11/9/18

AIR POLLUTION
CYCLONES

ü Have knowledge of air pollution:

Types, sources, properties, impacts, standards

ü Learn about transport and the environment

ü Be knowledgeable about the fate and dispersion of

air pollutants in the environment

ü Gain familiarity with indoor air quality

ü Be knowledgeable about air pollution control

Methods and equipment

INTRODUCTION

• Cyclone separators have been used for over 100 years, and are
still one of the most widely used of all industrial gas-cleaning
devices because they are:

» Inexpensive
» No moving parts
» Can withstand harsh operating conditions

• Cyclones are not adequate to meet air pollution regulations by

themselves, but are more useful than gravity settlers
(higher settling velocities)

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OUTLINE

• Generalities
» Description
» Categories and dimensions
» Advantages and disadvantages
• Theory of Collection Efficiency
• Design Considerations
» Collection efficiency
» Pressure drop
» Other considerations

GENERALITIES
Description
4. Cleaned gas exits from the
top through a “vortex-finder”
2. Centrifugal force (up to tube, and particles exit from
2 orders of magnitude bottom through a pipe
larger than gravity sealed by a valve
forces) and inertia
cause particles to
move outward, collide
with the outer wall,
and then slide 1. Particulate-laden gas enters
downward to the
bottom of the device tangentially near the top of
the cyclone, and is forced
into a downward spiral
3. Centrifugal force Near
the bottom, the gas
reverses its downward
spiral and moves
upward in a smaller
inner spiral

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GENERALITIES
Description (cont’d)
• Cyclones are used as precleaners for more expensive final
control devices (baghouses/ESPs), or in process industries
(refineries/food)

• Efficiency varies greatly with particle size and cyclone design

• Some manufacturer advertise 90-98% efficiency for PM

larger than 5-10 microns

• Higher efficiency Þ higher pressure drop Þ higher cost

GENERALITIES
Categories and Dimensions
3 categories: 1-High efficiency 2-Conventional 3-Throughput

General relationship of
collection efficiency versus Standard cyclones dimensions
particle size for cyclones

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GENERALITIES
Advantages and disadvantages
• Advantages:
» Very commonly used (not much changed in their
design for decades)
» Low capital cost
» Ability to operate at high temperatures
» Low maintenance requirements because there are no
moving parts

• Disadvantages:
» Low efficiencies (esp. for very small particles< 5-10 µ)
» High operating costs (due to pressure drop)

THEORY OF COLLECTION EFFICIENCY

Dt = Distance traveled
Inlet Velocity

(Perimeter per turn) x # turns

=
Inlet Velocity

= 2pRNe/Vi

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THEORY OF COLLECTION EFFICIENCY

(cont’d)
• Number of turns in the outer vortex:

Ne =
1[L +L c ]
b
H 2
Ne = number of effective turns
H = height of inlet duct, m or ft
Lb = length of cyclone body, m or ft
Lc = length (vertical) of cyclone cone, m or ft

THEORY OF COLLECTION EFFICIENCY

dvr vr Fe
(cont’d) dt
+ =
t¢ Mp
t’= C r d p
2 /18µ
p

• To be collected, particles must strike the

wall within the amount of time that the gas
travels in the outer vortex

• Gas residence time in outer vortex:

Dt = 2pRNe/Vi
R = cyclone body radius
Vi = gas inlet velocity

• Max. radial distance traveled by a particle:

width of inlet duct (W). Assuming
centrifugal force quickly accelerates particle
to its terminal velocity (Vt) in the outward
(radial) direction, Vt is achieved when
opposing drag force = centrifugal force

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THEORY OF COLLECTION EFFICIENCY

(cont’d)
• Terminal velocity that will just allow a particle to be collected in
time Dt:

Vt = W/Dt; Dt = 2pRNe/Vi

Vt = terminal velocity in the radial direction, m/s

Function of particle size, and equal to
characteristic time x external force per unit mass
From Chapter 3, recall:
dvr vr Fe
+ = t’= C rpd2p/18µ
dt t¢ Mp

