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Analysis of the performance of a novel dust collector combining cyclone


separator and cartridge filter

Article  in  Powder Technology · August 2018


DOI: 10.1016/j.powtec.2018.07.103

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Powder Technology 339 (2018) 695–701

Contents lists available at ScienceDirect

Powder Technology

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

Analysis of the performance of a novel dust collector combining cyclone


separator and cartridge filter
Biao Xie a,b, Shihang Li a,b, Hao Jin a,b, Shuda Hu a,b, Fei Wang a,b, Fubao Zhou a,b,c,⁎
a
Key Laboratory of Gas and Fire Control for Coal Mines, Ministry of Education, China University of Mining and Technology, Xuzhou 221116, China
b
School of Safety Engineering, China University of Mining and Technology, Xuzhou 221116, China
c
State Key Laboratory of Coal Resources and Mine Safety, China University of Mining and Technology, Xuzhou 221116, China

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

Article history: The cyclone separator has a simple structure but cannot effectively separate respirable dust of smaller particle
Received 7 February 2018 sizes. The cartridge filter has a high separation efficiency, but its pressure drop increases too rapidly, requiring
Received in revised form 30 July 2018 frequent cleaning operations. To make up for these defects, a novel cartridge-filtering cyclone combining both cy-
Accepted 31 July 2018
clone separator and cartridge filter is presented. Its performance parameters, including pressure drop, overall
Available online 01 August 2018
separation efficiency, grading efficiency, and cleaning interval, were studied experimentally and compared
Keywords:
with those of the common cyclone and cartridge filter. The cartridge-filtering cyclone first pre-separates the
Filter cartridge larger particles by swirling airflow, and then filters out the fine particles through the filter cartridges, thus
Pulse-jet cleaning slowing down the increasing rate of the pressure drop and forming denser dust layers attached to the surface
Swirling airflow of the filter cartridges. The experimental results show that the cartridge-filtering cyclone has a better dust re-
Pre-separation moval effect. At an inlet flow rate of 50 m3/h, the separation efficiency of the cartridge-filtering is 99.86%,
Dust layer which is 15.32% and 0.05% higher than that of the common cyclone and cartridge filter, respectively. In particular,
the cartridge-filtering cyclone has a preferable separation effect on fine particles, with a separation efficiency for
2.5 μm particles of 99.11%, which is 70.80% and 0.08% higher than that of the common cyclone and cartridge filter,
respectively. Compared with the cartridge filter, the cleaning interval of the cartridge-filtering cyclone is ex-
tended and the total dust emission is reduced. Over the whole experimental period, the average cleaning interval
and dust emission concentration of the cartridge-filtering cyclone are 1290.05 seconds and 12.06 mg/m3 respec-
tively, while that of the cartridge filter are 805.32 seconds and 14.59 mg/m3, respectively.
© 2018 Elsevier B.V. All rights reserved.

1. Introduction increase rapidly due to the dust that is deposited on the surface of the
filter cartridge, which not only leads to additional energy consumption
The cyclone separator, one of the most common dust collectors, has but also weakens the separation effect [6, 7]. Therefore, it is necessary to
been widely used in industrial production due to advantages such as the clean up the dust attached to the filter in time. Pulse-jet cleaning, one of
simple structure, easy operation, and low cost of operation and mainte- the common ways of filter regeneration, has been widely applied in in-
nance [1–3]. The dust particles can be separated from the airflow and dustry [8, 9]. However, the frequent cleaning operation will reduce the
trapped on the wall by the centrifugal force and then fall into the dust service life of the filter cartridge and increase the quantity of dust emis-
hopper by gravity. Larger-sized particles can be separated by this ap- sions, leading to a lower separation efficiency [10].
proach [4]. However, the separation capacity is weaker for respirable Various improvements of the cyclone separator and cartridge filter
dust of smaller particle sizes. In contrast, the cartridge filter can make have been made. Hsiao et al. [11] proposed to change the configuration
up for this defect. The dusty air passes through the filter cartridge and to optimize the cyclone performance. Huang et al. [12] installed a lami-
particles are trapped on its outer surface under the effect of diffusion, in- nator at the cyclone inlet to change the gas flow rate and particle num-
ertial impaction, and interception screening [5]. The clean air will then ber distribution at the entrance, which reduces the 50% cut size of the
pass through the filter cartridge and outflow. Relying on the high filtra- cyclone. Kepa [13] verified that a counter-cone placed in the appropri-
tion efficiency of the cartridge filter, fine dust particles can be effectively ate position can facilitate the separation efficiency of the cyclone. Al-
separated. However, the pressure drop of the cartridge filter will though these studies improved the overall separation efficiency of the
cyclone to a certain extent, fine dust particles cannot be effectively sep-
⁎ Corresponding author at: School of Safety Engineering, China University of Mining and
arated. Correspondingly, the improvement of the cartridge filter mainly
Technology, Xuzhou 221116, China. focuses on enhancing the cleaning effect and extending the cleaning in-
E-mail address: f.zhou@cumt.edu.cn (F. Zhou). terval. Li et al. [10] discovered that the extension of the cleaning interval

