slits was found to be significantly
lower.
After 150 h of operation, the peripheral wall of the traditional struc-
ture was completely covered with 1–1.5-cm thick layer of particles, and
a part of the surface area of the curved elements was also covered with a
0.5–1 mm layer of particles. Compared to normal laboratory conditions,
the density of the moisture-saturated vapour flow increased. The den-
8 m/s sity of the moist gas flowing directly from the autoclave increased by
145 N2.3 times at 145 °C. Meanwhile, the multi-channel cyclone underwent
115 partial cooling to 75 °C and attained a density of 1.242 kg/m3, or roughly
90 about 3%. This is why the gas flow in the multi-channel cyclone
75 has a downward trajectory. The observation of smooth adhesion is evi-
60
dence for the proper simulation of the aggressive gas flow induced by
 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492 487

Fig. 9. The adhesion of wood ash solid particles in the newly designed multi-channel cyclone with primary (No. 1) and secondary (1st – No. 2, 2nd – No. 3 and 4th – No. 4) gas inlets: a – the
main view of the interior of galvanized sheet; b – the interior central channel of the cyclone under the flow of 150,000 m3 of aggressive gas; c, d, e –adhesion to the internal elements under
the flows of 50,000, 100,000 and 150,000 m3, respectively, of aggressive gas at an average rate of 12 m/s in the cyclone channels.

Fig. 10. The adhesion of wood ash solid particles in the multi-channel cyclone with a single gas inlet under a flow of 150,000 m3 of aggressive gas at an average rate of 12 m/s in the cyclone
channels. a – General view of the cyclone; b – clogging of the peripheral wall and segmental circular slits.
488 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492
moisture and temperature. Moreover, the source (autoclave with the
experimental bench) formed a typical and properly functioning system.
Auto-adhesion was most pronounced when the initial FSP layer had al-
ready formed on the examined surface while the adhesion decreased.
The primary particle film layer continued to accumulate, thus creating
secondary auto-adhesion zones. The aggressive gas flow consisted of
moisture-saturated gas flow, which was further moisturized and in-
creased particle accumulation, resulting in the clogging of the multi-
channel cyclone. This created a layer in which the opening of the curved
elements was almost sealed. In this case, only a partially purified gas
flow entered directly into the interior channels rather than the open-
ings, and together with the particles, was released into the environ-
ment, thus reducing the purification efficiency.
In conclusion, the highest level of adhesion of FSPs in the cyclone
was observed on the high curvature surfaces such as the folded opening
slots in the curved elements at the inlet of the 1st channel of the cyclone.
As particles accumulate on the elements that make up the channels of
the cyclone, the cross-sectional area of the latter decreased, resulting
in decreased gas traffic flow. The particle layer that was formed on the
cyclone elements partially altered the geometry of the structure, thus
completely or partially blocking gas flow in certain zones and changing
the smoothness of the existing surfaces.
The gas flow trajectories changed due to the FSP layer. This is be-
cause the particles that accumulated at the bottom of the separation
chamber focused on areas with curved element openings in front with
the slots folded, such that the 3rd and 4th curved elements were
completely clogged. The single gas flow entering the 1st channel re-
duced the aggressive gas flow rate in the subsequent channels. Hence,
the particles were more likely to adhere to the metal surfaces of the cy-
clone elements due to stronger adhesion rather than be carried away by
the aggressive gas flow.
3.3. Aggressive gas flow rate experiments in the multi-channel cyclone
Gas flow rate investigations in the multi-channel cyclone were
performed using the four-channel cyclone employing the curved
Fig. 11. Gas flow rate distribution in the channels of the multi-channel cyclone with a single inlet and a new-generation multi-channel cyclone with secondary inlets under an average rate
of 12 m/s in the channels.
