KWAME NKRUMAH UNIVERSITY OF SCIENCE AND TECHNOLOGY Lab Reort

KWAME NKRUMAH UNIVERSITY OF SCIENCE AND
TECHNOLOGY, KUMASI.
COLLEGE OF ENGINEERING
CHEMICAL ENGINEERING DEPARTMENT
PCE 353 PETROCHEMICAL ENGINEERING LAB 1
REPORT ON GAS CYCLONE.
PRESENTED BY: GROUP EIGHT
DATE: 12TH SEPTEMBER, 2017.

GROUP MEMBERS
NAME INDEX SIGNATURE
ESSANDOH, JOSHUA 4037715 …………….
ASIMATEY, PATRICK DOE 4036715 ………........
NKRUMAH, AFARI ERASMUS 4038815 …………….
SEFOGAH, XORLA BRIGHT 4039415 …………….
AGYEI, DERRICK OSONO 4035815 …………….

TABLE OF CONTENTS
TABLE OF CONTENTS...........................................................................................................ii
LIST OF TABLES....................................................................................................................iii
OBJECTIVES............................................................................................................................1
INTRODUCTION......................................................................................................................1
Apparatus and chemicals............................................................................................................3
PROCEDURE............................................................................................................................4
DISCUSSION..........................................................................................................................18
CONCLUSION........................................................................................................................19
REFERENCES.........................................................................................................................20
i
LIST OF TABLES
TABLE 1: Worksheet for conducting the experiment...............................................................6
TABLE 5: Worksheet for conducting the experiment.............................................................10
TABLE 6: Worksheet for conducting the experiment.............................................................11
ii
OBJECTIVES
1. To compare pressure loss and degree of separation with theoretically calculated

values.
2. To determine the cyclone separation efficiency on different air flow rate.
3. To evaluate the relationship between separation efficiency and flow rate.
4. To study the effect of cyclone body diameter upon collection efficiency.
5. To determine how the solid material content and airflow volume affect pressure loss
at the gas cyclone, degree of separation, separation function and separation size.
INTRODUCTION
Cyclonic separation is a method of removing particulates from air, gas or liquid stream ,
without the use of filters , through vortex separation .A hydro cyclone is used when removing
solid material from liquids while a gas cyclone is used to remove solid material from gas. The
separation is based on rotational effects, centrifugal force, inertia and gravity.
It consist of a vertical cylinder with a conical bottom, a tangential inlet near the top and an
outlet for dust at the bottom of the cone. A cyclone separator is a mechanical device using
geometry and centrifugal acceleration to affect separation of suspended particles from a
gaseous or liquid stream. It can be designed for high temperature and pressure operation.
Cyclones are simple mechanical devices for removing relatively large particles (> 5 to 10
μm) from gas streams. They are more commonly applied in several disciplines such as:
1. Environmental Engineers to remove particulate pollutants.
2. Chemical Engineers and Mechanical Engineers to collect valuable particle products.
3. Industrial Hygienists to sample particles in working environments. Pharmaceutics to

classify their powdered drugs. Cyclones are often used as pre-cleaners for the more
sophisticated air pollution control equipment such as electrostatic precipitators or bag houses.
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,
1
crushers, incinerators, and kilns due to its efficiency for removing particulate matter than are
settling chambers, but are less efficient than either wet scrubbers, bag houses or electrostatic
precipitators. Cyclones used as pre-cleaners are often designed to remove more than 80% of
the particles that are greater than 20 μm in diameter. Smaller particles that escape the cyclone
can then be collected by more efficient control equipment.
Description of gas cyclone unit: 1) Disperser with feed material tank and transport unit, 2)
Flow meter, 3) Valve (air flow rate), 4) Air inlet with filter, 5) Displays and controls, 6)
Connection for fan, 7) Coarse material tank, 8) Process schematic, 9) Gas cyclone
2
Diagram showing the flow conditions in a gas cyclone: 1) raw gas inlet, 2) separated solid,
3) collected solids, 4) secondary vortex, 5) primary vortex, 6) immersion tube, 7) cleaned gas
3
A diagram showing gas Cyclone Unit: fan (right) and trainer (left)
4
APPARATUS AND CHEMICALS
1. Gas cyclone device (Trainer, air suction fan and tamper)