THEORY OF COLLECTION EFFICIENCY

(cont’d)
• For Stokes regime flow and spherical particles under a
centrifugal force, the terminal velocity becomes:
2 2
dp (rp - rg ) Vi
Vt =
18µR
dp = diameter of the particle, m
Vi = gas inlet velocity, m/s
rp = density of the particle, kg/m3
rg = gas density, kg/m3
µ = gas viscosity, kg/m-s
R = cyclone body radius, m

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THEORY OF COLLECTION EFFICIENCY

(cont’d)
• Using:
2 2
dp (rp - rg ) Vi
Vt =
18µR
From previously, we have:
Vt = W/Dt
Dt = 2pRNe/Vi

By substitution, we obtain:
9µW
dp = [ ]1/ 2
pN eVi (r p - r g )

THEORY OF COLLECTION EFFICIENCY

(cont’d)

• In theory, all particles of size dp or larger

should be collected with 100% efficiency

• In Practice, this does not happen because it

was assumed that:
» Vt was reached instantly
» Slipping factor, C = 1
» Number of turns = Ne 1[L +L c ]
b
H 2

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DESIGN CONSIDERATIONS
Collection Efficiency
1
hj =
1+ (d pc / d pj ) 2
9µW
dpc = [ 1/2
]
2 pNe Vi (rp - rg )
hj = collection efficiency for the jth particle
size range
dpj =characteristic diameter of the jth
particle size range
dpc = diameter of particles collected with
50% efficiency
• Overall efficiency: ho = Shjmj
Particle collection efficiency versus
• If dpj = dpc Þ hj = 50% particle size ratio for standard
conventional cyclones
• Pt = 1 - ho

EXAMPLE 1

• Consider a conventional
cyclone of standard Size range, µm Mass % in size
range
proportions as described
0-2 1
by Lapple (1951), with a 2-4 9
body diameter of 1 meter. 4-6 10
For air with a flow rate of 6-10 30
150 m3/min at T=350 K 10-18 30
and 1 atm, containing 18-30 14
particles with a density of 30-50 5
1600 kg/m3 and a size 50-100 1

distribution as given,
calculate the overall Back to Example 2
collection efficiency Back to Example 3

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EXAMPLE 1 (cont’d)

» First we calculate dpc using the equation

9µW
dpc = [ ]1 / 2
2pNe Vi (rp - rg )

The viscosity of air at T=350 K is 0.075 kg/m-hr, and

the density is 1.01 kg/m3 (Appendix B in the book).
The inlet velocity is the volumetric flow divided by the
inlet area (H x W):
150m3 1 1200m
Vi = x =
min (0.5m)(0.25m) min
1/2
é kg ù
ê 9(0.075 )(0.25) ú
dpc =ê m.hr ú = 6.26 x10-6 m = 6.3µm
ê 2p(6)(1200 m min é kg ù
)(60 ) ê(1600 - 1) 3 ú ú
êë min hr ë m û úû

EXAMPLE 1 (cont’d)

» Next we determine the

collection efficiency for
each size range from the
figure or the equation
1
hj =
1 + (dpc / dpj )2
» The arithmetic midpoint
of the range is often used
as the characteristic Particle collection efficiency versus
particle size ratio for standard
particle size conventional cyclones

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EXAMPLE 1 (cont’d)

» It is convenient to construct the following table

j Size range dpj, dpj/dpc hj mj, % collected
(µm) µm % hjmj
1 0-2 1 0.159 0.02 1 0.02
2 2-4 3 0.476 0.18 9 1.62
3 4-6 5 0.794 0.39 10 3.9
4 6-10 8 1.27 0.62 30 18.6
5 10-18 14 2.22 0.83 30 24.9
6 18-30 24 3.81 0.94 14 13.2
7 30-50 40 6.35 0.98 5 4.9
8 50-100 75 11.9 0.99 1 1
8
68.1 h0 = å hjmj = 68.1%
j =1

» The overall collection efficiency of this cyclone for this

particular mixture is approximately 68%, or 0.68

DESIGN CONSIDERATIONS
Collection Efficiency (cont’d)
• Effect of operating condition changes on cyclone
performance

