CYCLONE DESIGN AND ANALYSIS

by Esco Engineering
179 Lansdowne Avenue,
Kingsville, Ontario N9Y 3J2 Canada Revisions
ph 519 733 3122 26-Nov-98 Corrected error in cell D14
fax 519 733 6094 18-Jan-99 Added diagram
Contact: Neil Stone, Chief Engineer 3-Apr-99 Corrected cell O7, Efficien
e-mail jnstone@mnsi.net 2-Dec-99 Added metric option, NV
Website www.mnsi.net/~pas/esco.htm 13-Dec-99 Corrected error in density

Copyright 1997 by John Neil Stone. All rights reserved.

May be redistributed free of charge, but may not be sold without the author's explicit permission.
Provided "as is" without warranty of any kind.

HOW TO USE THIS SPREADSHEET

NOTE: This spreadsheet is for the use of knowledgeable professionals, capable of evaluating the accuracy
of the results. The author is not responsible for the use to which these results are put.

1 The 'Cyclone size' sheet calculates dimensions for various standard cyclones.
Enter the flow rate, design inlet velocity and gas density in the colored squares
and the sheet will give dimensions for five standard cyclones - two high efficiency, and
three low efficiency. The table also gives the predicted pressure drop, but be aware that this is a
very uncertain calculation (see original references). See 'Diagram' sheet for nomenclature.
On the 'Cyclone size' sheet you specify the units you want to use - metric or US Customary (Imperial)
THIS UNITS SELECTION APPLIES TO ALL SHEETS

2 Two methods are provided for calculating cyclone efficiency. You can calculate both, and
compare the results on the chart. Both sheets are set up with the same layout, so data can be copied
between sheets easily.

3 The efficiency calculation requires particle size data, cyclone dimensions, and physical property
data for the gas and the solids. The calculation assumes that the size distribution of the particles
is log normally distributed. The sheet is set up so that you can enter either the mean and standard
deviation of the log normal distribution, or the particle size data, from which these data are then calculated.

4 Procedure for efficiency calculations:

a) Enter the cyclone dimensions in cells D4 to D11. If you have calculated these using this
spreadsheet, the values in cells 13 to 20 for the selected cyclone design can be directly copied
into D4 to D11. NOTE: Paste special the values - do not just copy the cells.
b) Enter the gas property data in cells D18 to D21.
c) Enter the particulate data in cells D26 to D29. If you enter the mean and standard deviation, and
select 'N' for cell D28, then the overall efficiency is immediately given in cell H15, and the inlet and
outlet size distributions are given in cells O21 to O41 and R21 to R41.
 d) If you want to use the size distribution method, enter 'Y' in cell D28, and then the range limits starting in
cell N50 and the corresponding % in range starting in O50. If you want to use more than nine ranges, yo
can extend these columns to as many rows as you want - just remember to copy the formulae
in columns M and P through T into any rows that you add.
After entering the size distribution data, You have to run the regression tool. Choose the 'Tools' menu
then 'Data Analysis' then 'Regression'. For the 'X' value pick all the values in column Q, starting in Q50;
for the 'Y' values, pick all the values in column T, starting in T50. For the 'Output range' enter V48. You w
get a message saying results will overwrite cells - pick OK.
Once the regression is done, the results are available, as described in c) above.

5 The chart sheet graphs the penetration (col P = 1 - fractional efficiency) against particle size for the two efficiency
calculation methods. CAUTION: The two efficiency sheets are not linked, so make sure they are both calculating
from the same data if you want to compare the two efficiency calculations!