elements with opening slots folded at a 5° angle. To investigate the
rate distribution in the channels of the cyclone, average gas flow
rates of 8, 12, and 16 m/s were maintained in the cyclone. The curved
elements in the separation chamber of the cyclone were positioned
so that 50% of the overall incoming flow was channelled to the pe-
ripheral (reversible) flow and the other 50% was channelled to the
transitional (moving to the next channel) flow. At an average gas
flow rate of 12 m/s in the cyclone channels, the rates of the individ-
ual channel points varied from 6.9–17.4 m/s. Gas flows passing
through the inlets had the following values: 470, 290, 270, and 260
m3/h in the 1st, 2nd, 3rd, and 4th inlets, respectively. The total dis-
charge passing through the inlets was 1290 m3/h. In this case, the
gas flow rate in the duct at the front of the cyclone reached
17.8 m/s; the flow after the duct reached 17.6 m/s. The discharges
were equal to 1290 and 1275 m3/h at the front and after the cyclone,
respectively. The discharge from the traditional multi-channel cy-
clone was 1.4 times lower than that of the newly designed cyclone.
Moreover, discharges of 905 and 890 m 3/h were measured in the
front and following the cyclone, respectively. The average discharge
in the duct was 12.4 m/s. The average rates in the individual chan-
nels of the previously designed multi-channel cyclone varied slightly
from 11.3–13.2 m/s; and the maximum rate at the end of the 1st
channel was 14.9 m/s. The lowest rates were found at the beginning
of the 3rd and 4th channels, where rates reached 9.8 m/s and 7.8 m/s,
respectively (Fig. 11).
One of the highest rates (14.5 m/s) was found at the end of the 4th
channel. By estimating the values based on measured rates, and below
the average rate of 12 m/s, one of the smallest changes observed was
by a factor of 1.91. Therefore, the rates in all channels of the cyclone var-
ied evenly. Such rate distributions are useful, especially when the mobile
gas flow is polluted with FSPs. The centrifugal forces will be homoge-
neous and the emerging additional vortex (turbulent) flows are unde-
tected. The turbulence negatively affects the deposition of FSPs and the
particles moved chaotically, and therefore in the wrong direction, i.e.,
not towards the deposition slits; or if they enter the hopper, they were
lifted and carried through the exhaust duct along with the gas flow.
 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492
Under the highest selected rate (16 m/s) in the duct, gas flow rates of
24.8 m/s at the front and 24.7 m/s following the cyclone were
established, resulting in discharges of 1795 and 1790 m3/h, respectively.
The secondary inlets of the newly designed multi-channel cyclone
maintained an even flow distribution across all the cyclone channels,
and gas flow rates ranged from 9.9–23 m/s. The maximum rate was
set at the end of the 1st channel (point 1.3), whereas the lowest was ob-
served at the beginning of the 4th channel. This is due to the slight de-
crease in the cross-sectional area towards the end of the channels in
the newly designed multi-channel cyclone. Each of the secondary inlets
supplementing the total gas flow affected the gas flow distribution rate
in all channels when the gas flow passed the cyclone angle of π/2. The
calculated discharges for each of the inlets were as follows: 600, 430,
390, and 375 m3/h for the 1st, 2nd, 3rd, and 4th inlets, respectively.
The total discharge through all inlets was equal to 1795 m3/h. The max-
imum gas flow rate for the traditional cyclone structure was 19.9 m/s,
which was determined at the 3rd measurement point of the 1st channel.
Meanwhile, at the end of the 4th channel, the rate was 2% lower
(19.5 m/s). The average rates of the 2nd and 3rd channels were lower,
at 16.6 and 14.9 m/s, respectively. The lowest rate (10.5 m/s) in the cy-
clone was found at the beginning of the 4th channel. In the 3rd to the
4th channel, the cross-sectional area increased by 1.34 times; however,
towards the end of the 4th channel, the cross-section of the channel de-
creased by 1.97 times. A slight decrease in the gas flow rate in the cross-
sectional areas was observed due to the operational resistance forces
from the interaction of gas flow with the curved elements and folded
opening slots, as well as due to frictional forces with the interior surface
of the separation chamber.
