Particulate Science and Technology

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DESIGN GUIDELINES FOR CYCLONE IMPROVEMENT

P. SCHMIDT

To cite this article: P. SCHMIDT (1991) DESIGN GUIDELINES FOR CYCLONE IMPROVEMENT,
Particulate Science and Technology, 9:1-2, 91-103, DOI: 10.1080/02726359108906580

To link to this article: http://dx.doi.org/10.1080/02726359108906580

Published online: 15 May 2007.

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 DESIGN GUIDELINES FOR CYCLONE
IMPROVEMENT

I? SCHMIDT
FB 13, University-GH Essen. Germany

Abstract
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There is a potential for improving cyclone separators by design and operating

conditions. Secondary flow detrimental to dust separation can be avoided by
proper gas inlets. dimensioning of body and swirl, or by use of a flow guide in the
area of separation. Cyclone and bin are to be treated as one unit. Scavenging of
the bin is most effective for high effiency. Cut sizes smaller than 1 p m can be
realized with a cyclone separator unit consisting of a preseparator, a battery of
small cyclones, and a scavenging cyclone with gas recirculation. Such arran-
gements are capable to cope with dust streaks and to make positive use of dust
agglomeration. These principles are applicable also for big cyclone batteries as
used behind rotary dryers for wood chips, etc.

1. Introduction

Cyclone separators are still the cheapest and most reliable equipment for dust
separation from gases. The only problem is a low efficiency respectively a cut size
not small enough compared with filters, scrubbers, and electrostatic precipitators.
However, there is a potential for improving cyclone separators as discussed in the
following. The main purpose of this paper is-to demonstrate steps for realizing
cyclone improvements by design.

2. Basic Relations for Calculating the Cut Size

The most common cyclone is the reverse flow type. Fig. 1. The cut size, accor-
ding to first principles, li.e. because of equilibrium between centrifugal force Fc
and drag force Fd. Ill), is:

Particulate Science and Technology 9:91-103. 1991

Copyright O 1991 by Hemisphere Publishing Corporation
 I? Schmidt
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Fig. I : Main dimensions and dara for calcularing rhe cur size of a reverse flow cyclone.

respectively applying volume flow and the relation

ug = v e ( r e / r t ) " .

For solving a dedusting problem we have to know the dust concentration co, of
the raw gas, the particle size distribution Q(x) under operating conditions. and the
clean gas dust concentration c l . From this data we can calculate the cut size x50.
This is the basis for cyclone design according to equation 11). There is a limited
choice in the main geometry of the cyclone. Most important is dimensioning of
!he cyclone with respect to the cut size and pressure drop. Table 1 shows us that
p;actically every dust collecting problem can be solved if cyclones are small
enough, sufficent in number, and operating with a proper pressure drop. The
relations used for calculating Table 1 are:
 Design Guidelines for Cyclone lmprovemenr 93
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Table I :

Consequences in reducing the cur size of a cyclone scpararor lrom the starring posirion x50= 1.
dimension respectively diamerer ri = 1, volume flow i'= 1, pressure dropap = I, power demand
P = 1, number of cyclones n = I and Reynolds-number Re = I ro cur sizes x50 = 0,5 and 0.1.
Merhod a: increasing rhe volume flow \i only.
Method b: decreasing rhe diameter r; only and
Merhod c: combination of method a and b.

3. Secondary Flow in Cyclones

Unfortunately, the real flow in a cyclone does not correspond to simple theory
resulting in equation (1). There is a high degree of turbulence and secondary flow
(see Fig. 2), that we can diminish or even avoid by design. The main flow shows
the typical and very constant profile for the tangential velocity u because of the
well known Rankine-Vortex. The maximum of this velocity marks the area of
separation, a hypothetical cylinder with the radius r, and the height hi. The axial
velocity w changes its sign because of reverse flow. The profile of the radial
velocity v,i in the area of separation is not a constant one as assumed by first
principles. Because of the Rankine-Vortex flow there results a pressure p
 94 F! Schmidr

inducing the binflow i / ~being about 25% of the main flow \j. At the top of the
cyclone there is a Ring-Vortex because of squeezing of the incoming gas.
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Fig. 2: Gas flow in a reverse flow fype cyclone. Volume flow \i. enrrance velocify v,. ourler
rube velociry v;, rangenrial ve1oc;ry u, axial velociry w, radial veloc!ry v,; in :he zone of
separarion, sraric pressure p. volume flow GQ in and out from the bin.