https://doi.org/10.1016/j.powtec.2018.07.103
0032-5910/© 2018 Elsevier B.V. All rights reserved.
696 B. Xie et al. / Powder Technology 339 (2018) 695–701

and reduction of dust emission can be achieved by placing a cylindrical Fig. 1b presents the geometry and dimensions of the cartridge-filter-
cone inside the filter cartridge. Through experiments and numerical ing cyclone and pleated filter cartridge. The body diameter of the car-
simulation, Chen et al. [14] concluded that significant improvement of tridge-filtering cyclone is 100 mm and the inlet is tangential and
the cleaning efficiency and quality can be obtained by using filter car- rectangular with a size of 40 × 30 mm. The length and outer and inner
tridges with convergent trapezoidal pleats. In practical engineering ap- diameter of the filter cartridge are 150 mm, 25 mm, and 16 mm, respec-
plications, the cyclone separator, serving as pre-separation equipment, tively, and the pleat number is 40.
is usually used in series with the cartridge filter separating fine particles
as secondary dust removal equipment, achieving a preferable separa-
2.2. Dust
tion effect and extension of the cleaning interval [15], but the consider-
ably large volume and high pressure drop of the whole dust removal
In this experiment, the dust is silicon dioxide particles that were
system are drawbacks.
gathered after grinding. The proportion of PM2.5 and PM10 is 4.51%
In this research, a novel cartridge-filtering cyclone equipped with
and 69.82%, respectively. The medium diameter of the particles is 8.24
small pleated filter cartridges and a pulse-jet cleaning system based
μm. The particle size distribution is shown in Fig. 2.
on the common cyclone is presented. Most of larger particles which
size is larger than 2.5 μm are pre-separated by the swirling airflow in
its interior. Subsequently, the fine particles which size is not N2.5 μm 2.3. Experimental equipment and procedure
are filtered out by the filter cartridge. The performance parameters of
the cartridge-filtering cyclone, including pressure drop, overall separa- The schematic diagram of the experimental setup is shown in Fig. 3.
tion efficiency, grading efficiency, and cleaning interval, were studied Dust particles are quantitatively supplied to the cartridge-filtering cy-
through experiments. The results show that it has special advantages clone by the dust feeder (LSC-6 type) at a certain rate, which is precisely
over the conventional cyclone separator and cartridge filter, effectively controlled in the range of 0–50 g/min. A small frequency conversion fan
enhancing the effect of separation and capture of particles. (TF-A750 type) connected to the outlet provides negative pressure for
the entire experimental system. A high-precision filter is installed in
2. Experimental front of the fan inlet to capture the unseparated dust. A pressure tank
is used to store high-pressure gas. The filter cartridges will be cleaned
2.1. Cartridge-filtering cyclone after the high-pressure gas is ejected through the nozzle. An electro-
magnetic pulse valve (DMF-Z-20 type) is used to control the opening
The shell of the cartridge-filtering cyclone shown in Fig. 1a is made and closing of the pressure tank. A pressure gauge is used to monitor
of plexiglass. It contains four pleated filter cartridges that are connected the gas pressure inside the pressure tank. A main valve is used to regu-
to the outlet. Four nozzles with a diameter of 5 mm connected to the in- late the inlet flow rate of the dust collector. A flow meter (LUG-DN32
jection pipe are placed above the filter cartridges. The pipe inlet is fitted type) is used to measure the value of the inlet flow rate. The pressure
with an electromagnetic pulse valve; its opening and duration can be drop is measured using a U-tube manometer. The dust monitor detector
controlled by the pulse controller. The cleaning pressure is 0.4 MPa. (DFM/ZY type) installed at the outlet of the cartridge-filtering cyclone
The pulse duration is 0.15 ms. The maximum pressure drop before displays the dust emission concentration.
cleaning is 2400 pa. The pleated filter cartridges with fine flame Based on the feeding rate and time of the dust feeder, the mass of the
retardancy are able and durable to filter high-temperature flue gas dust into the experimental system mi can be calculated. Most of the dust
which temperature is N500 degrees Celsius. The filter media is woven was separated by the cartridge-filtering cyclone. A small unseparated
stainless steel mesh which is made for filter cartridge. The filtration amount was finally concentrated in the high-precision filter. After the
area of a filter cartridge is 0.108 m2. The material thickness is 0.8 mm. experiment was completed, the mass of the dust escaping from the car-
The gap between the metal fibers is approximately 5–10 μm based on tridge-filtering cyclone mo (i.e., the increased mass of the high-precision
SEM (scanning electron microscope) observations. filter) can be obtained. The overall separation efficiency E can then be