The gas flow rate ranged from 5.3–11.3 m/s, with an average rate of
8 m/s in the channels of the newly designed cyclone. The rates at the
2nd, 3rd, and 4th channels were similar, with values within the error
margin. The rate in the 1st channel was the highest and differed from
those in other channels by approximately 32.6, 25, and 18.9% at mea-
surement points 1, 2, and 3, respectively. The discharges prior to the
inlets were 305, 205, 210, and 200 m3/h at the 1st, 2nd, 3rd and 4th
inlets, respectively. The total discharge through all inlets was equal to
910 m3/h. The rate in the duct at the front of the cyclone reached
12.6 m/s and the rate following the cyclone was 12.5 m/s.
Our analysis found a gas flow rate of 8 m/s in the 3rd and 4th chan-
nels of the traditional multi-channel cyclone, which may be insufficient
for the centrifugal forces to transport particles to the peripheral wall.
Thus, the particles will not pass through the segmental slits to the hop-
per of the cyclone.
Under a lower gas flow rate, the filtration of the polluted gas flow
will not be effective, as the purified air from the previous channel will
not have enough energy to filter the polluted flow and the rate, due to
resistance will be insufficient. In addition, lignin FSPs will accumulate
at the bottom of the separation chamber, thus clogging of the system
further.
Additional investigations were carried out on the newly designed
multi-channel cyclone, where only an interior continuous circular slit
rather than interior segmental circular overlapping slits were installed
in the channels at the bottom of the separation chamber. In this case,
the gas flow rate in the duct at the front of the cyclone slightly decreased
by 0.8–3.2%; and the rate following the cyclone decreased by 1.2–4%.
These decreases occur due to variations in the gas flow trajectories
that increase the aerodynamic resistance at both, the gas flow inlet
and outlet of the cyclone.
In summary, we conclude that gas flow in the traditional multi-
channel cyclone structure varies evenly. Thus, at a rate of 16 m/s,
the highest and lowest values differed by 2.32, at a rate of 12 m/s;
and by 2.52, at a rate of 8 m/s, resulting in a 2.13-fold difference. It
is assumed that at a gas flow rate of 8 m/s, the aggressive gas flow
motion may be insufficient at measurement points, 2.1, 3.1, and
4.1. Thus, the inlets can accumulate FSPs coming in with the flow
that will cause adhesion and cyclone clogging. To avoid adhesion,
489
subsequent experiments set the optimal gas flow rate at 12 m/s in
the multi-channel cyclone.
The aerodynamic resistance of the multi-channel cyclone was inves-
tigated at an average aggressive gas flow rate of 8–16 m/s. At a gas flow
rate of 16 m/s under laboratory conditions, the aerodynamic resistance
of the four-channel cyclone with a single gas flow inlet was 370 Pa. The
resistance increased by 9.8% (to 410 Pa) when the flow of aggressive gas
entered the cyclone. Therefore, friction adds resistance when the gas
flow passes through vapour clouds created by the vapour supply. This
can be explained by an increase in gas flow temperature that results
in a proportional drop in dynamic pressure and rate. Maintaining an ap-
propriate average gas flow rate of 12 m/s in the cyclone channels, the
values of the aerodynamic resistance, decreased by 2.1 and 2.24 times,
respectively, under aggressive gas flow and compared to the values ob-
tained at an average gas flow rate of 16 m/s. The difference between the
resistance values in the varying environments was, on an average,
15.4%, i.e. 30 Pa. In all cases, the trend remained similar. Under labora-
tory conditions, the aerodynamic resistance of the cyclone was below
the aggressive gas flow. The lowest values were found at an air flow
rate of 8 m/s in the cyclone channels, where the aggressive gas flow cy-
clone resistance reached 105 Pa. However, under laboratory conditions,
the lowest resistance value was 85 Pa.