6 The spreadsheet is protected in order to prevent accidental overwriting of the formulae.

However, there is no password needed to unprotect it, so you can freely adapt it to suit your purposes.
 Corrected error in cell D14 on efficiency sheets
Added diagram
Corrected cell O7, Efficiency 1 - thanks to Laercio Frare for pointing out this error
Added metric option, NV sketch
Corrected error in density calc (size!E9, Efficiency 1! and 2!E19)

ting the accuracy

ry (Imperial)

an be copied

are then calculated.

e directly copied

dard deviation, and

15, and the inlet and
 the range limits starting in
more than nine ranges, you
opy the formulae

Choose the 'Tools' menu

olumn Q, starting in Q50;
put range' enter V48. You will

ize for the two efficiency

hey are both calculating

your purposes.
 DEFINITION OF CYCLONE DIMENSIONS

b De

a S
h

B ELEVATION
E DIMENSIONS

NV = Neutral vane
Extension of inner
side if inlet to centerline
of cyclone

PLAN
CALCULATE DIMENSIONS FOR CYCLONE NOTES Sheet 1 is for sizing
Sheets 2/3 are for efficiency (alternates)
Sheet 4 are charts of results of sheets 2/3

SPECIFY UNITS (U = US CUSTOMARY[IMPERIAL], M = METRIC) U This setting applies to the whole spread
Input Working
Flow rate Q cfm 2000 2000 cfm
Design inlet vel vi fps 50 50 fps
Gas density rg pcf 0.0740 0.074 pcf
Inlet area 0.67 sf
PD parameter 0.56 in water

Dimensions Type of cyclone

Stairmand Swift Lapple Swift Peterson/Whitby
HE HE LE LE LE

Dia D ft 2.58 2.69 2.31 2.31 2.34

Inlet ht a in 15.49 14.18 13.86 13.86 16.40
Inlet width b in 6.20 6.77 6.93 6.93 5.85
Outlet length S ft 1.29 1.34 1.44 1.39 1.37
Outlet dia De in 15.49 12.89 13.86 13.86 14.07
Cylinder ht h ft 3.87 3.76 4.62 4.04 3.13
Overall ht H ft 10.33 10.48 9.24 8.66 7.43
Dust outlet dia B in 11.62 12.89 6.93 11.09 14.07
# vel hds Nh 5.14 4.87 4.49 4.69 4.77
Press drop, no NV in water 2.85 2.70 2.49 2.60 2.65
Press drop, with NV in water 1.34 1.27 1.17 1.22 1.24

Cyclone data from "New design approach boosts cyclone efficiency", W.H.Koch and W.Licht, Chem Eng Nov 7 1977, 80
Pressure drop vel head correlation from "A better way to calculate cyclone pressure drop" J.Casal and J.M. Martinez-Benet, Ch
r efficiency (alternates)
s of results of sheets 2/3

etting applies to the whole spreadsheet

Copy one col of outline

data (copy values only)
to efficiency sheet.

Chem Eng Nov 7 1977, 80

asal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99
CALCULATE EFFICIENCY FOR CYCLONE (method 1)
CALCULATIONS ARE IN US CUSTOMARY [IMPERIAL] UNITS
Geometry Input Working Limits/warnings
Dia D ft 2.58 2.58
Inlet ht a in 15.49 15.49
Inlet width b in 6.20 6.20
Outlet length S ft 1.29 1.29
Oulet dia De in 15.49 15.49
Cylinder ht h ft 3.87 3.87
Overall ht H ft 10.33 10.33
Dust outlet dia B in 11.62 11.62
Natural length L ft 6.40 6.40
# vel hds Nh 5.14
Press drop, no NV in water 2.85
Press drop, with NV in water 1.34 Overall efficiency 84.2

Gas data
Flow rate Q acfm 2000 2000.00 33.33333 cfs
Density rg pcf 0.0740 0.0740 0.076 air @ 1 atm, spec'd temp
Viscosity u cP 0.010 0.010 6.72E-06 lb/f-s
Temperature T °F 60 60
Salt. temp fact fT 1.00 1
Salt dens. fact fp 1.00 1

Particle data Value used

Log mean dia dp µm 12 11.9055652
Log SD sd µm 3 3.1077764
Use distribution? (Y/N) y If yes, run regression - adjust input ranges (cols Q,T
Specific gravity 0.8 49.92 pcf

References
Efficiency from "New design approach boosts cyclone efficiency",
W.H.Koch and W.Licht, Chem Eng Nov 7 1977, 80
Pressure drop vel head correlation from "A better way to calculate cyclone pressure
drop" J.Casal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99