Fig. 1. Schematic view of the cartridge-filtering cyclone (a. structure diagram, b. geometry parameters).
B. Xie et al. / Powder Technology 339 (2018) 695–701 697

Fig. 2. Particle size distribution of the dust.

calculated using Eq. (1). common cyclone. Dusty air enters the cyclone from the tangential en-
trance, with particles settling into the hopper under the effect of
mi −mo swirling airflow and clean air flowing out from the outlet. Fig. 4b refers
E¼  100% ð1Þ
mi to the cartridge-filtering cyclone. The difference between the cartridge
filter shown in Fig. 4c and the cartridge-filtering cyclone is that the for-
The particle size distribution of the dust collected on the high-preci- mer cannot produce swirling airflow due to the dusty air entering
sion filter was measured with a laser particle size analyzer. A certain straight from the lower inlet; thus, it relies only on the filter cartridges
dust particle diameter is represented by di. The mass fraction of the to separate the dust particles.
dust particle with size di to the dust collected on the high-precision filter
is fo(di) and that to the dust entering the cartridge-filtering cyclone is fi 3. Results and discussion
(di). The grade efficiency G(di) can then be calculated using Eq. (2).
3.1. Pressure drop
mi f i ðdi Þ−mo f o ðdi Þ
Gðdi Þ ¼  100% ð2Þ
mi f i ðdi Þ If the pressure drop, one of the important indexes to evaluate the
performance of the dust collector, is too large, more energy needs to
The experimental system is used to test the performance parameters be consumed [16]. In this experiment, the U-tube manometer was
of the three different dust collectors shown in Fig. 4. Fig. 4a refers to the used to measure the pressure drop under different flow rates. It was
found that the pressure drop of the three dust collectors increased
with increasing inlet flow rate and the difference of the pressure drop
between them increased gradually, as shown in Fig. 5a. At the same
inlet flow rate, the common cyclone had the least pressure drop,

Fig. 3. Schematic diagram of the experimental setup (1. U-tube manometer; 2. dust feeder;
3. flow meter; 4. cartridge-filtering cyclone; 5. pressure tank; 6. pressure meter; 7. dust Fig. 4. Three different types of dust collectors (a. common cyclone; b. cartridge-filtering
detector; 8. main valve; 9. high-precision filter; 10. air blower). cyclone; c. cartridge filter).
698 B. Xie et al. / Powder Technology 339 (2018) 695–701

Fig. 5. Evolution of the pressure drop of different dust collectors (a. depending on the inlet flow rate, b. depending on the time).