We then tested the aerodynamic resistance of the newly designed
multi-channel cyclone. At an average gas flow rate of 16 m/s in the cy-
clone with secondary gas inlets, the aerodynamic resistance (305 Pa)
was 1.21 times less than that of a multi-channel cyclone with a single
inlet. Under an aggressive gas flow, the aerodynamic resistance was de-
termined to be 335 Pa. When gas flow rate in the cyclone channels was
the lowest at 8 m/s, the aerodynamic resistance (90 Pa) of the newly de-
signed multi-channel cyclone did not vary significantly compared to the
established value of the cyclone with a single inlet. It should be empha-
sized that, at gas flow rates of 12 m/s and lower, the aerodynamic resis-
tance of the newly designed multi-channel cyclone was 18.2% higher
than that of the multi-channel with a single inlet. When treating an ag-
gressive gas flow, the difference between the aerodynamic resistance of
the multi-channel cyclone with a single inlet and the newly designed
cyclone decreased considerably. At aggressive gas flow rates of 16, 12,
and 8 m/s, the aerodynamic resistance was 335, 215, and 110 Pa,
respectively.
When only an exterior continuous circular slit was installed at the
bottom of the separation chamber in the newly designed multi-channel
cyclone, only minor variations were identified when compared with the
installation of interior segmental circular overlapping slits in the chan-
nels. At an average gas flow rate of 16 m/s in the cyclone channels, the
newly developed multi-cyclone achieved an aerodynamic resistance of
485 Pa, a value 1.59 times higher than that of the traditional cyclone.
At average gas flow rates of 12 and 8 m/s in the cyclone channels, the
aerodynamic resistances were 325 and 175 Pa, respectively.
At a discharge value of approximately 1800 m3, the aerodynamic re-
sistance was about 300 Pa, i.e. the energy lost (due to resistance) is 20%
lower than that lost in the conventional cyclone (whose cleaning effi-
ciency of PM up to 10 μm is about 70–80%); and 3–5 times lower than
the high-efficiency cyclone (whose cleaning efficiency of PM up to 10
μm is about 85–90%) [31]. Therefore, the design of the conventional cy-
clone is constantly being improved [32,33], to avoid high energy losses
and to maintain high levels of cleaning efficiency, especially of the fine-
dispersed particulate matter.
In conclusion, the aggressive gas flow increased the aerodynamic re-
sistance, on average, by 17.5% and 14.1% in the multi-channel cyclone
with a single inlet and the newly designed cyclone, respectively. The
aerodynamic resistance of the newly developed multi-channel cyclone
differed from values obtained under laboratory conditions. Moreover,
under aggressive gas flow, the gas flow rate was reduced by 8–12 m/s;
whereas in the multi-channel cyclone with a single inlet, the gas flow
rate was reduced by 12–16 m/s. The aerodynamic resistance mostly
rose from 12 to 16 m/s along with an increase in the gas flow rate in
490 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492
the cyclone channels, and the parameter values changed, on an average,
by a factor of 2.17. Under a gas flow rate of b12 m/s, the aerodynamic re-
sistance became less significant, and the impact of local obstacles on the
energy losses in the experimental multi-channel cyclone bench became
more evident.
3.4. Efficiency of multi-channel cyclone purification
The multi-channel cyclone removed wood ash FSPs from aggressive
gas flows at efficiencies that are represented in Fig. 11. Variations in the
purification efficiency depended on the aggressive gas flow rates (8, 12,
and 16 m/s) in the cyclone channels. No large FSP accumulations were
observed in the newly designed multi-channel cyclone purifying an ag-
gressive gas flow. Therefore, purification efficiency measurements were
performed only in the last period of cyclone operation, following a treat-
ment of 150,000 m3 of gas or approximately 116 work hours. The
efficiencyof the multi-channel cyclone with a single inlet was deter-
mined for individual work periods. The initial reference point was at
the zero-operation time under non-aggressive gas flow under labora-
tory conditions, and a discharge of 30,000 m3. One cubic metre of puri-
fied aggressive gas-vapour-fog flow is equivalent to 30 working hours,
and 50,000 m3 is equivalent to 50 working hours.
