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a,*
Abstract
A numerical and experimental study has been made for the development of high eciency cyclone dust
separator applicable to the extreme environments of high pressure of 6 bar and temperature up to 400 C.
The main objective of this study is to develop a handy and reliable computer program and thereby to gure
out the physical mechanism of dust collection for high temperature and pressure condition.
The program is developed using Patankars SIMPLE method for the application of 2-D axi-symmetric
ow eld. The two-equation turbulence ke model is employed for the resolution of Reynolds stresses. Further the particle trajectory calculation is made by the incorporation of drag, centrifugal and coriolis force in
a Lagrangian frame.
The calculated results predict well the general trend and its magnitude of the experimentally measured
pressure drop with the condition of increased pressure and temperature as a function of ow rate. Further,
experiment shows that the increase of pressure and temperature generally aect signicantly the collection
eciency of ne particle less than 10 lm but the eect of pressure and temperature appears contrary each
other. That is, the increase of pressure increases the collection eciency, while the increase of the temperature results in the decrease of the eciency over a certain range of ow rate. This is explained well by the
Corresponding author. Tel.: +82 42 821 6677; fax : +82 42 823 8362.
E-mail address: p_dsjang@cnu.ac.kr (D.-S. Jang).
1359-4311/$ - see front matter 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.applthermaleng.2004.11.002
1822
variation of the gaseous density and viscosity eect on the drag force and also conrmed successfully by the
result of numerical calculation. Therefore the decrease of fractional collection eciency caused by the high
operating temperature can be remedied by the increase of operating pressure.
In order to investigate in more detail the eect of extreme condition on the physics of collection eciency, a series of parametric numerical investigations are performed in terms of major cyclone design or
operational parameters such as tangential velocity and vortex nder length, etc. As expected, tangential
velocity plays the most important eect on the particle collection even for the elevated temperature and
pressure condition. But there is no remarkable dierence noted between reference and extreme condition.
And the length of vortex nder has relatively insignicant eect on collection characteristics but the diameter of vortex nder plays an important role for the enhancement of collection eciency.
The incorporation of a proper turbulence model of the nonlinear term appeared by relative velocity
between gas and particle phase for drag calculation of particle trajectory is considered as one of the important tasks for the more accurate resolution of physical feature for elevated temperature and pressure condition in near future.
2004 Elsevier Ltd. All rights reserved.
Keywords: Cyclone separator; Pressure drop; Collection eciency; High temperature and pressure
1. Introduction
The development of new energy saving technologies in power generation causes a strong impetus to develop new devices for hot ue gas cleaning at pressurized condition. A cyclone is considered as one of advantageous tools for high temperature gas cleaning due to their simplicity and
low maintenance requirements. By using suitable materials and methods of construction cyclones
may be adapted for use in extreme operating conditions such as high temperature, high pressure,
and further corrosive gases environments. Therefore, the objective of this study is to investigate
the behavior of dust particle at an elevated temperature and pressure condition.
The schematic diagram of cyclone is shown as in Fig. 1. The dirty gas enters the cyclone tangentially, describes a descending outer vortex, inverts the direction of motion due to the action of
increase of static pressure and ascends by an inner vortex exiting at the cyclone top through the
vortex nder.
The larger particles are swept into the cyclone wall by a centrifugal force, which is locally opposed by aerodynamic drag of radial direction, and are carried towards the bottom of the cyclone
by the descending outer vortex. The ner particles exit at the top with the carrier gas, together
with coarser particles that may have been re-entrained and swept by the ascending inner vortex.
Since cyclones have been used extensively in various industries, a considerable number of experimental and theoretical investigations have been performed on cyclone separators to the present.
