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Image Credit: Koger Air Corporation, Aget Manufacturing Company, Ecologix Environmental Systems
Cyclone separators utilize gravity and a vortex to remove particulates from gaseous streams. Industrial cyclones are used in pollution control applications most commonly as a first stage, lower cost method for removing larger particulate matter (PM) from effluent gas streams. Because cyclone separators do not incorporate filter media or moving parts, the pressure drop (therefore, operating costs) and maintenance requirements tend to be low. They can also be constructed to withstand harsh operating conditions, and since separation in cyclones is a dry process, the equipment is less prone to moisture corrosion.
Advantages Low capital cost. Disadvantages High operating costs (due to pressure drop).
General layout and function of a rev erse flow cyclone, indicating the flow paths of the gas and particulate matter (labeled pow der in this diagram). Image Credit: GEA Niro
It is important to keep in mind that the centrifugal force (Fc ) a cyclone generates on a particle is related to the tangential air velocity (vt), particle mass (m), and the particles radial distance from the cyclone wall (r) by the function: Fc = m vt2 / r
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Selection
For custom designs or manufacturer assisted selection, an engineer or industrial buyer will fill out a data sheet of specifications for the cyclone and its design environment.
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Typical data sheet for custom or manufacturer assisted cyclone selection, including a large range of design specifications. Image Credit: Fisher-Klosterman, Inc.
When selecting a cyclone separator, industrial buyers must consider various performance specifications, process conditions, construction, and applications. This guide is designed to help with this selection process by pointing out the key considerations and design aspects of cyclones.
Cyclone Performance
Cyclones may be purchased from existing manufacturers stock or custom built to certain customer design specifications. In either case, it is important to know the required specifications and process conditions for operation.
Specifications
The primary means to selecting the right cyclone separator(s) is matching its performance specifications with the application requirements. These specifications include process airflow and minimum filtered particle size. Airflow or volumetric flow rate is the air flow generated or handled by a cyclone. This is usually given in cubic feet per minute (cfm). Some manufacturers provide ranges in standard cubic feet per minute (scfm), as flow rates can vary greatly as environmental conditions stray for standard temperature and pressure. To convert a given actual flow rate (QA) in actual cubic feet per minute (acfm) to standard flow (QS) in scfm, utilize the combined ideal gas equation which includes volume (V), pressure (P), and temperature (T) at actual and standard conditions.
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Pressure drop is the amount of flow resistance the cyclone will create in the system. Pressure drop is usually measured in units of inches of water column (in WC) or Pascals (Pa). Pressure drop is a function of flow rate, gas density, and cyclone design. Design Tip: Correctly designed cyclones should have a recommended pressure drop range of operation, which for most designs is between 2 and 6 in WC (About 500 to 1500 Pa) at ambient conditions. Above this range, costs for flow losses begin to outweigh increases in efficiencies. Below the limits, particle recovery becomes ineffective.
Process Conditions
Process conditions are the characteristics surrounding a cyclones operation. These include the air conditions and the particulate/dust conditions that are essential to finding or designing an appropriate cyclone for a given system. When having a cyclone custom built, these conditions are requested from the cyclone manufacturer. Air conditions include the pressure (psig or psia), temperature (F or C), and moisture content (weight or volume percent) at the inlet of the cyclone. Solids collection becomes more difficult as humidity rises because the moisture tends to cause PM to adhere to the cyclone walls. Dust conditions at the inlet of the cyclone can include material type, specific gravity, bulk density (lb/ft3), dust load (lb/hr or grains/ft3 air), and particle size distribution. Sizing, densities, and loads are needed to determine the required capacity and design specifications for sufficient capture. It is also important to specify any unique characteristics of the particulate matter that may lead to corrosion or degradation of certain construction materials.
Construction
A cyclone must be constructed properly in order to meet the sizing and performance requirements of its operation. The biggest variables in cyclone design are its openings (inlets and outlets) and its body size.
Classifications
Cyclones can be classified into two types based on the construction and orientation of the inlet and outlet. These types are reverse flow and uniflow. In reverse flow (seen in Figure 1 above), the gas enters through a tangential inlet at the top of the cyclone body, shaped to create a confined vortex gas flow. The clean gas exits through a central pipe also at the top of the body. In uniflow or straight through cyclones, the gas enters at one end of the body and leaves at the other end; this type is less frequently used in industry because it is a much less practical design in most cases. Cyclones can also be classified into two types based on the body size. High efficiency designs are characterized by long bodies in addition to small openings. This construction allows for high recovery rates at higher pressure drops. High rate designs are characterized by shorter bodies in addition to larger openings, which allow for a larger volume with lower capture rates or pressure drops.
Sizing a cyclone involves many factors, but the most important dimensions to consider are those of the inlet and the main body chamber. The sizing of inlets affects the airflow capacity of a cyclone, and also influences its pressure drop at a given flow velocity. Larger openings will tend to accept greater volumes of air and also will have lower pressure drops, but at the cost of efficiency. Inlet configurations can also vary based on the type of cyclone. The four types include tangential, axial, helical, or spiral. Body size is important because, as mentioned above, the length of the cyclone body is an important factor in collection efficiency. Body size is also directly
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proportional to a cyclones overall capital cost, and determines the space it occupies and its height.
Application Considerations
Some cyclone models are predesigned for specific applications, while others are built for specialized environments. Among the most important application considerations is the dust and gas composition. Specific types of particulate may be corrosive, abrasive, sticky, explosive, or toxic, thus requiring special construction materials or designs in order to function properly. Cyclones are used for filtration in a wide variety of applications: abrasives, coolant mists, explosive media, fine powders, metalworking chips, toxic media, and various production plant exhausts. GEA Niro - Cyclone, Figure 1 Fisher-Klosterman - How to select and maintain a cyclone for maximum efficiency, Figure 2 Dr. L. Svarovsky - Gas Cyclones Youtube - Modeled Cyclone Separator, Video Read user Insights about Cyclone Separators Supplier Datasheets View Suppliers by State View Datasheets by Spec Related Products
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