CYCLONE SEPARATORS Jayeeta Mitra

CYCLONE SEPARATORS

➢Cyclone separators provide a method of removing particulate

matter from air or other gas streams at low cost and low
maintenance.
➢Cyclones are somewhat more complicated in design than simple
gravity settling systems, and their removal efficiency is much better
than that of settling chamber.
➢Cyclones are basically centrifugal separators, consists of an upper
cylindrical part referred to as the barrel and a lower conical part
referred to as cone (figure 1).
➢ They simply transform the inertia force of gas particle flows to a
centrifugal force by means of a vortex generated in the cyclone
body.

JAYEETA MITRA, AGFE DEPT.

 CYCLONE SEPARATORS

➢The particle laden air stream enters tangentially

at the top of the barrel and travels downward
into the cone forming an outer vortex.

➢The increasing air velocity in the outer vortex

results in a centrifugal force on the particles
separating them from the air stream.

➢When the air reaches the bottom of the cone, it

begins to flow radially inwards and out the top as
clean air/gas while the particulates fall into the
dust collection chamber attached to the bottom of
the cyclone.

JAYEETA MITRA, AGFE DEPT.

CYCLONE SEPARATORS
A high speed rotating (air)flow is established within a cylindrical or conical container called
a cyclone.
Air flows in a helical pattern, beginning at the top (wide end) of the cyclone and ending at the
bottom (narrow) end before exiting the cyclone in a straight stream through the centre of the
cyclone and out the top.
Larger (denser) particles in the rotating stream have too much inertia to follow the tight curve
of the stream, and strike the outside wall, then fall to the bottom of the cyclone where they can
be removed.
In a conical system, as the rotating flow moves towards the narrow end of the cyclone, the
rotational radius of the stream is reduced, thus separating smaller and smaller particles.
The cyclone geometry, together with volumetric flow rate, defines the cut point of the cyclone.
This is the size of particle that will be removed from the stream with a 50% efficiency.
Particles larger than the cut point will be removed with a greater efficiency, and smaller
particles with a lower efficiency.

JAYEETA MITRA, AGFE DEPT.

Cyclones have no moving parts and available in many
shapes and sizes, for example from the small 1 and 2
cm diameter source sampling cyclones which are used
for particle size analysis to the large 5 m diameter
cyclone separators used after wet scrubbers, but the
basic separation principle remains the same.
Three different types of cyclone are shown in figure.
First figure i.e. (a) shows a cyclone with a tangential
entry.
These types of cyclones have a distinctive and easily
recognized form and widely used in powder and
cement plants, feed mills and many other process
industries.

JAYEETA MITRA, AGFE DEPT.

Figure (b) shows the axial entry cyclones, the gas
enter parallel to the axis of the cyclone body.
In this case the dust laden gases enter from the top
and are directed into a vortex pattern by the vanes
attached to the central tube.
Axial entry units are commonly used in multi cyclone
configuration, as these units provide higher efficiencies.

JAYEETA MITRA, AGFE DEPT.

Another type of larger cyclonic separator shown in figure
c is often used after wet scrubbers to trap particulate
matter entrained in water droplets.
In this type, the air enters tangentially at the bottom,
forming vertex.
Large water droplets are forced against the walls and
are removed the air stream.

JAYEETA MITRA, AGFE DEPT.

CYCLONE COLLECTORS

Cyclone collectors can be designed for many applications, and they are
typically categorized as high efficiency, conventional (medium efficiency),
or high throughput(low efficiency).
High efficiency cyclones are likely to have the highest-pressure drops of the
three cyclone types, while high throughput cyclones are designed to treat
large volumes of gas with a low-pressure drop.
Each of these three cyclone types have the same basic design.
Different levels of collection efficiency and operation are achieved by varying
the standard cyclone dimensions.

JAYEETA MITRA, AGFE DEPT.