which is mainly due to the kinetic energy loss caused by the viscosity filter can be divided into three stages, namely, accelerating increase, de-
and friction of the swirling airflow. The pressure drop of the cartridge celerating increase, and constant increase [17]. In the final stage, it
filter was higher, which is mainly produced as the airflow passes tended to be smooth, closing to 2400 Pa. At this time, the cartridge-fil-
through the filter cartridges. The maximum pressure drop occurred in tering cyclone was still undergoing a period of accelerating increase.
the cartridge-filtering cyclone because it includes the kinetic energy Therefore, it can be inferred that the cartridge-filtering cyclone can
loss caused by the swirling airflow and passing through the filter car- slow down the rise rate of the pressure drop compared with the car-
tridges. In addition, it is worth noting that the pressure drop of the car- tridge filter.
tridge-filtering cyclone was smaller than that caused by the series The separation mechanism of the cartridge-filtering cyclone can be
connection of the common cyclone and cartridge filter, although ex- divided into two processes: larger particles settle to the dust hopper
ceeding each of them. by the centrifugal force and gravity; and the smaller particles are
In the running state, the pressure drop is not a fixed value but rather intercepted on the surface of the filter cartridges. The retardation of
dynamically changing over time. By setting the inlet flow rate to 50 m3/ the pressure drop rise of the cartridge-filtering cyclone attributes to
h (the inlet airflow velocity is 11.57 m/s) and inlet dust concentration to the effect of pre-separation caused by the swirling airflow. Using the
8000 mg/m3, the evolution of the pressure drop of the three dust collec- laser particle size analyzer to measure the particle size at different loca-
tors was recorded in the time range of 1000 s, as shown in Fig. 5b. The tions, it was found that the dust taken from the dust hopper has a larger
pressure drop of the common cyclone did not show significant pressure particle size, with an average size of 13.62 μm, and the dust taken from
changes compared with the start of experiment. In contrast, the pres- the surface of the filter cartridge is smaller, with an average size of 1.82
sure drop of the cartridge filter increased rapidly with a rate signifi- μm. The SEM photographs are shown in Fig. 6. Due to the absence of
cantly higher than that of the cartridge-filtering cyclone, which was swirling airflow and the pre-separation effect in the cartridge filter, a
exceeded by the cartridge filter after reaching the same value of 732 large number of dust particles of different sizes were directly
Pa at a time of 223 s. Overall, the pressure drop changes of the cartridge intercepted on the surface of the filter cartridges, which caused a faster
accumulation of dust cakes and resulted in the rapid increase of the
overall pressure drop. Correspondingly, the dust accumulation rate on
the surface of the filter cartridges inside the cartridge-filtering cyclone
is slower, representing the slower rise of the pressure drop.

3.2. Overall separation efficiency

By setting the inlet dust concentration to 2500 mg/m3 at different


inlet flow rates, the overall separation efficiency of the dust collectors
was calculated with Eq. (1). The results are shown in Fig. 7a. The sepa-
ration efficiency of the common cyclone greatly changed in the range
of 75% to 85% at different inlet flow rates. It was increasing before the
inlet flow rate reached 40 m3/h because the centrifugal force on the par-
ticles increases with increasing inlet flow rate in a certain range, which
contributes to the separation of particles in the dusty air. After the inlet
flow rate reached 50 m3/h, the separation efficiency gradually de-
creased due to shortening of actuation duration of the swirling airflow
on particles and increase of the short-circuit flow and turbulence inten-
sity caused by excessive inlet flow. Compared with the common cy-
clone, the separation efficiency of the cartridge filter and cartridge-
filtering cyclone (N 98%) had significantly improved. With the changing
Fig. 6. SEM photograph of dust particles at different positions of the cartridge-filtering inlet flow rate, the separation efficiency presented the same trend; it
cyclone: (a) inlet, (b) dust hopper, and (c) surface of the filter cartridge. began to decrease after increasing to the maximum. The difference
B. Xie et al. / Powder Technology 339 (2018) 695–701 699

Fig. 7. Separation efficiency (a) and dust emission concentration (b) of the dust collectors under different inlet flow rates.