The newly designed multi-channel cyclone achieved the highest
wood ash FSP removal efficiencies among all the cases. Maximum effec-
tiveness was reached at an average rate of 12 m/s in the cyclone channels,
peaking at 83.6%. The average diameter of the particles used in the study
was 10.8 μm, and therefore one third of all particles in the sample ranged
from 2.5–10 μm in size. Such particles are classified as fine or ultrafine and
they make up approximately 10–20% of the total industry emissions.
Larger particles present in the multi-channel cyclone were trapped
more efficiently. Therefore, we strongly suggest that the purification effi-
ciency of the newly designed, multi-channel cyclone would be greater
when employed under actual field conditions. At a lower aggressive gas
flow rate of 8 m/s, the efficiency of identifying both types of FSPs was
lower by around 4.1%. At a maximum aggressive gas flow rate of 16 m/s
in the cyclone channels, a slight decrease in purification efficiency
by 0.6% was observed. Considering all the investigated cases, the removal
of wood ash from the gas flow did not affect the newly designed multi-
Fig. 12. The efficiency of removing fine wood ash solid particles from aggressive gas flows through the newly designed multi-channel cyclone with secondary gas inlets and through the
traditional multi-channel cyclone with a single inlet. The gas flows were at different flow rates in the channels.
channel cyclone as it remained fully operational after the release of
150,000 m3 of high-temperature and high-humidity dusty gas flow.
Fig. 12 shows that under laboratory conditions, the highest efficiency
for removing wood ash FSPs (86.9%) was achieved at an average rate of
12 m/s in the channels of the traditional cyclone. When the rate was re-
duced to 8 m/s, the efficiency decreased by 2.4%. In addition, some of
FSPs were found to accumulate at the bottom of the cyclone separation
chamber. A large amount of the particles clogged the curved element
slits and those elements at the bottom of the separation chamber
were used by the particles to enter the hopper. For this reason, it is ad-
visable to apply a higher gas flow rate in the channel if the aggressive
gas flow is of higher temperature and humidity. An important point is
that the maximum rate can be limiting so that the particles cannot be
pumped from the hopper, and thus not be returned to the cyclone nor
enter the environment.
After passing through 150,000 m3 of aggressive gas flow, the newly
designed multi-channel cyclone with secondary gas inlets showed no
negative effects on the internal structure. No elements were clogged,
and therefore, the unit can be used further. Meanwhile, previous studies
on the traditional multi-channel cyclone structures revealed that the ac-
cumulation of particles in all of the cyclone channels can be significantly
accelerated, depending on the amount of aggressive gas flow. The inte-
rior elements such as the segmental slit and spacings were completely
clogged between the curved element and the inside folded slots, and
thus the unit could not be used to purify such a high flow of gas.
The conventional cyclone is often used to separate the particulate
matter in wet gas flow. The overall efficiency is equal to 50–80% at rel-
ative humidity values of between 25 and 40% [34]. Many theoretical
studies have been conducted with the aim of achieving the highest
cleaning efficiency. In general, the conventional cyclone emits 5–15%
of the particulate matter (where the mean particle diameter is equal
to 10–30 μm). The purification efficiency of the conventional cyclone
decreases significantly when the mean particle size is smaller than 5–
7 μm [31]. The adhesion phenomenon may also apply to these conven-
tional cyclones. If so, then the gas inlet and the conical hopper could be
the potential clogging zones [35].
It is important to consider the effect of chemical contaminants in ag-
gressive gas flows on the purification efficiency of the multi-channel
 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492
Fig. 13. The efficiency of removing fine wood solid particles from the aggressive gas flow in the newly designed multi-channel cyclone with secondary gas inlets under different
concentrations of acetone in a gas flow at a rate of 12 m/s in the cyclone channels and with different gas flow discharges.
cyclone. The selected wood ash FSPs can be distinguished based on the
different technological processes used in the wood processing industry.