2. Feed material (powdered silica)
3. 1 spatula
4. Mass balance.
5. Beaker.
PROCEDURE
1. The feed was placed in a cylinder on a firm surface and the plunger was also placed in
the feed cylinder with the Philips screw facing upwards. The tamper was taken and
pressed down on the plunger until it touched the surface.
2. The empty field cylinder with the plunger was weighed, the course material cylinder
with the empty tank for the course material.
3. A spatula was then used to transfer approximately 2g of feed material into the feed
cylinder. Carefully and only by its own weight (i.e. no pressure) repeatedly was the
tamper placed on the top of the feed material in the feed cylinder.
4. This step was repeated 10-12 times until the feed cylinder was completely field. The
filled feed cylinder was then compared with the empty feed cylinder in terms of their
weight and their difference was found to be about 24g.
5. The main switch on the trainer was turned to “OFF”. The feed cylinder was ten placed
into the brush housing from below and screwed with 2 knurled screws. The switch
for the brush was then switched to “Auto”.
6. The desired feed rate on the potentiometer (3, 6 and 10 for each reproducible volume
flow) was adjusted. The main switch on the trainer was turned “ON”, one stage of the
suction fan was turned on and the desired volume flow (10, 20, 30, 40, 50 and 60
m3/h.) with the gate valve was set. Another stage of the air suction was turned on,
each value for each volume flow was reproduced. The volume flow, temperature and
differential pressure on the worksheet was noted.
5
7. The switch for the feed was turned to “Forward”. The “feed” lamp turned white. The
values of the displays for the volume, feed, temperature and differential were noted.
The duration of the experiment was about 15…..90 seconds. When the “Upper end
position” lamp light up red the tank for the feed material was emptied and the feed
material was fully inserted into the inlet section and/or the cyclone.
8. The air suction fan was turned off, switch for feed was also turned “OFF” and then
“Reverse” the “feed” lamp turned white. A time was taken until “Lower end position”
lamp turned red. The two knurled screws on the feed cylinder was loosen and
carefully removed. The filled cylinder was weighed.
6
TABLE OF RESULTS
TABLE 1: Worksheet for conducting the experiment
Unit Measurement Measurement Measurement

no. no. no.
Preparation of the experiment (without
feed material)
Volume flow Vgas m3/h 10.000 10.000 10.000
Temperature oC 25.600 25.700 25.700
Differential pressure ∆p mbar 3.4000 3.3000 3.400
Conducting the experiment (with feed

material)
Feed (potentiometer) - 3.0000 6.0000 10.0000
Feed vfeed mm/s 1.1000 2.3000 4.7000
Temperature oC 25.7000 25.7000 25.8000
Calculation of the separation size xs
Mass of feed material mfeed g 23.9800 24.0200 23.9700
Mass of coarse material mcoarse g 20.2100 20.0500 20.1100
Mass flow of the feed material mfeed g/s
Load µ -
Separation size xs mm
Calculating the total degree of
separation E
Limit load µlimit -
Total degree of separation E measured -
Total degree of separation E calculated -
Calculating the pressure loss ∆p
Pressure loss ∆p calculated mbar
7

no. no. no.
feed material)
Temperature oC 25.8000 25.7000 25.7000
material)
Feed vfeed mm/s 1.4000 2.7000 4.7000
Temperature oC 25.8000 25.8000 25.9000
Load µ -
separation E
8
9

no. no. no.
Preparation of the experiment
(without feed material)
Temperature oC 26.7000 26.1000 26.1000
material)
Feed vfeed mm/s 0.9000 2.7000 5.3000
0
Temperature C 26.0000 26.2000 26.3000
Load µ -
separation E
Total degree of separation E -
measured
calculated
10

no. no. no.
0
Temperature C 26.7000 26.1000 26.1000
material)
Feed vfeed mm/s 1.1000 2.8000 4.7000
0
Temperature C 26.3000 26.3000 26.2000
Load µ -
separation E
measured
calculated
11

no. no. no.
feed material)
0
Temperature C 26.2000 26.3000 26.3000
Differential pressure ∆p Mbar 57.2000 57.1000 57.1000
material)
Feed vfeed mm/s 0.7000 2.7000 5.2000
0
Temperature C 26.3000 26.3000 26.4000
Differential pressure ∆p Mbar 47.4000 42.3000 39.9000
Mass of feed material mfeed G 23.8100 23.9900 23.8300
Mass of coarse material mcoarse G 20.3100 20.1200 20.2100
Load µ -
Separation size xs Mm
separation E
Pressure loss ∆p calculated Mbar
12
13

no. no. no.
0
Temperature C 26.4000 26.5000 26.4000

material)
Feed vfeed mm/s 1.3000 2.7000 5.2000
0
Temperature C 26.5000 26.5000 26.5000
Calculation of the separation size Xs
Load µ -
14
separation E