The first step in improving the flow is to make it as symmetrical as possible by

choosing a favorable inlet (see Fig. 3). Such inlets are axial or radial vanes, a 360'-
scroll, a helical inlet. or some flow guide.
 Design Guidelines for Cyclone Improvement 95
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Fig. 3: Designes of pas inlet openings for improving fhe symmetry of flow in cyclone
separarors: a double ;nlef. b 36P-scroll, c flow guide spiral. d helical inlet, e axial vanes,
1 radial vanes.

3.1 Improving Cyclone Gas-Flow by Design

The next problem is realizing constant radial inflow with the velocity vfi through
the area of separation along its height hi. Unfortunately, in the vortex of con-
ventional cyclones there is a remarkable sinkflow into the outlet tube near its
opening resulting in a poor sharpness of cut and efficiency. This unfavorable flow
can be minimized by optimizing the swirl respectively the ratio ulw of tangential
and axial gas velocity 121. Also, the geometry of the zone of separation (i.e. the
ratio hJdi of lenght to diameter), has an influence on the velocity distribution vri (h).
Another way to solve this problem is to enforce constant radial velocity vri by
installing a flow guide directly into the area of separation. The simplest one is a
cylinder of wire mesh extending from the outlet tube about 314 of the height hi
downward. Much more effective is an elongated outlet tube of the same lenght,
slotted lenghtwise with a spiral as cross-section and a closed bottom (Fig. 4 al);
the opening of the slot is directed against the flow. The reason for the constant
radial velocity v,, now realized is the very high and extremely constant tangential
velocity ui (h) in the zone of separation always observed in cyclone flow. This
velocity is being transformed into a constant dynamic pressure at the entrance of
the slot and, because of its constant width, this finally results in a constant
outflow v,i (h).
 R Schmidr
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Fig 4: Flow guide m the zone respecrively area 01 separation of cyclone separarors: a t
srraighr slor. a2 stor with adjacent dillusor, a3 rwo hall rubes, b helical slot resulting in
an involute cross section, c 3/4.circIe in cross secrion and d roll design.

An additional improvement of this slotted outlet tube shows a diffusor adjacent to

the slot (Fig. 4 a2). Also, two slots are a possible design with the advantage of
simple manufacture from two half-tubes (Fig. 4 a3). All of these devices can be
shaped like a helix I31 (Fig. 4b). Additionally, to the constant velocity distribution v,i
(h) this results also in a reduction of pressure loss of about 50%. Figures 4c and
4d show similar designs of helically slotted outlet tubes easy to produce.

4. Bin-Flow i n Cyclones

Cyclone separators mostly are being treated without considering the bin. How-
ever, there is a strong interaction between both of them 141: they have to be
treated as one unit. Gas flow of about 20% into the bin is necessary for the
transport of dust separated in the cyclone. The returning gas, however, disturbs
dust deposition. The influence of the dust hopper design on cyclone performance
is illustrated by Fig. 5. There are several dimensionless numbers characterizing
 Design Guidelines for Cyclone lrnprovernenr 97

the efficiency of the cyclone-hopper-configuration. For the cyclone alone there

are the numbers

n1 = q (efficiencyl: x2 = c (raw gas concentration): n3 = vsdi2/i' (Stokes-Number):

n = daldi = const.; n5 = hidi = const.: n6 = ~ ~ = const.