Among these, Stairmand [1] presented one of the most popular design guides which suggested that
the cylinder height and exit tube length be, respectively, 1.5 and 0.5 times of the cyclone body
diameter for the design of a high eciency cyclone. Bryant et al. [2] observed if the vortex touched
the cone wall, particle re-entrainment occurred and Leith [3] and Bhatia and Cheremisino [4] discussed the eects of the cone opening size. Rongbiao et al. [5] were suggested that ow rate
strongly inuenced the eciency and the reduction in cone size results in higher collection
Nomenclature
u
v
w
CD
Re
dp
Greek
/
q
C/
S/
l
k
e
Subscripts
g
gas
p
particle
Dirty gas
Cleaned gas
Dirty gas
De
Dc
H
Dust tube
B
Dust
H : Cyclone height
h : Cylinder height
S : Exit tube length
Dc : Cyclone body diameter
De : Gas exit diameter
a : Inlet height
b : Inlet width
B : Dust outlet diameter
1823
1824
eciency without signicantly increasing the pressure drop. Bohnet et al. [68] investigated the
eects of the pressure drop and grade eciency at high temperature and high pressure.
Although our knowledge of what goes on inside a cyclone has increased over the years, the
exact mechanisms of removing particles and eects of each cyclone dimension as shown in
Fig. 1 are still not fully understood due to the complexity of the turbulence itself and the interaction
between particle and carrier gas. In addition, a radical change of operating conditions by high temperature and pressure add even more diculties to the complicated problem. Therefore, most existing cyclone theories are based on simplied models or are heavily dependent upon empiricism. The
theoretical models need experimentally dened factors to t theory on experimental data [6].
Recently, research eorts by computational uid dynamics are frequently carried out for the resolution of ow eld and dust particle behavior with dierent degree of numerical and modeling accuracy in order to assist in the time consuming experimental works. In conjunction with the complex
ow structure, numerical simulation is momentarily not able to completely substitute experiments
but can reduce, to a certain degree, experimental costs for design and optimization. Therefore, the
purpose of this study is to help better understand the particle removing characteristics of cyclone
separator especially by exploring the eects of extreme operating conditions caused by high temperature and pressure. To this end a relatively well-established numerical method for the simple 2-D axisymmetric approximation of cyclone geometry is adopted in this study. The computer program
developed is validated by the comparison of the experimental data performed in the laboratory
of Prof. Bohnet in the dept of Chemical Engineering of University of Braunschweig.
2. Experimental set-up
To receive reliable data for extreme operating conditions, the set-up shown in Fig. 2 has been
installed. It allowed measurements of pressure drop and grade ecient in a temperature range 20
600 C at a maximum pressure of 6 bar. A three stage compressor delivers the ow rate, which is
adjusted by two control valves in the bypass. The pressure is adjusted by one control valve at the
end of the set-up. The air is heated electrically with two heaters. A rotating brush dosing device
installed within a pressure vessel is used to feed solids continuously to the gas. A valve in the main
stream controls the ow rate through the dosing devices. The collection eciency curve is determined by measuring the particle size distribution and the particle concentration within the inlet
and outlet gas stream of the cyclone. These data are measured with two light scattering aerosol
counters in-line and simultaneously. The cyclones are xed in a pressure vessel. This simplies
the variation of the cyclone geometry, because the cyclone itself has to be designed temperature
resistant only [911].
3. Numerical modeling
3.1. Governing equation
The basic gas-phase conservation equations for mass, momentum, energy, turbulence quantities
and species concentration can be expressed, in Eulerian cylindrical framework, as
1825
oq/
r q~
u/ r Cr/ S /
1
ot
where, / denotes general dependent variables expressed as a physical quantity per unit mass. Further, u, v, w, T, q, C/ and S/ standard for x, y, tangential velocity components, density, temperature, diusion coecient, and source term corresponding to /, respectively. Turbulence is modeled
using the high Reynolds number version of the RNG and standard ke model for Reynolds stress.
Table 1 summarizes the diusion coecient, C/, and source term, S/, used in this study [12].
