Lesson 2 Cyclones Lesson Goal and Objectives Goal To familiarize you with che particulate-removal device used by many industries—the cyclone—its collection mechanisms, dif- ferent designs in use, and operating principles. Objectives Ac the end of this lesson, you should be able to: explain how particles are collected in cyclones, list the four major cyclone design features. recall why a variety of inlet designs have been developed. identify different uses for different cyclone designs. list three advantages of using cyclones to collect particulate matter. list three possible problems associated with cyclone use. 7, relate efficiency and pressure drop to cyclone operation. Incroduction The cyclone is a simple mechanical device commonly used to remove relatively large particles from gas streams. Cyclones hhave a distinctive and easily recognized form (Figure 2-1) and can be found in almost any industrial area of a town or city~at lumber companies, feed mills, cement plants, smelters—and at many other industrial sites. They can be located on the roof of a plant or beside a building. They range in size from a few centimeters in diameter when used in analytical equipment to several meters in diameter when used for air pollution control. In industrial applications, cyclones are often used as precleaners for the more sophisticated air pollution control equipment such as electrostatic precipicators or baghouses. Cyclones are more efficient for removing particulate matter than are settling chambers, but are less efficient than either wet scrubbers, baghouses, or electrostatic precipitators. Cyclones used as precleaners are often designed to remove more than 80% of the particles that are greater than 20 um in diameter. Smaller particles that escape the cyclone can then be collected by more efficient control equipment. 21Cyclones are relatively inexpensive to construct since they have no moving parts. Fans move the gas chrough the system but are an auxiliary device. They are usually inexpensive to operate. The first cyclone design was patented in 1886. This is the basic design shown in Figure 2-1. Since 1886, experience has led to both improved design and to unique modifications. Cyclones in series, or banks of small cyclones in parallel (multiclones), can be used to effectively remove particles having diameters of approximately 5 to 10 am. Changing details in cyclone design and in relative dimensions has led to improved efficiencies without always increasing costs of operation. Particle Collection Mechanisms Cyclones force the incoming gas stream to twist and cum in a spiral fashion. Large particles entering with the gas stream cannot turn with the gas because of their momentum or iner- tia, As a result, they break out of the gas stream and hie che wall of the cyclone. The particles then fall down the wall and are collected in a hopper. Figure 2-2 shows a top view of chis action. The spiral pattern of gas flow (Figure 2-3) is developed by the manner in which the gas is introduced. It enters along the side of the cyclone body wall and turns a number of times to spiral down to the bottom, much like the funnel of a tornado. ‘When the gas reaches the bottom of the cyclone, it reverses direction and flows up the center of the tube, also in a spiral fashion. This spiral or vortex pattern turns in the same direc- tion when it goes up as when it was descending. In the cylindrical section of the cyclone, particulate matter is forced to the wall. Or, in other words, the particles move towards the wall by the action of an “apparent” centrifugal force. In the cone section, the body is tapered to give the gas enough rotational velocity to keep the particles against the wall. This helps prevent reentrainment — the return of collected particles back into the gas stream. As the particulate matter falls to the bottom, it is collected in the hopper and is either continuously or periodically removed. 22 Figure 2.2. Cyclone particle collection.Review Exercise 1. The removal efficiency of cyclones is generally greater than that of 2. electrostatic precipitators. b. baghouses. ¢. gravity settling chambers. 4. all the above 2. Cyclones used as precleaners are normally designed to remove particles that are larger than ____um in diameter at better than efficiency, a. 0.1 wm, 80% b. 20 wm, 80% c. 1 gm, 90% 4. 5 am, 100% 1. ¢. gravity settling chambers. 3. In the figure below, draw and label the direction of gas flow and indicate where the particles are collected. 2. bd. 20 um, 80% 234, In cyclones, particles are collected a. because their inertia causes them to break through gas streamlines. b. because they are electrostatically attracted to the walls. ¢. because the gravitational forces overcome the centripetal forces. d. by sieving action. ee 5. The cyclone is given its name because of the characteristic spiral motion of the gas in the device. How many direc- tions are present in a cyclone? a. one descending direction, only b. two directions: one descending and one ascending ¢. three directions: one descending, one in the hopper. and one ascending 6. True or False? The upward gas spiral rotates in the same direction as does the downward gas spiral. 