CYCLONE EFFICIENCY

The collection efficiency of cyclones varies as a function of density, particle size

and cyclone design.
Cyclone efficiency will generally increase with increases in particle size and/or
density; inlet duct velocity; cyclone body length; number of gas revolutions in the
cyclone; ratio of cyclone body diameter to gas exit diameter; inlet dust loading;
smoothness of the cyclone inner wall.
Similarly, cyclone efficiency will decrease with increases in the parameters such
as gas viscosity; cyclone body diameter; gas exit diameter; gas inlet duct area;
gas density; leakage of air into the dust outlet.

JAYEETA MITRA, AGFE DEPT.

CYCLONE EFFICIENCY

The efficiency of a cyclone collector is related to the pressure drop across the collector.
This is an indirect measure of the energy required to move the gas through the system.
The pressure drop is a function of the inlet velocity and cyclone diameter.
Therefore, small cyclones are more efficient than large cyclones.
Small cyclones, however, have a higher pressure drop and are limited with respect to
volumetric flow rates.
Another option is arrange smaller cyclones in series and/or in parallel to substantially
increase efficiency at lower pressure drops.

JAYEETA MITRA, AGFE DEPT.

CYCLONE EFFICIENCY
A typical series arrangement: In such arrangements large particle can be arrested in the
first cyclone and a smaller, more efficient cyclone can collect smaller particles.
Hence, it reduces dust loading in the second cyclone and avoids problems of abrasion
and plugging. Also, if the first cyclone is plugged, still there will be some collection
occurring in the second cyclone. The additional pressure drop produced by the second
cyclone adds to the overall pressure drop of the system and higher pressure can be a
disadvantage in such series system design.
Cyclone efficiency can also be improved if a portion of the flue gas is drawn through
the hopper. An additional vane or lower pressure duct can provide this flow. However,
it may then become necessary to recirculate or otherwise treat this as purge exhaust to
remove uncollected particulate matter.

JAYEETA MITRA, AGFE DEPT.

Typical series arrangement

JAYEETA MITRA, AGFE DEPT.

CYCLONE PERFORMANCE
Centrifugal separators--transform the inertia force of gas particle to a centrifugal
force by means of a vortex generated in the cyclone body.
The particle laden gas enters tangentially at the upper part and passes through the
body describing the vortex. Particles are driven to the walls by centrifugal forces,
loosing its momentum and falling down to the cyclone leg. In the lower section, the gas
begins to flow radially inwards to the axis and spins upwards to the gas outlet duct.

(1)
ρp = particle density, (kg/m3)
dp = particle diameter, inches (μm) vp = particle tangential velocity (m/s) r = radius
of the circular path, (m)

JAYEETA MITRA, AGFE DEPT.

The main variables describing the cyclone performance are pressure drop, efficiency and
cut diameter.
Cut diameter: an indicator of the size range of particles that can be collected. The size of
the particles collected with 50% collection efficiency comes under this. It is a convenient way
of defining as it provides information on the effectiveness for a particle size range. A
frequently used expression for cut off diameter is

(2)
μ = viscosity (Pa.s); Bc = inlet width (m) N = effective number of turns (5-10 for common
cyclone) vi = inlet gas velocity (m/s) ρp = particle density (kg/m3); ρ = gas density (kg/m3).
Values of N can vary from 1 to 10, with typical values in the 4-5 range.

JAYEETA MITRA, AGFE DEPT.

COLLECTION EFFICIENCY
The collection/separation efficiency is defined for a given particle size.
As mentioned, fractional efficiency is defined as the fraction of particles of a given size
collected in the cyclone, compared to those of that size going into the cyclone.
collection efficiency of cyclone separator increases with
▪increasing particle mean diameter and density;
▪increasing gas tangential velocity;
▪decreasing cyclone diameter;
▪increasing cyclone length;
▪extraction of gas along with solids through the cyclone legs.
two methods of calculating cyclone efficiency. First the theory proposed by Leith and Licht
(1973) for calculating fractional efficiency and a convenient graphical method developed
by Lappel (1951) will be presented.

JAYEETA MITRA, AGFE DEPT.