Statistical correlation constants

2.515517
0.802853
0.010328
1.432788
0.189269
0.001308
 Calculated data

Log SD 1.133907
Inlet velocity fps 50
Ratio inlet/salt vel 2.155166
Corrected L ft 6.397135
Core dia ft 1.628202
Eff vol cf 26.49728
Inlet vol cf 2.534862
Cycl const Kc 0.916939
G 733.5509
Vortex exp n+1 1.648398

Efficiency calcs
Dia, um
Min Max Inlet mass Penetration
fraction
0 0.4 0.0020 0.8752
0.4 0.6 0.0028 0.7215
0.6 1.2 0.0168 0.6321
1.2 1.8 0.0260 0.5304
1.8 2.4 0.0309 0.4579
2.4 3 0.0330 0.4020
3 3.6 0.0336 0.3568
input ranges (cols Q,T) to suit data 3.6 4.2 0.0333 0.3195
4.2 4.8 0.0324 0.2879
4.8 7 0.1080 0.2346
7 10 0.1197 0.1640
10 13 0.0926 0.1126
13 16 0.0724 0.0805
16 22 0.1052 0.0530
22 28 0.0698 0.0305
28 34 0.0486 0.0185
34 40 0.0351 0.0117
40 49 0.0372 0.0071
49 64 0.0384 0.0034
64 79 0.0220 0.0014
79 94 0.0136 0.0006
0.9736
Overall efficiency
Distribution data
Size, um Cum % % in
Min Max range
0 2 6 6
2 3 11 5
3 5 22 11
5 10 44 22
10 20 67 23
20 30 80 13
30 40 85 5
40 50 90 5
50 100 97 7
 Int calcs
Distribution Relax time Penetration
Outlet amtOutlet mass fl fh tl th pl ph
fraction
0.0017 0.0111 0 0.009991 0 7.108E-07 1 0.750367
0.0020 0.0129 0.009991 0.018218 7.108E-07 1.599E-06 0.750367 0.692614
0.0106 0.0672 0.018218 0.037832 1.599E-06 6.397E-06 0.692614 0.571628
0.0138 0.0871 0.037832 0.048784 6.397E-06 1.439E-05 0.571628 0.48908
0.0141 0.0893 0.048784 0.054068 1.439E-05 2.559E-05 0.48908 0.426729
0.0133 0.0839 0.054068 0.056018 2.559E-05 4E-05 0.426729 0.377171
0.0120 0.0758 0.056018 0.05603 4E-05 5.758E-05 0.377171 0.336522
0.0106 0.0672 0.05603 0.054921 5.758E-05 7.837E-05 0.336522 0.302446
0.0093 0.0590 0.054921 0.053178 7.837E-05 0.000102 0.302446 0.273417
0.0254 0.1602 0.053178 0.04504 0.000102 0.000218 0.273417 0.195875
0.0196 0.1241 0.04504 0.034769 0.000218 0.000444 0.195875 0.132112
0.0104 0.0659 0.034769 0.026983 0.000444 0.000751 0.132112 0.09317
0.0058 0.0368 0.026983 0.021255 0.000751 0.001137 0.09317 0.06775
0.0056 0.0352 0.021255 0.013811 0.001137 0.00215 0.06775 0.038174
0.0021 0.0135 0.013811 0.009455 0.00215 0.003483 0.038174 0.022821
0.0009 0.0057 0.009455 0.006743 0.003483 0.005136 0.022821 0.014227
0.0004 0.0026 0.006743 0.004969 0.005136 0.007108 0.014227 0.009157
0.0003 0.0017 0.004969 0.003297 0.007108 0.010667 0.009157 0.004951
0.0001 0.0008 0.003297 0.00183 0.010667 0.018197 0.004951 0.001947
0.0000 0.0002 0.00183 0.001106 0.018197 0.027727 0.001947 0.000832
0.0000 0.0001 0.001106 0.000711 0.027727 0.039256 0.000832 0.000378
0.1582 1.0000
84.2 %
ln dia max SUMMARY OUTPUT