was that the cartridge filter achieved the maximum of 99.87% at an inlet emission concentrations, with minimums of 3.25 mg/m3 and 2.75 mg/
flow rate of 40 m3/h and the cartridge-filtering cyclone achieved the m3, respectively. At an inlet flow rate of b40 m3/h, the emission concen-
maximum of 99.89% at 60 m3/h. The separation effect on fine particles tration of the cartridge filter was lower than that of the cartridge-filter-
of the filter cartridge mainly depends on the dust layer formed on the ing cyclone. The opposite was true when the inlet flow rate exceeded
surface of the filter material, rather than merely relying on direct cap- 50 m3/h. Therefore, the dusty airflow in need of separation is larger
ture of the filter fiber layer. The existence of the dust layer can enhance and the separation performance of the cartridge-filtering cyclone is
the sieve effect in the filtration process, greatly improving the separa- better.
tion efficiency [18]. Therefore, the dust layer can be formed in a shorter
time as the inlet flow rate increases appropriately, which is beneficial to 3.3. Grading efficiency
the reduction of the dust emission and improves the separation effect.
However, if the inlet flow rate is too large, the filtration velocity will rap- To accurately evaluate the ability of separation of dust particles of
idly rise and the differential pressure between the inside and outside of different sizes, the grading efficiency of the three dust collectors was ex-
the filter cartridge will increase significantly, which forces parts of the perimentally measured. Based on the previous results of this work, it is
fine particles to escape through the gaps among the filter fibers, leading known that the dust layer on the surface of the filter cartridge will
to the decrease of the separation efficiency. Because the swirling airflow greatly affect the separation effect. Therefore, the measurement was
in the cartridge-filtering cyclone pre-separates larger particles and re- started after the formation of the dust layer. The inlet dust concentra-
duces the dust attached to the filter cartridge, a larger inlet flow rate is tion and inlet flow rate were set to 2500 mg/m3 and 50 m3/h, respec-
required at the same period to form an effective dust layer for achieving tively. The grading efficiency calculated with Eq. (2) is shown in Fig. 8.
a maximum separation efficiency. The common cyclone was less efficient in separating smaller particles,
The average dust emission concentration of the three dust collectors with a separation efficiency for 2.5 μm particles of 28.31% and 50% cut
is shown in Fig. 7b. The common cyclone had the highest emission con- sizes of 3.79 μm. The cartridge filter and cartridge-filtering cyclone had
centration, with a minimum of 386.5 mg/m3, far exceeding the environ- a preferable separation effect on fine particles, with a separation effi-
mental standard. Therefore, it is difficult to meet the requirements of ciency for 2.5 μm particles of 99.03% and 99.11%, respectively. The grad-
dust separation only by means of the common cyclone. In contrast, ing efficiency of the cartridge-filtering cyclone was slightly higher than
the cartridge filter and cartridge-filtering cyclone had much lower that of the cartridge filter as the dust layer composed of fine particles is
denser, with lower porosity and higher filtration accuracy, after larger
particles were separated by the swirling airflow in the cartridge-filter-
ing cyclone.
Fig. 9 shows the dust emission concentration of different size grades.
The emission concentrations of the cartridge filter and cartridge-filter-
ing cyclone were b5% of that of the common cyclone in each size
grade; that of the common cyclone of the grade with a size b5 μm
reached up to 290.92 mg/m3. The emission concentration of the car-
tridge-filtering cyclone was slightly lower than that of the cartridge fil-
ter, with a difference of 0.89 mg/m3 when separating particles with
sizes below 2.5 μm. The concentration difference decreased with in-
creasing size grade, that is, the cartridge-filtering cyclone is of advan-
tage when separating smaller dust particles.

3.4. Cleaning interval

The previously mentioned experimental results indicate that the


common cyclone has a weaker separation effect on fine dust particles,
which hardly meets the needs of industrial dust removal. Therefore,
the research emphasis is placed on comparing the application effects
Fig. 8. Grading efficiency curves of the different dust collectors. of the cartridge-filtering cyclone and cartridge filter, with differences
700 B. Xie et al. / Powder Technology 339 (2018) 695–701