Empirical pressure drop equation :

Kc = a proportionality factor, if the ΔP is measured in inches, it varies from 0.013 to 0.024,

with 0.024 the norm.
Design considerations
Select either the high efficiency or high throughput design, depending on the
performance required
Obtain an estimate of the particle size distribution of the solids in the stream to be
treated.
Calculate the number of cyclone needed in parallel.
Estimate the cyclone diameter for an inlet velocity of say 15 m/s. Then obtain the other
cyclone dimensions from the graphs (refer to page 452, Sinnott, 2005)
JAYEETA MITRA, AGFE DEPT.
DESIGN CONSIDERATIONS …CONTD…

Then estimate the scale up factor for the transposition of the figure. (refer to page 452 and
453, Sinnott, 2005)
Estimate the cyclone performance and overall efficiency, if the results are not
satisfactory try small diameter.
Calculate the cyclone pressure drop and check if it is within the limit or else redesign.
Estimate the cost of the system and optimize to make the best use of the pressure drop
available (Sinnott, 2005).

JAYEETA MITRA, AGFE DEPT.

DESIGN
A particle entering tangentially onto a horizontal plane of a spinning gas stream at r3,
Because of the centrifugal force, the particle will follow a path outward across the flow
streamlines. Its velocity vector will have a tangential component (uθ) and a radial component
(ur).
The velocity of the spinning gas is assumed to have only a tangential component, vθ, with vr
= 0. Tangential gas flows of this type usually are of the form vθrm = constant.
For an ideal, inviscid fluid in such a vortex flow m = 1, although in real flows the value of m
may range downward to 0.5. The analysis of cyclone performance stated here begins with
ideal, laminar flow. Then, it considers ideal, turbulent flow.
Because both of these represent idealized cases that are not attained in real cyclones, it
turns finally to a semi-empirical theory that has been widely used in practical cyclone design.

JAYEETA MITRA, AGFE DEPT.

 IDEAL, LAMINAR CYCLONIC FLOW

flow enters through a rectangular slot of area W (r2- r1),

the gas velocity components are (Crawford i976):
(1)

(2) (3)

so-called ideal laminar cyclonic

flow refers to a frictionless flow in
(4)
which the streamlines follow the
contours of the cyclone.

JAYEETA MITRA, AGFE DEPT.

PARTICLE'S TRAJECTORY IN THE CYCLONE

Since the θ-component of the particle's velocity is that of the fluid, uθ = vθ,
(5)

(6)
a differential equation describing the particle's trajectory.
If the particle enters the cyclone at r =r3 and hits the outer wall at θ = θf then integrating
Eq. (6) gives

(7)

JAYEETA MITRA, AGFE DEPT.

An alternative is to solve Eq. (7) for r3 to find the entrance position of
a particle that hits the outer wall at θ = θf
(8)

To obtain an expression for the collection efficiency of a cyclone, assume that

the entering particle concentration and gas velocity are uniform across the entrance
cross section (Figure 3).
If the cyclone has an angle θf, all particles that enter the device at r ≥ r3 hit the Figure 3
wall over 0 ≤ θ≤ θf. The collection efficiency is just that fraction of the particles in
the entering flow that hit the outer wall before θ = θf. Therefore,
(9)

JAYEETA MITRA, AGFE DEPT.

Substituting Eq. (8) into (9)and rearranging

(10)

The value of θf at which ɳ(Dp) = 1 is given by

(11)

JAYEETA MITRA, AGFE DEPT.

At at298K and 1 atm flows at the rate of 5.0 m3/s and carries with it particulate matter
with a density of 1500 kg/m3. The stream enters a cyclonic region with r1= 0.2 m and
r2= 0.4 m in ideal, laminar flow. Through what angle must the flow turn in the cyclone if
the efficiency is to be unity for 30 μm particles. The height of the channel, W , is 1 m.
Plot the efficiency as a function of particle size for this angle.

Efficiency curve

JAYEETA MITRA, AGFE DEPT.