/ d ~ ~
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Fig. 5: lnteracrion berween cvclone and bin. Relation between efficiency and volume flow
relarion p ~ &bWcyclone respecrively relarion i?s/d? bin volurne/cyclone volume.

The settling velocity v, and the inlet area A, are used as characteristic quantities
in n3 and X6. For the cyclone including binflow there are the most important
numbers

n7 = \jB l di2 and n8 = dB / di

In the case of bin scavenging or bleeding there is instead of n 7 and n8 the

number

n9 = \jBA/i'. n-Relations between n, and ng respectively nl and n7 are to be

seen also in Figure 5.

A chinese hat in the discharge opening prevents, to a high degree, re entrance of

dust from the dust hopper into the core and directly into the clean gas via outlet
tube.
 98 I? Schrnidf

5. Dust Streaks

In the case of high dust concentration. of co = 1 glm3, a dust streak arises com-
prising all the surplus dust 151: this is being discharged directly into the hopper.
Fig. 6 shows the portion of dust collection due to the streak-effect and due to
vortex deposition according to equation (1). In practice this is the situation
relevant especially for cyclones used in pneumatic conveying. For one cyclone
only, a dust streak is a positive effect. For a battery of cyclones, however, there is
a negative effect
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r a w gas dust concentration co

Fig. 6: Formarion of dusr Streaks ;n cyclones. Efficiency hlo1 of dust deposition due ro streak
and vortex deposirion dependrng on raw gas dusf concenfrarion c and on Srokes
number Slk.

6. High Efficiency Cyclones

In the past, there have been problems with cyclone separators because of too
high a dust concentration in the outlet. Limits set by legislation are somewhere
between 10 and 100 mg/m3. This requires cut sizes beiow 1 pm. even below 0.5
pm. Results obtained with small cyclones 161 confirm the prediction of Table 1. It
is surprising to find real cut sizes even lower than calculated ones in that realm.
This contradictory tendency to theory increases with decreasing particle size (Fig.
 Design Guidelines for Cyclone Improvement 99

7).So, a cyclone calculated for 1 @m cut size in reality may have a cut off at 0.5
@m.An explanation to this phenomenon is dust agglomeration, The conclusion
w e can draw is to operate a bank of small cyclones delivering as much as possible
clean gas and another separator, a cyclone or filter, to catch or to deposite the
dust.

Xpri Agglomeration develops e s p e c i a l l y i n

t h e zone of h i g h s h e a r flow
,)

'.&tangential velocity ,\\:

!. ' . . . I \ \\
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Fig 7:
-
InNuence of agglomerarion on cur size, virrual cur size x50 declines below the
rheorerical one xp,jm for primary panicles if they are smaller rhan abour x 5 pm.

Batteries, banks, or multiple cyclones are designs well known. Very often, how-
ever. the trouble with them is a short circuit flow in the common dust hopper.
Concerning this, w e have to cope with two phenomena: If the dust concentration
in the dust laden gas is high enough to show dust streaks already in the raw gas
channelthen one or f e w cyclones of the battery have to separate practically all of
the dust. Paradoxically. these cyclones show a lower pressure drop. It is because
of high friction reducing the swirl. So, these cyclones take even more gas and
dust. But because of the lower swirl, only poor or no separation can take place
and most of the dust is flowing directly into the clean gas duct. In this case, a low
pressure drop preseparatorqclone is to be installed in order to avoid dust streaks
in the raw gas channel.

The second problem is the short circuit flow between cyclones through the
discharge opening and the hopper; it is very intensive in the domain of dust streak
 100 I? Schmidt

flow mentioned above. But even gas with low dust concentration shows short
circuit flow. Normally, outflow and inflow through the discharge opening is
balanced. But small differences in diameter or friction factor can disturb this and
also the whole dust deposition. Hopper bleeding of about 15 to 25% volume flow
is a very effective mean in overcoming this. 161.