steady. After the pressure drop reached 2400 Pa, the electromagnetic
pulse valve was opened and the filter cartridges were cleaned by
pulse-jet airflow. The dust cake attached to filter cartridges significantly
decreased by cleaning, which greatly reduced the pressure drop. Subse-
quently, the next round of filtration–cleaning process was performed. In
the monitoring time of 16,000 s, the cartridge filter and cartridge-filter-
ing cyclone went through 19 and 12 times of cleaning respectively. The
cleaning interval of them gradually decreased and finally stabilized. The
average cleaning intervals of the cartridge filter and cartridge-filtering
cyclone were 805.32 s and 1290.05 s respectively. The average residual
pressure drops of the first twelve times for the cartridge filter were
1138, 1210, 1294, 1416, 1434, 1493, 1527, 1532, 1562, 1554, 1567 and
1564 Pa, with an average of 1440.9 Pa, while the average residual pres-
sure drop of the first twelve times for the cartridge-filtering cyclone was
1371.7 Pa. Therefore, the cartridge-filtering cyclone slows down the
dust accumulation rate on the filter cartridges, thus extending the
cleaning intervals and reducing the residual pressure drop [19].
The dust emission concentration and pressure drop were measured
simultaneously. At the initial stage of the experiment, the dust emission
concentration was higher because the dust layer on the filter cartridges
had not yet completely formed. It subsequently gradually decreased and
finally reached a stable level. In the period of pulse-jet cleaning, the dust
emission concentration rose sharply in a short time and then recovered
Fig. 9. Dust emission concentration of different size grades. to the normal level. When cleaning for the first twelve times, the dust
emission concentration of the cartridge filter reached the maximum of
66.52, 67.24, 66.12, 65.09, 65.30, 62.81, 59.24, 59.70, 56.05, 57.25,
mainly reflecting the dust emission concentration and cleaning interval. 56.88 and 53.18 mg/m3, respectively, with an average of 61.28 mg/m3,
The evolution of the dust emission concentration and pressure drop in while the average peak concentration of the cartridge-filtering cyclone
clean-on-demand mode is shown in Fig. 10. The initial experimental was 63.55 mg/m3. The average dust emission concentrations of the car-
conditions were set as follows: inlet dust concentration of 8000 mg/ tridge filter and cartridge-filtering cyclone over the whole experimental
m3, inlet flow rate of 50 m3/h, maximum pressure drop before cleaning period were 14.59 mg/m3 and 12.06 mg/m3, respectively. The experi-
of 2400 Pa. The pressure drop continuously increased from the begin- mental results show that the cartridge-filtering cyclone enhances the
ning of experiment, initially rapidly rising and subsequently becoming dust emission concentration relative to the cartridge filter at the instant

Fig. 10. Evolution of the pressure drop and dust emission concentration.
B. Xie et al. / Powder Technology 339 (2018) 695–701 701

of cleaning but decreases the average dust emission concentration over Acknowledgements
the whole experimental period.
Under the effect of pulse-jet airflow, dust attached to the filter car- This work was supported by the Program for Changjiang Scholars
tridge will instantly fall off and diffuse inside the dust collector, forming and Innovative Research Team in University [grant number IRT17R103];
a local dust cloud. Larger dust particles or agglomerations will rapidly the Priority Academic Program Development of Jiangsu Higher Educa-
fall into the dust hopper by gravity. Fine particles in suspension, most tion Institutions.
of which will reattach to the surface of the filter cartridge, forming a
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tering cyclone has a separation efficiency for 2.5 μm particles of 99.11%, [19] S. Calle, P. Contal, D. Thomas, D. Bemer, D. Leclerc, Evolutions of efficiency and pres-
sure drop of filter media during clogging and cleaning cycles, Powder Technol. 128
which is 70.80% and 0.08% higher than that of the common cyclone and (2002) 213–217.
cartridge filter, respectively. Because of the improved filtration accuracy [20] L.M. Lo, D.R. Chen, D.Y.H. Pui, Experimental study of pleated fabric cartridges in a
of the dust layer, extended cleaning intervals, and fewer cleaning times, pulse-jet cleaned dust collector, Powder Technol. 197 (2010) 141–149.
the cartridge-filtering cyclone could effectively reduce the total dust
emission over the whole experimental period. The average dust emis-
sion concentration of the cartridge-filtering cyclone is 12.06 mg/m3,
which is 2.53 mg/m3 lower than that of the cartridge filter.

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