0.693147 2.372092 1.555097 -1.555097 Regression Statistics

1.098612 2.101083 1.226669 -1.226669 Multiple R 0.999874
1.609438 1.740188 0.77197 -0.77197 R Square 0.999749
2.302585 1.28139 0.150652 -0.150652 Adjusted R 0.999713
2.995732 1.489069 0.43948 0.43948 Standard E 0.022894
3.401197 1.794123 0.841457 0.841457 Observatio 9
3.688879 1.947881 1.036431 1.036431
3.912023 2.145966 1.281729 1.281729 ANOVA
4.60517 2.648229 1.881213 1.881213 df SS MS F
Regression 1 14.59118 14.59118 27837.76
Residual 7 0.003669 0.000524
Total 8 14.59485

Coefficients
Standard Error t Stat P-value
Intercept 2.477006 0.007748 319.6806 7.739E-16
X Variable 1.133907 0.006796 166.8465 7.332E-14
Significance F
7.332E-14

Lower 95%Upper 95%

Lower 95.000%
Upper 95.000%
2.458684 2.495328 2.458684 2.495328
1.117837 1.149978 1.117837 1.149978
CALCULATE EFFICIENCY FOR CYCLONE (method 2)
CALCULATIONS ARE IN US CUSTOMARY [IMPERIAL] UNITS
Geometry Input Working Limits/warnings
Dia D ft 3.33 3.33
Inlet ht a in 20.00 20.00
Inlet width b in 8.00 8.00
Outlet length S ft 1.67 1.67
Oulet dia De in 20.00 20.00
Cylinder ht h ft 5.00 5.00
Overall ht H ft 13.33 13.33
Dust outlet dia B in 15.00 15.00
Natural length L ft 8.26 8.26
# vel hds Nh 5.14
Press drop, no NV in water 1.03
Press drop, with NV in water 0.48 Overall efficiency 91.4

Gas data
Flow rate Q acfm 2000 2000.00 33.33333 cfs
Density rg pcf 0.0740 0.0740 0.076 air @ 1 atm, spec'd temp
Viscosity u cP 0.010 0.010 6.72E-06 lb/f-s
Temperature T °F 60 60
Salt. temp fact fT 1.00 1
Salt dens. fact fp 1.00 1

Particle data Value used

Log mean dia dp um 24 11.9055652
Log SD sd um 3 3.1077764
Use distribution? (Y/N) y If yes, run regression - adjust input ranges (cols Q,T) to
Specific gravity 5 312 pcf
Re-entrainment coeff alpha 0 default = 0 (see original paper for definition)

References
Efficiency from "A new collection theory of cyclone separators",
L.Enliang & W Yingmin, AIChEJ Vol 35, #4 April 1989, 666
Pressure drop vel head correlation from "A better way to calculate cyclone pressure
drop" J.Casal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99

Statistical correlation constants

2.515517
0.802853
0.010328
1.432788
0.189269
0.001308
 Calculated data

Log SD 1.133907
Inlet velocity fps 30
Ratio inlet/salt vel 0.969756
Vortex exp 1-n 0.205812
theta 37.41762
rw 1.666667
rn 0.833333
uw 46.44141
Dr 0.100623