6.1 Cyclone-Batteries

Figure B shows a high-efficiency cyclone separator unit consisting of a prese-

parator, a battery of main cyclones and a bleeding cyclone. The pressure drop
respectively power demand for the hopper bleeding or scavenging flow may be
delivered from an additional blower (Figure 8, top). But, it can also be taken from
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the main blower by recirculating the bleeding gas into the core of the main
cyclones (Figure 8, bottom). In Figure 8, top, there are reverse flow type cyclones;
in Figure 8, bottom, direct flow cyclones: on the left there is a conventional
cyclone body: on the right side a flow guide with slotted outlet tube. In order to
cut down blower capacity a radial diffusor is favorable at the end of the outlet
tube.

Very often there is relatively coarse dust to be separated, e.g. sanding dust, sugar
beet chips behind a rotary dryer or wood chips for particle board. Batteries of
about 10 cyclones is a common design for this problem. Fig. 9. Often they show
one or more imperfections. An improved design is shown in Fig. 10.
 Design Guidelines for Cyclone lmprovemenr
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Fig. 8: Cvclone separaror unir consisrmg of a presepararor a. a barrerv b of smaller cyclones

being rhe main separator producmg as much as possible of clean gas and a bleeding
respecrively scavenging cyclone c rec!fcularing its clean gas via an additional
scavenging blower efropl or wa a cenrral feedback pipe e fborroml. The barren/ on rop
consists of reverse flow rypes cyclones f, on rhe borrom there are direct flow
cyclones I. The lefr ones are of convenrional design, rhe right ones show slorred
ourler tubes g as flow gujdes. Radial diflvsors h and scavenging /low i are common to
all bartery cyclones. On rop righr. the cyclone shows a borrom spiral; avoiding the tea
pot effect i e . dust flow fo the cenrer.
 F Schmidt
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Fig. 9: Battery of cyclones as frequently used behind roiary dryers. Poor design with shorr
cur flow along and through a screw conveyer.

Fig. 10: lmproved design of a cyclone barrery compared ro Rg. 9; a presepararor, b interme
diare hopper, c hat. d chain conveyer or common hopper e with a bleeding. f bleeding
gas filrer or g bleeding gas cyclone, h recirculalion of clean bleeding gas, and i main
blower.
 Design Guidelines for Cyclone Improvement 103

7. Conclusion

Cut sizes for cyclones in the range of 0.3 - 1.0 pm are realistic but they require not
only small. many, and correctly switched cyclones, they also need a lot of power.
Maximum tangential and exit pipe velocities in the range of 100 mls are
necessary affording about 500 to 10.000 Pa pressure drop. A reduction of pres-
sure drop to about 50% can be achieved with slotted outlet tubes mentioned
above especially in combination with a radial diffuser. However, a higher precision
in manufacture as usual is necessary also.

References:
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Ill W. Barth. Berechnung und Auslegung von Zyklonabscheidern. BWK 8(1956l.

119

I21 J. L. Smith. Jr.. An Experimental Study of the Vortex in the Cyclone Separator,
Trans. ASME, J. Basic Engineering 1962, p. 6021617

I31 P. Schmidt. Zyklonabscheider mit Schraubenspaltdiffusor. Staub 45(19851.

1631165

141 J. Abrahamson et al.. The Physical Mechanismn of Dust Collection in a

Cyclone. Trans. I. Chem. E.. Vol. 56(1978).1681177

[51 E. Muschelknautz and M . Trefz. Design and Calculation of Higher and Highest
loaded Gas-Cyclones. 2. World Congress Particle Technology. Kyoto 1990

161 R. Kirch. Der EinfluR der Turbulenz auf die Partikelbewegung i m Gaszyklon,
Fortschr.-Ber. VDI-Z. Reihe 7. Nr. 145(1989)

171 P. W. Sage and M . A. Wright. The Use of Gas Bleeds to Echance Cyclone
Performance. Filtr. & Separation (1986).32/36