IDEAL, TURBULENT CYCLONIC FLOW
Assume that the effect of the turbulent eddies is to distribute the particles uniformly
over the cross section, not only at the entrance, but at any given angle θ. This is a
conservative assumption because the centrifugal force effects may serve to damp out
the turbulent eddies which naturally occur in turbulent duct flow. Relatively little is
known about this area.
Consider the effect of a laminar layer next to the outer
edge of the cyclone, as shown in Figure. Once a particle,
vigorously mixed in the core of the flow, enters this
layer, it travels to the outer wall and is removed. The
distance the particle travels in the θ direction in the
laminar sublayer over a time interval dt is uθ2dt = r2dθ,
where uθ2 is evaluated at r = r2. The thickness of the
laminar sublayer is

(12)
JAYEETA MITRA, AGFE DEPT.
where ur2 is also evaluated at r = r2. The fractional diminution of particles over the angle
dθ is the fraction of the particles which lies in the boundary layer, or

(14)
integrating this equation between the entrance (θ = 0) and any angular position

(15)
where n0 is the initial number of particles of diameter Dp per unit volume of gas. The
collection efficiency of a cyclone that has an angle θf is

(16)

JAYEETA MITRA, AGFE DEPT.

TURBULENT FLOW CONTINUES….
For lack of a better approximation use the inviscid gas velocity components Eq. (1) to
represent the fluid velocity field in the turbulent flow cyclone. Therefore,

(17) (18)

And the collection efficiency of the cyclone is

(19)

JAYEETA MITRA, AGFE DEPT.

At at298K and 1 atm flows at the rate of 5.0 m3/s and carries with it particulate
matter with a density of 1500 kg/m3. The stream enters a cyclonic region with r1=
0.2 m and r2= 0.4 m in ideal, laminar flow. Through what angle must the flow turn in
the cyclone if the efficiency is to be unity for 30 μm particles. The height of the
channel, W , is 1 m. Plot the efficiency as a function of particle size for this angle.

(a) Consider the data of Example .1 . Estimate the collection efficiency for 30-µm
particles assuming that the flow is‘ turbulent and the cyclone angle is 2.041rad.
(b) determine the angle of turn to obtain 99% collection efficiency for the 30-µm
particle.

JAYEETA MITRA, AGFE DEPT.

SOLUTION
(a) First apply equation
eta (30µm) = 0.528 (52.8 %)
(b) solve the above equation for θf

Substituting
Numerical values, the angle for 99% collection efficiency of the 30µm particles is θf
= 12.53 rad= 2 full turns.

JAYEETA MITRA, AGFE DEPT.

 PRACTICAL CYCLONE DESIGN- EMPIRICAL APPROACH
The flow pattern in a cyclone device is a complex one and the two model presented
previously represent extremes in performance. Because operating cyclones do not conform to
either of these limiting conditions, semi-empirical design equations predict their performance.
Leith and Licht (1980) developed a theory useful in predicting cyclone design. Alexander
(1949) experimentally found that the exponent in the fluid tangential velocity profile vθrm=
constant is given by
(20)
where Dc, is the cyclone body diameter in meters and T is the gas temperature in K. The
collection efficiency, according to the model by Leith and Licht, is given by
(21)

where K is a dimensionless geometric configuration parameter and Cc is the Cunningham

correction factor.

JAYEETA MITRA, AGFE DEPT.

STANDARD CYCLONE CONFIGURATIONS
Table 1 presents, the dimension ratios of these, along with values of the geometric configuration
parameter K, and a constant NH, relating the pressure drop through the cyclone to the inlet
velocity head. The next figure illustrates the various dimensions in Table1.