Variable Change Efficiency Relationship

Gas flow rate Increase Increase Pt2/Pt1 = (Q1/Q2)0.5
Gas viscosity Increase Decrease Pt2/Pt1 = (μ2/ μ1)0.5
Density difference Increase Increase Pt2/Pt1 = [(ρp- ρg)1/ [(ρp- ρg)2]
Dust loading Increase Increase Pt2/Pt1 = (L1/ L2)0.18

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EXAMPLE 2

• Estimate the new efficiency of the cyclone of Example 1 if

(a) the air flow rate is increased to 200 m3/min or (b) the
air temperature is increased to 400 k.
0.5 0.5
æ Q1 ö æ 150 ö
» (a) Pt2 = Pt1 çç ÷÷ = 0.32ç ÷ = 0.28
è Q2 ø è 200 ø
Thus, h2 = 0.72 = 72%

» (b) An increase in air temperature has two main effects: it

increases the volumetric flow rate to 171 m3/min and it increases
the air viscosity to 0.083 kg/m-hr. The overall effect on
penetration is the product of the individual effects.
0.5 0.5 0.5 0.5
æQ ö æ µ2 ö æ 150 ö æ 0.083 ö
Pt2 = Pt1 çç 1 ÷÷ çç ÷÷ = 0.32ç ÷ ç ÷ = 0.315 ~ 0.32
è Q2 ø è µ1 ø è 171 ø è 0.075 ø
Thus, h2 = 0.68 = 68% (no change)

DESIGN CONSIDERATIONS
Pressure Drop

• Besides the efficiency of particulate removal, we need to

calculate the Pressure Drop (DP) to design for the Fan
Power Input

• Higher efficiencies are obtained by forcing the gas

through the cyclone at higher velocities ® increased
pressure drop ® increased fan work ® increased
operating cost

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DESIGN CONSIDERATIONS
Pressure Drop (cont’d)
• Static pressure drop

DP=1rgVi2Hv Hv =KHW
2 D 2
e

DP = pressure drop, N/m2 or Pa

rg = gas density, kg/m3
Vi = inlet gas velocity, m/s
Hv = pressure drop, expressed in number of inlet velocity heads
K = a constant that depends on cyclone configuration and
operating conditions (range: 12 to 18)

DESIGN CONSIDERATIONS
Pressure Drop (cont’d)

Once the pressure drop has been calculated,

the fluid power requirement can be obtained:

! f = QDP
w
wf = work input rate into the fluid (fluid power),
W
Q = volumetric flow rate, m3/s

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Hv =KHW ! f = QDP
w
EXAMPLE 3 D 2 DP=1r V 2H
e g i v
2
• For the cyclone of Example 1, assume a K value of 15 and
calculate (a) the cyclone pressure drop in kPa, and (b) the
fluid power consumed in the cyclone in kW.

» (a) » (b)
(0.5)(0.25) 150m3 1 min
Hv = 15 = 7.5 !f =
w x1515N / m2 x
(0.5)2 min 60s
1200m 1 min ! f = 3788
N.m
Vi = x = 20m / s w = 3788 J / s = 3.79kW
min 60s s
1 kg m2 1N
DP = x1.01 3 x 400 2 x x 7.5
2 m s 1kg.m / s 2

DP = 1515N / m2 = 1.515kPa

DESIGNING A CYCLONE

Typical design parameters:

» Vinlet = Typical Inlet Velocity = 15 - 30 m/s

» ΔP = Typical Pressure Drop
= 0.5 - 10 velocity heads
250 - 4000 Pa
1 - 16 inches of water
» Typical K: 12 - 18 (can be set as 16)

Trial and error procedure

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DESIGNING A CYCLONE (cont’d)

Cyclone design procedure:

1. Select body diameter

D ® H, W, De, S, Lb, Lc, dd
2. Calculate Diameter of particles collected with 50% efficiency
(dpc)
3. Calculate h
4. If hcalculated < hdesired, select a smaller D and return to Step 1
5. If hcalculated > hdesired, then check on DP

If DP is too large, then:

– Choose a different type of cyclone and return to Step 1, or
– Split flow gas into 2 cyclones in parallel

OTHER DESIGN CONSIDERATIONS

Multi-tube cyclone
• Impractical to use a single cyclone to
treat a large volume of gas Þ use
several cyclones in parallel (multiple-
tube cyclone or multiclone) ® 90%
efficiency for 5- to 10-micron particles
(small diameter tubes)