The equations of particle motion can be expressed as
dup
aug up
dt
w2p
dvp
avg vp
dt
rp
dwp
vp wp
awg wp
dt
rp
where,
a
18lg C D Re
;
qp d 2p 24
C D 0:22
24
1 0:15Re0:6
Re
In this study the turbulence modeling appeared in drag force caused by the nonlinear term of
relative velocity between gas and particle phase is not made at this stage in order to eliminate the
eect of the turbulence modeling of the particle phase on the particle trajectory calculation for the
extreme environments. Fig. 3 shows the schematic diagram of the possible 13 trajectories employed in the trajectory calculation [13].
1826
Table 1
/ and C/ expression for 2-D cylindrical coordinate
Variables
C/
Axial momentum
le
Radial momentum
le
Tangential momentum
le
Kinetic energy
o
ou
1o
ov
op
leff
leff r
ox
ox
r or
ox
ox
o
ou
1o
ov
v qw2 op
leff
leff r
2leff 2
x
ox
or
r or
or
r
or
leff qv 1 oleff
w
2
r
r or
r
Gk1qe
e
C 1 C k1 C 2 qe
j
Cp
"
"
2 #
#
ou 2
ov
v 2
ow 2
o w 2
ou ov 2
leff
2leff
ox
or
r
ox
or r
or ox
Temperature
Gj1
leff
rk
leff
rs
S/
Outflow
B.C
Symmetry
B.C
1827
Inlet
condition
R1
R2
Right wall
B.C
RF
Bottom wall
B.C
where, aE, aW, aN, aS, and aP are coecients of east, west, north, south and main grid nodes,
respectively.
Fig. 4 represents the boundary condition of cyclone employed in this study.
1828
Table 2
The specication of cyclone geometry and operating condition employed in this study
Variables
Geometry (mm)
Standard
3
a*
Dc*
D e*
H*
h*
S*
B*
13
100
32
248
55
71
31
* Refer Fig. 1.
160
Calculated
140
15 , 6 bar
200 , 6bar
100
400 , 6bar
P(mbar)
120
15 , 1.1bar
80
60
40
20
0
0
20
40
60
80
100
120
140
160
180
Flow rate(m3/h)
Fig. 5. Measured and calculated pressure drops as a function of ow rate for the condition of elevated temperature and
pressure.
with the increase of gaseous density, that is, high pressure and low temperature condition. This is
attributed to the eect of increased dynamic pressure and thereby large pressure drop by the
increase of density for the same ow rate.
1
18 ,1.1bar,60 m3/h
efficiency,
0.8
400 ,1.1bar,60m /h
0.6
0.4
0.2
0
0.1
10
particle size(m)
Fig. 6. The eect of temperature on the measured fraction collection eciencies for 18 and 400 C temperature.
1829
Fig. 6 shows the eect of temperature on the measured fractional collection eciency curves for
two temperature conditions of 18 and 400 C at atmospheric pressure. As shown in Fig. 6, the
fractional collection eciency of high temperature show lower than that of low temperature over
most particle size range except the very ne particle, below 0.5 lm and particle size greater than
4 lm. The decrease of collection eciency for the case of high temperature is considered due to
the increased viscosity eect as shown in the following argument. If we assume that the radial
velocity component becomes terminal speed by the equilibrium of centrifugal force with the aerodynamic drag force from particle trajectory equations of Eqs. (2)(5), then the terminal velocity
given approximately by the radial velocity component can be expressed approximately as in terms
of gaseous density and viscosity.
vp lg 106 qg
Based on the equation given above, we can conclude that the change of gaseous viscosity plays the
more important role than gaseous density to reduce the particle terminal velocity to the wall of
cyclone.
Further the relatively small eect of gaseous temperature on the fractional collection eciency
for the range of ne (below 0.5 lm) and large (greater than 1.0 lm) particle size is considered as
the signicantly increased and reduced collection eciency due to the change of particle inertia.
Therefore, this analysis leads to the tentative conclusion that the eect of the increase of operating
temperature in cyclone plays an important role over a certain range particle size, that is, moderate
region of particle inertia.