measured
calculated
CALCULATIONS
For the 1st desired volume flow, Vgas of 10m3/h for feed (potentiometer) of 3
mfeed
Mass flow of the feed material, m.feed =
time ,t
hcyc
But t =
v feed
h cyc = fill height of the feed cylinder = 90mm
v feed = feed rate = 1.3mm/s
90 mm
t=
1.3 mm/s
ht = 69.23s
23.45 g
m.feed =
69.23 s
= 0.3387g/s
15
m. feed m. feed
Load, µ = =
mgas p gas × v gas
0.3387 g
∗3600
µ= s
3 3
1.199 kg/m ×10 m /h
= 0.102
Separation size, xs
xs =
√ 9× n gas
ps
×
1
U × √ Hi √
×
π ×r i
v gas
3
ps = grain gross density = 2.65g/cm3
ngas = dynamic viscosity = 1.83×10−5 pa.s
U = velocity ratio
V ǫI F
U= = (α× ℜ + λ × H )-1
VI
b
α = 1- (0.36×F0.6 × ( )0.45)
ra
A e a . b 32mm .15 mm
F= = = 2 = 0.68
Ai π r i 2
2
π ×15 mm
b = 15mm, ra = 80mm
15 mm 0.45
α = 1- (0.36×0.68 0.5×( ) )
40 mm
α = 0.81, Re = 2.17
λ=0.005 ×¿ ))
= 0.005× (1+ (2×√ 0.102 )
16
λ=0.0105
Using MATLAB Programming to calculate for Xs
Let a= λ , Re=R, n= ngas, h= Hi, r = ri, z = π ,p = ps , f =F
% calculation for A
a=0.81;f=0.68;R=2.17;H=16.7;n=1.83*10^-5;p=2650;h=13.3;r=0.015;z=22/7;
A=input('input A:');
U=inv(a*(f/R)+A*H);
V=input('input V:');
Xs=sqrt((9*n)/p)*(1/U*sqrt(h))*sqrt((z*r^3)/V)
Equation of the grain size curve
Y= -116045.68x4+80030.53x3-20426.51x2+2319.77x
For y= 50.3, X= 0.028
√
3
R2 F
Limit load, µlimit = 0.1× × ∝ × × U 2 × Hi ×¿
R−1 ℜ
√
3
2.67 2 0.81× 0.68
= 0.1× × × 2.33 2 × 13.3 ×¿ = 0.0199
2.67−1 2.17
Total degree of separation E measured
mcoarse 19.98
E= = = 0.8520
mfeed 23.45
Total degree of separation E calculated using MATLAB PROGRAMMING
 total degree of separation E with load above the limit load µlimit
X
µ µ max
E= 1- limit + limit × ∫ T ( x ) × q a ( x ) dx
µ µ X
min
17
%group 2 matlab program for solving cyclone problem
Xs=input ('input value for Xs: ');
Ulimit=input ('input value for Ulimit: ');
u=input ('input value for u: ');
syms X
E=1-(Ulimit/u)+(Ulimit/u)*int((1+(2/(X/Xs)^3.564)^-1.235)*(-232698*X^4+116924*X^3-
24083*X^2+2444.7*X-1.0707),0.001, 0.16)
E= >>
(3876332597914311732327335441794759509197409222656*2^(533/12500)*5^(8123/1250
0)*107396943997137^(8123/50000))/
6037341421439531191005888003175558460988216796875 -
(13033931273842522358327408690846553019561017344*2^(42747/50000)*5^(8123/1000
0)*107396943997137^(8123/50000))/
94333459709992674859467000049618100952940887451171875 +
7301718197321353253/1630000000000000000
18
ans = 362.6623
Calculating the pressure loss △ p
△ p total=△ p +¿¿ △ p f +△ p =(¿ ζ +ζ +ζ )× p