The high-temperature and high-humidity gas flows containing VOC com-
pounds can affect the cyclone operation, and therefore assessing their im-
pact on the efficiency of trapping solid particles in the cyclone is an
important task. VOCs consist of many types of organic compounds, but ac-
etone, propanol, butanol, ethanol, and others are found in varnish and
paint. These are the most commonly occurring pollutants emitted from
the wood industry. Hence, acetone was selected for experimental studies.
The presence of acetone in the aggressive gas flow affected the
multi-channel cyclone. The results were obtained from multi-channel
cyclones operating at different gas flow discharges of 1300, 2600 m3,
and 3900 m3, corresponding to 1, 2, and 3 working hours. In all cases,
the average gas flow rate in the cyclone channels was 12 m/s.
Raising the concentration of acetone in the aggressive gas flow at an
even rate from 0 to 4 g/m3 (1560 ppm) uniformly increased the purifi-
cation efficiency from 86.4 to 88.5%. The increasing trend in purification
efficiency was observed as the acetone concentration increased. The ef-
ficiency also increased slightly when the multi-channel cyclone oper-
ated continuously, and the amount of discharged gas flow increased
(Fig. 13).
Below the lowest concentration (1 g/m3 of acetone or 391 ppm), the
purification efficiency increased slightly by over 0.8% and only within
3 h of operation. Meanwhile, when the concentration of acetone was
2 g/m3, the purification efficiency increased on an average by 0.7%,
and when the acetone concentration was 4 g/m3 the purification effi-
ciency increased by an average of 1.3%.
It can be argued that the efficiency values of the first two hours of
treatment varied by 0.3–0.5%. The difference between the latter and
those from the third hour were the highest with acetone concentration
of 1 g/m3. However, the difference was 0.4% when the concentration of
acetone was increased to 2 g/m3 or 4 g/m3.
One reason for the increase in the efficiency of particle separation in
the aggressive gas flow in the multi-channel cyclone is that the presence
of acetone decreases viscosity of the aggressive gas flow. The probability
of particle deposition in cyclones is inversely proportional to the dy-
namic gas viscosity. The share of acetone vapour in the total gas flow de-
creases with its viscosity, thus increasing the efficiency of the deposited
solid particles. Previous studies [36] found that at a temperature of 100
°C and 95% relative humidity, the viscosity of the vapour flow of aggres-
sive gas was 2.125 × 10−5 Pa·s, which is 1.18 times higher than that
seen with non-aggressive gas flow (temperature of 20 °C and 50% rela-
tive humidity). When the gas-vapour mixture consisted of an aggressive
491
gas flow with acetone vapours reaching 4 g/m3, the dynamic viscosity
decreased to 0.5%.
It can be assumed that the effect of other VOC pollutants on the sep-
aration of the solid particles by multi-channel cyclones treating differ-
ent technological processes will likely be similar. VOCs emitted from
paints, varnishes, or other wood processing activities (dyeing, impreg-
nation, etc.) have similar densities and dynamic viscosity values. There-
fore, their effect on the separation of solid particles from aggressive gas
flows will be similar.
These results demonstrate the benefits of the multi-channel cyclone
with secondary inlets in purifying dusty flows of aggressive gas. The ap-
plication of a newly designed cyclone has the potential to achieve and
maintain higher purification efficiencies than that by a traditional de-
sign cyclone. After discharging 150,000 m3 of aggressive gas flow, the
interior structure of the new multi-channel unit showed no signs of
clogging due to the solid particles, and the device achieved N9% separa-
tion efficiency.