JAYEETA MITRA, AGFE DEPT.

while forcing the gas through the cyclone at higher
velocities results in improved removal efficiencies, to
do so increases the pressure drop and the operating
costs.
There is ultimately an economic trade-off between
efficiency and operating cost. Several methods have
been proposed to estimate the total pressure drop
in the flow of gas through a standard cyclone.
Most methods agree to express the pressure drop in
terms of a multiple of the inlet velocity head. Or
(22)

NH is a constant which depends on the cyclone

configuration
ρf is the gas density
vE is the gas velocity in the cyclone inlet duct= Q/ab
JAYEETA MITRA, AGFE DEPT.
➢Equation 22 can be rewritten in terms of the cyclone body diameter and gas volumetric
flow rate.

➢ Where

➢The pressure drop is extremely sensitive to the cyclone body diameter, increasing
rapidly as the device becomes smaller.
➢Looking the table 1 for a given set of operating conditions and body diameter, Swift
standard configurations is more efficient (higher value K) but results in a higher pressure
drop (higher value of NH).
➢Lapple configuration, with a relatively high pressure drop, is not nearly as efficient as
the other two.

JAYEETA MITRA, AGFE DEPT.

THE NUMBER OF EFFECTIVE TURNS (Ne)

The number of effective turns in a cyclone is the number of revolutions the gas spins while passing
through the cyclone outer vortex.
A higher number of turns of the air stream result in a higher collection efficiency.
The Lapple model for Ne calculation is as follows:

where
Ne = number of turns inside the device (no units)
H = height of inlet duct (m )
Lb = length of cyclone body (m )
Lc = length (vertical) of cyclone cone (m)

JAYEETA MITRA, AGFE DEPT.

CUT POINT DIAMETER

The cut-point of a cyclone is the aerodynamic equivalent diameter (AED) of the particle
collected with 50% efficiency.
As the cut-point diameter increases, the collection efficiency decreases.

Where, dp = diameter of the smallest particle that will be collected by the cyclone
μ = gas viscosity (kg/m. s)
W = width of inlet duct (m)
Ne=(1/H)[Lb+Lc/2]=number of turns
Vi = inlet gas velocity (m/s)
ρp=particle density (kg/m3)
pg = Density of fluid

JAYEETA MITRA, AGFE DEPT.

GAS RESIDENCE TIME
To be collected, particles must strike the wall within the amount of time that the gas travels in the outer
vortex. The gas residence time in the outer vortex is

JAYEETA MITRA, AGFE DEPT.

JAYEETA MITRA, AGFE DEPT.
FRACTIONAL EFFICIENCY CURVE

Based upon the cut-point, Lapple then developed an empirical model for the prediction of the collection
efficiency for any particle size, which is also known as fractional efficiency curve:

dpc= collection efficiency of particles in the jth size range (0 < nj < 1)
dpj = characteristic diameter of the jth particle size range (in microns).

JAYEETA MITRA, AGFE DEPT.

PRESSURE DROP (ΔP)

Two steps are involved in the Lapple approach to estimation of cyclone pressure drop. The first step is to
calculate the pressure drop in the number of inlet velocity heads (Hv)
The second step is to convert the number of inlet velocity heads to a static pressure drop (ΔP) by equation.
There is one problem associated with this approach. “The Lapple pressure drop equation does not consider
any vertical dimensions as contributing to pressure drop” (Leith and Mehta, 1973). This is a misleading in
that a tall cyclone would have the same pressure drop as a short one as long as cyclone inlets and outlets
dimensions and inlet velocities are the same. It has been considered that cyclone efficiency increases with
an increase of the vertical dimensions. With the misleading by Lapple pressure drop model. one could
conclude that the cyclone should be as long as possible since it would increase cyclone efficiency at no
cost in pressure drop (Leith and Mehta, 1973). A new scientific approach is needed to predict cyclone
pressure drop associated with the dimensions of a cyclone.

Where
Hv = pressure drop, expressed in number of inlet velocity heads
K = constant that depends on cyclone configurations and
Operating conditions (K = 12 to 18 for a standard tangential-
entry cyclone)
JAYEETA MITRA, AGFE DEPT.
CYCLONE EFFICIENCY

Overall separation efficiency

Consider the mass balance of solid particle in cyclone. As explained by Hoffmann and Stein in their book on gas
cyclones, Mf, Mc and Me are the mass flow rate of the feed, mass flow rate of particle collected and mass flow
rate of escaped particles, respectively.
Then force balance of solid particle over the cyclone can be denoted by eq. the following eqn.
M f = M c + Me

The overall separation efficiency can be calculated directly as the mass fraction of feed that is successfully
collected.