Efficiency calcs
Dia, um
Min Max Inlet mass Penetration Outlet amtOutlet mass
fraction fraction
0 0.4 0.0020 0.9998 0.0020 0.0232
0.4 0.6 0.0028 0.9987 0.0028 0.0328
0.6 1.2 0.0168 0.9814 0.0165 0.1919
1.2 1.8 0.0260 0.9000 0.0234 0.2720
1.8 2.4 0.0309 0.7003 0.0216 0.2513
2.4 3 0.0330 0.4072 0.0134 0.1564
3 3.6 0.0336 0.1523 0.0051 0.0596
input ranges (cols Q,T) to suit data 3.6 4.2 0.0333 0.0303 0.0010 0.0117
4.2 4.8 0.0324 0.0024 0.0001 0.0009
4.8 7 0.1080 0.0001 0.0000 0.0001
7 10 0.1197 0.0000 0.0000 0.0000
10 13 0.0926 0.0000 0.0000 0.0000
13 16 0.0724 0.0000 0.0000 0.0000
16 22 0.1052 0.0000 0.0000 0.0000
22 28 0.0698 0.0000 0.0000 0.0000
28 34 0.0486 0.0000 0.0000 0.0000
34 40 0.0351 0.0000 0.0000 0.0000
40 49 0.0372 0.0000 0.0000 0.0000
49 64 0.0384 0.0000 0.0000 0.0000
64 79 0.0220 0.0000 0.0000 0.0000
79 94 0.0136 0.0000 0.0000 0.0000
0.9736 0.0860 1.0000
Overall efficiency 91.4 %
Distribution data
Size, um Cum % % in ln dia max
Min Max range
0 2 6 6 0.693147 2.372092
2 3 11 5 1.098612 2.101083
3 5 22 11 1.609438 1.740188
5 10 44 22 2.302585 1.28139
10 20 67 23 2.995732 1.489069
20 30 80 13 3.401197 1.794123
30 40 85 5 3.688879 1.947881
40 50 90 5 3.912023 2.145966
50 100 97 7 4.60517 2.648229
 Int calcs
Distribution Penetration
Outlet mass fl fh kh wh lh pl ph

0 0.009991 0.000309 0.00574 1.175E-05 1 0.99956

0.009991 0.018218 0.000695 0.012914 5.948E-05 0.99956 0.997777
0.018218 0.037832 0.002781 0.051658 0.000952 0.997777 0.965015
0.037832 0.048784 0.006258 0.11623 0.004818 0.965015 0.835033
0.048784 0.054068 0.011126 0.206631 0.015228 0.835033 0.565647
0.054068 0.056018 0.017384 0.32286 0.037177 0.565647 0.248807
0.056018 0.05603 0.025033 0.464919 0.07709 0.248807 0.055881
0.05603 0.054921 0.034072 0.632806 0.142819 0.055881 0.004777
0.054921 0.053178 0.044503 0.826522 0.243644 0.004777 0.00011
0.053178 0.04504 0.094646 1.757795 1.102002 0.00011 1.236E-18
0.04504 0.034769 0.193155 3.587337 4.589762 1.236E-18 2.601E-75
0.034769 0.026983 0.326431 6.062599 13.10882 2.601E-75 9.51E-214
0.026983 0.021255 0.494476 9.183582 30.07946 9.51E-214 0
0.021255 0.013811 0.934868 17.36271 107.5179 0 0
0.013811 0.009455 1.514332 28.12472 282.1125 0 0
0.009455 0.006743 2.232867 41.46961 613.3464 0 0
0.006743 0.004969 3.090474 57.39739 1174.979 0 0
0.004969 0.003297 4.637643 86.13196 2645.906 0 0
0.003297 0.00183 7.911613 146.9373 7700.343 0 0
0.00183 0.001106 12.05478 223.8857 17877.16 0 0
0.001106 0.000711 17.06714 316.9771 35834.52 0 0
 SUMMARY OUTPUT

1.555097 -1.555097 Regression Statistics

1.226669 -1.226669 Multiple R 0.999874
0.77197 -0.77197 R Square 0.999749
0.150652 -0.150652 Adjusted R 0.999713
0.43948 0.43948 Standard E 0.022894
0.841457 0.841457 Observatio 9
1.036431 1.036431
1.281729 1.281729 ANOVA
1.881213 1.881213 df SS MS F Significance F
Regression 1 14.59118 14.59118 27837.76 7.332E-14
Residual 7 0.003669 0.000524
Total 8 14.59485

Coefficients
Standard Error t Stat P-value Lower 95%Upper 95%
Intercept 2.477006 0.007748 319.6806 7.739E-16 2.458684 2.495328
X Variable 1.133907 0.006796 166.8465 7.332E-14 1.117837 1.149978
Lower 95.000%
Upper 95.000%
2.458684 2.495328
1.117837 1.149978
 EFFICIENCY

Koch and Licht Enliang

1.2

0.8
Penetration

0.6

0.4

0.2

0
0 5 10 15 20 25 30

Particle dia um
5 30