4. Conclusions
This study assessed the performance of a multi-channel cyclone
treating high-temperature and high-moisture (aggressive) gas flows
polluted with fine solid particles. We also identified the shortcomings
of the traditional multi-channel cyclone structure. This shortcoming is
the result of the interaction between the solid particles and the interior
surfaces; that is, the particles accumulate in the cyclone channels when
exposed to the flow of aggressive gas on the cyclone elements. This inter-
feres with the conventional operation of the treatment equipment by
clogging the unit. We also examined the aerodynamic parameters for
the newly designed multi-channel cyclone; and its efficiency in purifying
dusty flow of aggressive gas. Furthermore, we compared that to that of a
traditional multi-channel cyclone. The maximum gas flow rate in the 1st
channel of the newly designed multi-channel cyclone was 15.9–
17.4 m/s. When the multi-channel cyclone had a single inlet, the maxi-
mum gas flow rate was 13.1–14.9 m/s. At the beginning of the 2nd and
3rd channels, the rate decreased by 1.36–1.6 times. The gas flow rate in
the middle of the channels was approximately 1.4 times higher than
that at the beginning, and 1.2 times lower than that at the end of the
channels. These results indicate that the secondary gas flows distribute
the total discharge of gas flow through all inlets, and therefore the rate
at the beginning of the channels of the newly designed cyclone is
much lower than those in the outdated multi-channel cyclone. The rate
in the 4th channel varied slightly, and by about 10%. The maximum
492 P. Baltrėnas, A. Chlebnikovas / Powder Technology 356 (2019) 480–492
aerodynamic resistance of the newly designed multi-channel cyclone
system reached 335 Pa at an average gas flow rate of 16 m/s in the cy-
clone channels. In the inlet, the maximum aerodynamic resistance was
1.22 times stronger at 410 Pa. At lower gas flow rates, such as 8–
12 m/s, the aerodynamic resistance was greater on an average by 1.05–
1.15 times in the newly designed multi-channel cyclone. This is due to
the installation of additional secondary gas inlets through which gas
flows to each of the channels, changing its trajectory at angles from π/2
to 3π/2. By increasing the aggressive gas flow at 110 °C and 95% of hu-
midity at an average rate of 12 m/s, the aerodynamic resistance was in-
creased by 9.8% compared to that under laboratory conditions.
The inner elements of the newly designed multi-channel cyclone
were made of stainless steel, which we identified as an optimal material
compared to galvanized sheet and black metal. The average surface
smoothness-roughness value of the stainless-steel sample was 0.273
μm, while that for galvanized sheet and black metal were 1.302 μm
and 0.600 μm, respectively.
The installed secondary gas flow inlets reduced adhesion of the com-
ponents of the gas flow discharge to the curvilinear elements and the
peripheral wall at distances of 2.5–0.2 cm from the inlet. They also
completely prevented the accumulation of particles on the convex bot-
tom of the separation chamber. In addition to the conventional tangen-
tial inlet in the 1st cyclone channel, the cyclone structure added more
secondary gas inlets to each of the exterior cyclone channels. For this
specific cyclone, the gas flow was supplemented by fresh inflow every
second step of π/2 from the primary gas inlet. Thus, the gas flow rate
is reduced at the beginning of the 2nd and 3rd channels. However, the
fluctuations of the gas flow rate in all the channels of the cyclone de-
creased. This technology is one of the structural solutions used to
adapt the multi-channel cyclone for the purification of high-dust,
high-temperature-and-humidity (aggressive) gas flows to avoid clog-
ging due to the adhesion of solid particles. A reduced aerodynamic resis-
tance of 335 Pa enabled us to achieve treatment efficiencies (removal of
wood ash FSPs) exceeding 83%. Even though the structure of the newly
designed cyclone is more complex than that of a traditional device, the
former with its secondary gas inlets can be efficiently used to remove
FSPs from aggressive gas flows under complex conditions.
The efficiency of removing FSPs from chemically polluted dusty flows
of aggressive gas increased on an average by 1.1% with a concentration of
4 g/m3 acetone. Furthermore, under continuous operation times of 1–
3 h, the treatment efficiency of the multi-channel cyclone increases to
2.1%, and changes mostly when the concentration of acetone is lower.
The process of purifying aggressive gas needs to overcome the in-
tense adhesion of FSPs depending on the type of the surface and its
smoothness. To reduce surface adhesion, polishing (i.e., sanding), or
coating the surface with materials may improve smoothness. Further
research on the treatment efficiency of the newly designed multi-chan-
nel cyclone surfaces that have been sanded or coated with heat- and
wear-resistant varnishes should be conducted.
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