4. a. because their inertia causes them to break through gas streamlines. 5. b. two directions: one descending and one ascending Cyclone Construction Cyclones can be designed in a number of different ways. The ‘most common design is the tangential entry cyclone already shown in Figure 2-5. This type of cyclone has four major design features: inlet, cyclone body, dust discharge system. and outlet (Figure 2-4). . Inlet Let us first consider different inlet designs. Gas coming into the cyclone must be transformed from straight flow into a cir- cular pattern to form the vortex. Problems can arise in the inlet if turbulence develops and inhibits vortex formation. For this reason, modifications of the basic tangential entry have been used (Figure 2-5). Inlet deflector vanes added to a tangential entry can narrow and force the gas stream to move against the wall. Helical and involute entries can help provide a smoother transition of the gas into a vortex pattern. The success of these modifications is sometimes marginal, although increased efficiencies have been reported. 24 6. True‘Tangeacal cy Tangential entry with deflector vanes Body The panicle removal efficiency of a cyclone depends to a great ‘extent upon the cyclone’s dimensions. A designer of cyclones must first know both the anticipated volumetric gas flow rate through the system and what is expected in terms of removal efficiency. The most important dimension is the diameter of the body. A longer cyclone in relation to its diameter will pro- vide for more vortex revolutions and thus more chances for particle collection. Also, small-diameter cyclones collect small particles more efficiently than do large-diameter cyclones. ‘Smaller body diameters create larger separation forces. Cyclones less than 0.25 m (10 in.) in diameter are generally considered to have high efficiency, although efficiencies can vary depending on the relative cyclone dimensions. Figure 2-6 shows an example of relative dimensions in a high-efficiency tangential entry cyclone.Dust Discharge System Collected particulate matter should be removed from the cyclone or else it will be reentrained and sucked back up in the inner vortex. A number of methods can be used for either periodic or continual removal of the collected material. A manual slide gate (Figure 2-7) at the bottom of the cone is one of the simplest constructions allowing periodic removal (Figure Figure 2-7. Slide gus. 2-7). A rotary valve (Figure 2-8) can provide continuous removal. Outlet Modifications to gas outlets have been developed in attempts to improve the operating characteristics of the cyclone. The gas leaving a cyclone will normally continue moving in a circular pattern. If this flow could be straightened without producing turbulence, the amount of energy needed to move the gas through the system could be reduced. This has been accom- plished to some extent by outlet devices similar to those shown in Figure 2-9, the involute scroll outlet, and Figure 2-10, the outlet drum. igure 29. lavaluse scroll ude Outer drum, 26Other Configurations We have just discussed a number of design features of the com- mon tangential entry cyclone. Other mechanical configura- tions, that can still take advantage of centrifugal action to remove particles from a gas stream, are pousible. ‘The large cyclonic separator shown in Figure 2-11 is a simple design that also uses the principle of centrifugal action. The cyclonic separator is often used after wet collectors— control devices that use water sprays to trap particles in large droplets. ‘These large water droplets contain entrained particulate mat- ter, and can be removed quite effectively by this simple cyclone. Here the gas and droplets enter tangentially at the bottom of che drum, forming a vortex. The large droplets are forced against the walls and drained off at the bottom. ‘The axial inlet cyclone shown in Figure 2-12 is used in the multicyclone arrangement. Here the gas inlet is parallel to the axis of the cyclone body. The gas enters from the top and is directed into a vortex pattern by the vanes attached to the cen- tral tube. This helps prevent the turbulence around the entrance that can be a problem in tangential entry cyclones. In the mulkicyclone (Figure 2-13), axial cyclones are arranged in parallel. The dirty gas enters uniformly through all of the individual cyclones. The large number of inlets enables small high-efficiency cyclones to be used without greatly impeding the process gas flow. The inlet vanes are, however, prone to plugging, Figure 2-19, Multicycloae 