i t i f t
gas 2
× vi ¿
2
ζ i = loss coefficient for the inlet
ζ f = loss coefficient for the main flow
ζ t = loss coefficient for the immersion tube
ζ i = 0 for a slot inlet
2
ζ f = U ×¿
R
4
ζ t = 2+3×U 3 +U 2
v gas
vi = 2
π × ri
for volume flow V gas of 10 at 3 feed( potentiometer)
2
ζ f = 2.56 ×[ ( 1−0.01 ) 16.7 ×2.56] -1
2.67
¿ 3.7778
ζ t = 2+3(2.56)4/3+(2.56)2
¿ 19.06
10
v i= 2
π ×15
¿ 3.889 m/s
1.199 2
△ p=( 0+3.78+19.06)× ×3.889
2
¿ 214.133 Pa
¿ 2.14 mbar
19
GRAIN SIZE CURVE
120
100
f(x) = − 116045.684468198 x⁴ + 80030.5284389426 x³ − 20426.5121290025 x² + 2319.76638277362 x
R² = 0.999834298088517
total throughout in mass % (kg)
80
60 Series2
Polynomial (Series2)
40
20
0
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
screen mesh size in mm
20
Volume Flow
(m3h) Separation size (1) Separation Size (2) Separation Size (3)
10 3.66E-04 3.77E-04 3.94E-04
20 2.50E-04 2.54E-04 2.63E-04
30 2.03E-04 7.39E-04 2.14E-04
40 3.06E-04 1.76E-04 1.82E-04
50 1.53E-04 1.56E-04 1.59E-04
60 1.40E-04 1.42E-04 1.46E-04
A GRAPH OF SEPARATION SIZE (Xs) AGAINST

VOLUME FLOW (Vgas)
4.50E-04
4.00E-04
3.50E-04
3.00E-04
Xs (mm)
2.50E-04
2.00E-04
1.50E-04
1.00E-04
5.00E-05
0.00E+00
0 10 20 30 40 50 60 70
Vgas (m3h)
21
Volume Flow (m3h) Load µ(1) Load µ(2) Load µ(3)
10 0.1017 0.1497 0.2453
20 0.0558 0.0782 0.1321
30 0.0544 0.0667 0.1212
40 0.024 0.0527 0.0965
50 0.029 0.0428 0.0644
60 0.0275 0.0435 0.0652
A GRAPH OF SEPARATION SIZE (Xs) AGAINST

LOAD (µ)
4.50E-04
4.00E-04
3.50E-04
3.00E-04
2.50E-04
Xs (mm)
2.00E-04
1.50E-04
1.00E-04
5.00E-05
0.00E+00
0 0.05 0.1 0.15 0.2 0.25 0.3
Load (µ)
Vgas=10 Vgas=20 Vgas=30 Vgas=40 Vgas=50 Vgas=60
DISCUSSION
From the grain size curve, increase in mass percent gives a corresponding increase in screen
mesh size. This shows that the mass% is directly proportional to screen mesh size. This is
22
because when the size of a sieve increases, the amount of particles that go through also
increases. Moreover the graph is a polynomial graph.
Increase in feed rate results in a corresponding pressure drop, this is due to the fact that
volume and pressure are inversely proportional to each other. Increase in volume will result
in a pressure drop. For example for a feed rate of 1.3, 1.9 and 3.2, the differential pressure
(mbar) decreases as 1.7, 1.6 and 1.4 respectively. This shows that the change in differential
pressure is not so much affected by the feed rate.
A graph of separation size against volume flow gave a negative slope. From the table of
values a mass of 23.45g was fed into the cyclone and the mass of coarse material obtained
was 19.98g. This shows separation has been efficient.
It was observed that the separation size increases as the load increases. As the load of the gas
increased the limit load was reached which meant that for a load above the load limit,
separation took place both in the cyclone vortex and at the wall of the cyclone.
CONCLUSION
It can be concluded that gas cyclone is about 85% efficient. This is because after a mass of
23.45g was fed into the cyclone, a mass of 19.98g coarse material was obtained.
Pressure lost results in an increase in degree of separation.
PRECAUTIONS
1. No human effort (weight) was added to the tamper to ensure that, the tamper uses its
own weight.
2. Whiles the gas cyclone unit was in operation it was carefully ensured that, the hands
were not place on the feed unit to prevent hand injury.
3. Masks were worn to prevent inhalation of the silicate since it capable of causing
respiratory problems.
4. The brushing of the coarse materials on the wall of the cylinder mounting into the
coarse material cylinder was done carefully to prevent the coarse material from
23
dispersing into the air or from falling onto the control/display of the trainer since it
could affect the mass of the coarse material.
24
REFERENCES
1. J.J. Derksen, Separation performance predictions of a Stairmand high- efficiency
cyclone, AIChE Journal 49 (2003) 1359 – 1371.
2. [2] E. Muschelknautz, Die Berechnung von Zyklonabscheidern für Gase, Chemie
Ingenieur Technik 44 (1970) 1–12.[3] A.C. Hoffmann, H. Arends, H. Sie, An
experimental investigation
3. Elucidating the nature of the effect of solids loading on cyclone
4. Performance, Filtration and Separation 28 (1991) 188
5. –193. [4] A.C. Hoffmann, A. van Santen, R.W.K. Allen, Effects of geometry and
6. solid loading on performance of gas cyclones, Powder Technology 70
7. (1992) 83 – 91
8. Awarikabey Emmanuel (2016) Petrochemical Engineering Laboratory 1 Manual, year
three, Chemical Engineering Department, KNUST, Pages 5 -7.
25
ANSWERS TO POST LAB QUESTIONS
1. For the graph of separation size, Xs as a function of the volume flow of gas V gas , it
was seen that, the separation size was inversely proportion to the volume flow of gas .
That is as the separation size decreases the volume of gas increases which means that,
the separation process is more effective when the volume flow of gas increases.
2. The smaller separation size makes the separation process more effective.
3. For the graph of separation size as the function of the load. It was observed that the
separation size was directly proportional to the load that is, separation size increases
as the load increases. As the load of the gas increased the limit load was reached
which meant that for a load above the load limit, the separation took place both in the
cyclone vortex and at the wall of the cyclone.
4. a). Ensure good electrical connections to avoid power interruption.
b) Wear nose marks to prevent inhalation of feed material (poisonous).