• Cyclones in series increase overall

efficiency at the cost of significant
increase in pressure drop ®
efficiency of second cyclone <
efficiency of first
(most large particles removed by first)

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EXAMPLE 4

Design a conventional Lapple cyclone to function as a Size Mass % in

range, µm size range
precleaner on a gas stream that flows at 120 m3/min.
The cyclone must achieve a minimum overall efficiency 0-2 1
of 70% for the following particulate distribution, with a 2-4 9
maximum allowable ΔP of 3000 Pa. The particulate 4-6 10
density is 1500 kg/m3, the gas density is 1 kg/m3, and 6-10 30
the gas viscosity is 0.07 kg/m-hr. Specify your final 10-18 30
choice of body diameter , overall cyclone efficiency, 18-30 14
inlet gas velocity, and pressure drop (Assume K=14) 30-50 5
50-100 1
» The trial-and-error solution is easily achieved
using a spreadsheet. Note that many of the 1é L ù
Ne = Lb + c ú
variables in the equations of Ne, dpc and h are H êë 2û
1/2
functions of one key parameter – the cyclone é 9µW ù
dpc = ê ú
body diameter, D. êë 2pNe Vi (rp - rg )úû
1
hj =
1 + (dpc / dpj )2
h0 = å hjmj

EXAMPLE 4 (cont’d)

» Set up the spreadsheet with all calculations based on the cell

where we input body diameter. Then, all that needs to be done is
to input different values of D until a feasible solution is obtained.

» By a feasible solution, we mean one that meets all the listed

constraints - in this case, an efficiency greater than or equal to
70%, and a pressure drop less than or equal to 3000 Pa.

» Often, the solution can be optimized depending on whether a

smaller pressure drop or larger efficiency is more important, but

» keep in mind that the final cyclone diameter that is specified

should result in a cyclone that can be readily purchased or built
without incurring extraordinary costs for special sizing.

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EXAMPLE 4 (cont’d)

» Since the problem specifies a » Other formulas to be

conventional Lapple cyclone, choose a coded into the
type 3 cyclone from the table; the spreadsheet are:
dimensional relationships are: H=0.5D; 1é L ù
W=0.25D; De=0.5D; Lb=2D; Lc=2D Ne = Lb + c ú
H êë 2û
1/2
é 9µW ù
dpc = ê ú
ëê 2pNe Vi (rp - rg )ûú
1
hj =
1 + (dpc / dpj )2
h0 = å hjmj

Vi = Q /(HW)

HW
Hv = K 2
De
1 2
DP = rg Vi Hv
2

EXAMPLE 4 (cont’d)

» We must also remember to include conversion factors (such as 60

min/hr) when needed to make the units work.

» Once the spreadsheet is built, start simply by entering a value of

D, say 1 m. If the efficiency is too low, then choose a smaller D. If
the pressure drop is too high, then choose a larger D.

» Keep trying values of D until a feasible solution is obtained.

» If it turns out that a feasible solution does not exist, one or more
constraints must be relaxed, or a different type of cyclone must be
chosen.

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EXAMPLE 4 (cont’d)

» The figure displays a spreadsheet

to solve this problem. Using the
spreadsheet, 4 values of D were
entered and the following results
were obtained:

D,m h, % ΔP, Pa ΔP, in H2O

1 61.8 896 3.6
0.9 66.5 1366 5.5
0.8 71.4 2188 8.8
0.7 76.5 3732 15

» Based on the results shown

above, a diameter of 0.8 m is
selected

OTHER DESIGN CONSIDERATIONS

Pressure Drop

• Solution to pressure drop:

fan or blower in the system
• If system is already under pressure: no problem
• If not, place the fan/blower before or after the
cyclone
» Upstream: fan is exposed to dirty gas Þ particles
collect on the blades and throw it out of balance
» Downstream: cyclone operates under weak vacuum Þ
if seal not very good, air will be sucked in and will re-
entrain the collected particles Þ degraded overall
efficiency

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Some properties of air

Back to Example 1

End of Lecture

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