27 Figure 2-12, Axial inlet cyclone,Cyclone Operating Parameters In cyclones, collection efficiency generally increases as the pressure drop increases. The small openings that create high inlet pressure also produce a high gas velocity through the cyclone. This higher velocity results in greater centrifugal force on the particles, and thus greater collection efficiency. The pressure drop in conventional tangential cyclones can range from 5 to 40 cm (2 to 16 in.) of water. ‘The pressure drop and efficiency depend on the relative dimensions of the cyclone. The effect of changes in these dimensions and changes in gas stream parameters is sum- marized in Table 2-1, Cyclones provide one of the least expensive methods of removing relatively large particles from gas streams. They can be made of almost any type of material—a distinct advantage if condensed acids are present. They have been operated at temperatures higher than 1000°C (1882°F) using refractory linings, and have also been constructed to operate at high pressures. Capital costs are low, and operating costs are also low compared to those associated with more complicated systems. Problems do arise, however. Sticky or agglomerating materials can plug the smaller-diameter high-efficiency cyclones. Varying gas flow rates will affect cyclone performance since particle collection efficiency depends upon the incoming ‘gas velocity. Also, hard, sharp-edged particles can rapidly wear the internal surfaces of the cyclone. Overall, cyclones are a common type of control device used to prevent particulate matter from entering the atmosphere. They are widely used in industry to control emissions from dryers, crushers, incinerators, and kilns; and as precleaners for the control equipment that we will be discussing in subsequent lessons. 28Review Exercise 1. List the four major design features of the cyclone. 2. Different types of inlets have been developed to avoid 1, * inlet problems of * body ¢ duse discharge system © oudlet 3. Cyclones with smaller inlet and exit areas, or smaller body 2, turbulence diameters, are more/less efficient than are cyclones with larger diameters. 4. What will eventually happen if particulate matter is not 3. more removed from the cyclone collection hopper? a. The gas will make more curns in the cyclone body. b. Cyclone efficiency will increase. ¢. Particulate matter will be reentrained into the inner 5. Axial cyclones are commonly used in a. conjunction with wet scrubbers. b. baghouses. ¢. multicyclones. 6. Areas to consider when designing a cyclone for a specific application, are . size ane relative dimensions. fas temperature. incoming gas volumetric flow rate. dust concentration. all the above ppoge 4. ¢. Particulate matter will be reentrained into the inner vortex. 5. c. multicyclones. 7. Pressure drop is relaced to a. barometric pressure b. the amount of energy needed to move gas through a con- trol device. ¢. collection efficiency in a cyclone. d. band c only ¢. aand b only 6. ¢, all the above 29 7. 4. b and ¢ only8. Lise at least three advantages of using a cyclone to collect particulate matter. ? 9. List at least three possible problems associated with the use of 8. © low capital costs cyclones for collecting particulate matter. * low operating costs * conseruction with variety of materials * no moving parts 9. © possible plugging problems ‘+ limited efficiency in collection of small Particles © efficiency sensitive to varying inlet flow rates © wear problems References Bethea, R. M. 1978, Air Pollution Control Technology. New York: Van Nostrand Reinhold, pp. 117-144. Bhatia, M. V. and Cheremisinoff, P. N. 1977. Cyclones. Air Pollution Control and Design Hand- book. P. N. Cheremisinoff and R. A. Young, eds. pp. 281-$16, New York: Marcel Dekker, Inc. Caplan, K. 1964. All About Cyclone Collectors. Air Eng. Sept.: 28-38. Caplan, K. 1977. Source Control by Centrifugal Force and Gravity. Air Pollution Vol. IV Engineering Control of Air Pollution, A. C. Stern, ed. pp. 97-148, New York: Academic Press. Danielson, J. A., ed., 1975. Atr Pollution Engineering Manual, Research Triangle Park, NC: U.S Environmental Protection Agency. pp. 91-99. Doerschlag, C. and Miczek, G. 1977. How to Choose a Cyclone Dust Collector. Chem. Eng. Feb.: 64-72. Hesketh, H. E. 1979. Air Pollution Control. Ann Arbor: Ann Arbor Science Publishers, pp. 184-198. Koch, W. H. and Licht, W. 1977. New Design Approach Boosts Cyclone Efficiency, Chem. Eng. Nov.: 79-88. Lapple. C. E. 1950. Gravity and Centrifugal Separation, Industrial Hygiene Quarterly 11: 40-48. Leith, D. and Mehta, D. 1978. Cyclone Performance and Design. Atmos. Envtron. 7: 527-549 Schneider, A. G. 1975. Mechanical Collectors. Handbook for the Operation and Maintenance of Air Pollution Control Equipment, F. L. Cross, Jr. and H. E. Hesketh, eds. pp. 41-68, Westport: Technomic Publishing. 2.10