JAYEETA MITRA, AGFE DEPT.

PRESSURE DROP

The pressure drop significantly affects the performance parameters of a cyclone. The
total pressure drop in a cyclone will be due to the entry and exit losses, and friction
and kinetic energy losses in the cyclone.
Normally most significant pressure drop occurs in the body due to swirl and energy
dissipation.
pressure drops vs design variables equations are esists. having such an equation, one
could work back and optimize the design of new cyclones. The empirical equation
given by Stairmand (1949) can be used to estimate the pressure drop.

(5)

JAYEETA MITRA, AGFE DEPT.

ΔP = cyclone pressure drop
ρf = gas density;
u1 = inlet duct velocity;
u2 = exit duct velocity
rt = radius of circle to which the centre line of the inlet is tangential;
re = radius of exit pipe
ɸ = cyclone pressure drop factor
Ψ = fc (As/A1)
fc= friction factor, taken as 0.005 for gases
As = surface area of cyclone exposed to the spinning fluid For design purposes this
can be taken as equal to the surface area of a cylinder with the same diameter as the
cyclone and length equal to the total height of the cyclone
At = area of inlet duct

JAYEETA MITRA, AGFE DEPT.

ALTERNATIVE DESIGN EQUATION FOR CYCLONES

Where q = volumetric flow rate

Bc = inlet width,
Hc = inlet height,
Dc = outlet diameter,
Zc = cone length,
Lc = cylinder length
In this equation kc is a dimensionless factor express of cyclone inlet vanes. Kc = 0.5
for cyclones without vanes; Kc = 1.0 for cyclone vanes that do not expand the
entering gas or touch the outer wall; however Kc = 2.0 for cyclone vanes that expand
and touch the outlet all. The above equation when compared with experimental data
shows poor correlation coefficient (Theodore, 2008).

JAYEETA MITRA, AGFE DEPT.

Lappel (1951) first computed the ratios dp/[dp]cut from equation 2 and it is observed
that cyclone efficiency correlates in a general way with this ratio.
For a typical cyclone, efficiency will increase as the ratio increases.
The preceding correlation has been found to agree well with experimental data.
To calculate fractional efficiency, the following procedure given below should be
used.
The sum of the products in the rightmost column will give the overall efficiency.

JAYEETA MITRA, AGFE DEPT.

The main variables describing the cyclone performance are pressure drop, efficiency and cut
diameter. Equations involving each of these parameters are provided in this section.
Cut diameter
It is an indicator of the size range of particles that can be collected. The size of the particles
collected with 50% collection efficiency comes under this. It is a convenient way of defining as
it provides information on the effectiveness for a particle size range. A frequently used
expression for cut off diameter is

(2)
μ = viscosity (Pa.s); Bc = inlet width (m) N = effective number of turns (5-10 for common
cyclone) vi = inlet gas velocity (m/s) ρp = particle density (kg/m3); ρ = gas density (kg/m3).
Values of N can vary from 1 to 10, with typical values in the 4-5 range.

JAYEETA MITRA, AGFE DEPT.

The fractional efficiency equation of Leith and Licht is given as:
Where C = cyclone dimension factor
ψ = impaction parameter
n = vortex exponent (3)

c is a factor that is a function only of the cyclone’s dimensions.

The symbol ψ expresses characteristics of the particles and gas and is known as
inertia or impaction parameter.
The value of n is dependent on the cyclone diameter and temperature of the gas
stream. And ρp times vi expresses the particle’s initial momentum. Although the
calculation involved in this method are tedious but are straightforward.

JAYEETA MITRA, AGFE DEPT.

JAYEETA MITRA, AGFE DEPT.