c) Use tamper's weight only (no pressure), during compressing feed material in feed
cylinder.
26

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KWAME NKRUMAH UNIVERSITY OF SCIENCE AND

CHEMICAL ENGINEERING DEPARTMENT

PCE 353 PETROCHEMICAL ENGINEERING LAB 1

REPORT ON GAS CYCLONE.

PRESENTED BY: GROUP EIGHT

DATE: 12TH SEPTEMBER, 2017.

NAME INDEX SIGNATURE

ESSANDOH, JOSHUA 4037715 …………….

ASIMATEY, PATRICK DOE 4036715 ………........

NKRUMAH, AFARI ERASMUS 4038815 …………….

SEFOGAH, XORLA BRIGHT 4039415 …………….

AGYEI, DERRICK OSONO 4035815 …………….

Apparatus and chemicals............................................................................................................3

TABLE 1: Worksheet for conducting the experiment...............................................................6

TABLE 2: Worksheet for conducting the experiment...............................................................7

TABLE 3: Worksheet for conducting the experiment...............................................................8

TABLE 4: Worksheet for conducting the experiment...............................................................9

TABLE 5: Worksheet for conducting the experiment.............................................................10

TABLE 6: Worksheet for conducting the experiment.............................................................11

1. To compare pressure loss and degree of separation with theoretically calculated

1. Environmental Engineers to remove particulate pollutants.

2. Chemical Engineers and Mechanical Engineers to collect valuable particle products.

3. Industrial Hygienists to sample particles in working environments. Pharmaceutics to

1. Gas cyclone device (Trainer, air suction fan and tamper)

TABLE 1: Worksheet for conducting the experiment

Unit Measurement Measurement Measurement

Conducting the experiment (with feed

Unit Measurement Measurement Measurement

Unit Measurement Measurement Measurement

Unit Measurement Measurement Measurement

Unit Measurement Measurement Measurement

Unit Measurement Measurement Measurement

Differential pressure ∆p mbar 83.2000 83.1000 82.8000

Conducting the experiment (with feed

Feed vfeed mm/s 1.3000 2.7000 5.2000

Volume flow Vgas m3/h 60.000 60.000 60.000

Differential pressure ∆p mbar 71.3000 63.8000 59.4000

Calculation of the separation size Xs

Mass of feed material mfeed g 23.7800 23.9900 24.0200

Mass of coarse material mcoarse g 20.1200 20.4100 20.1200

Mass flow of the feed material mfeed g/s

Total degree of separation E -

Pressure loss ∆p calculated mbar

h cyc = fill height of the feed cylinder = 90mm

v feed = feed rate = 1.3mm/s

ps = grain gross density = 2.65g/cm3

ngas = dynamic viscosity = 1.83×10−5 pa.s

= 0.005× (1+ (2×√ 0.102 )

Using MATLAB Programming to calculate for Xs

Let a= λ , Re=R, n= ngas, h= Hi, r = ri, z = π ,p = ps , f =F

Equation of the grain size curve

For y= 50.3, X= 0.028

Total degree of separation E measured

Total degree of separation E calculated using MATLAB PROGRAMMING

Calculating the pressure loss △ p

△ p total=△ p +¿¿ △ p f +△ p =(¿ ζ +ζ +ζ )× p

A GRAPH OF SEPARATION SIZE (Xs) AGAINST

A GRAPH OF SEPARATION SIZE (Xs) AGAINST