Fig. 7 shows the sole eect of increased pressure on the measured fractional collection eciency. As shown in Fig. 7, the improvement of the collection eciency with the increase of pressure from 1.1 to 6 bar at a temperature of 18 C is clearly observed. As expected, this is caused by
the increased gas phase inertia for a given ow rate, which results in a higher tangential velocity
leading to higher centrifugal force on a particle.
Fig. 8 is a comparison result of the combined eect of increased pressure and temperature on the
measured fractional collection eciency between the high temperature and high pressure and the
ambient reference condition. The overall collection eciencies of two cases are similar each other
and for the sub-micron range of particle size the elevated pressure and temperature condition
1
efficiency,
0.8
18 ,1.1bar,60
/h
18 ,6.0bar,60
/h
0.6
0.4
0.2
0
0.1
10
particle size(m)
Fig. 7. The eect of increased pressure on the measured collection eciency for the pressure of 1.1 and 6 bar.
1830
efficiency,
0.8
400 ,6.0bar,60
/h
/h
0.6
0.4
0.2
0
0.1
10
particle size(m)
Fig. 8. The combined eect of increased pressure and temperature on the measured collection eciency as a function of
particle size for the condition of 1.1 bar, 18 C and 6 bar, 400 C.
Inlet
o
0.05
0.04
0.03
Y
Outlet
0.02
0.01
0
0.05
0.1
0.15
0.2
0.05
0.04
0.03
Y
0.02
0.01
00
0.05
0.1
0.15
0.2
0.05
0.04
0.03
Y
0.02
0.01
0
0.05
0.1
0.15
0.2
0.05
0.04
0.03
Y
0.02
0.01
0
0
0.05
0.1
0.15
0.2
x
Fig. 9. Particle trajectory of various particles (110 lm) with high temperature and pressure (collection eciency:
(a) 90%, (b) 85%, (c) 93%, (d) 87%).
1831
shows a little bit better eciency and vice versa for the particle size more than 1 lm. Based on
the result of this Fig. 8, it is clear that the decrease of collection eciency by the increase of temperature can be alleviated by the proper increase of operating pressure of cyclone.
A number of calculated particle trajectories have been performed with variation of the pressure
and temperature for the ow rate of 20, 40, and 60 m3/h, in which representative particle trajectories are classied with particle size and initial starting location at inlet port. For the case of
60 m3/h, the particle trajectories are presented in Fig. 9 together with the overall collection eciency based on the result of the representative particle trajectories. As shown in the gure, the
collection eciency generally increases with the increase of pressure and decrease of temperature.
The highest collection eciency is 93% for the 6 bar and room temperature and the lowest is 85%
for the 1.1 bar and 400 C. For the case of the ow rate 40 m3/h, the overall collection eciency
shows a little lower or so.
In general, the calculated result is fairly consistent with the qualitative trend of the experimental
observation but the direct comparison with calculation and experiment is not made at this stage
since the nite grouping of representative classication with particle size and initial location is not
sucient to give fairly accurate quantitative evaluation.
0.05
0.04
0.03
Y
0.02
0.01
0
0.05
0.1
0.15
0.05
0.2
0.04
0.03
Y
0.02
0.01
0
0.05
0.1
0.15
0.05
0.2
0.04
0.03
Y
0.02
0.01
0.05
0.1
0.15
0.2
Fig. 10. Trajectory of particles (110 lm) with the increase of diameter of vortex nder (collection eciency: (a) 94%,
(b) 87%, (c) 84%).
1832
In order to gure out further the eect of increased temperature and pressure on the cyclone
eciency a series of parametric investigation have been performed in terms of important cyclone
operating and design variables. Since the pressure and temperature cause opposite eect on cyclone collection eciency, the combined eect of pressure and temperature does not show any
consistent and noticeable dierence compared to the result of reference condition. Figs. 1012 represent the particle trajectories calculated with 6.0 bar and 400 C for the ow rate of 60 m3/h.
0.05
0.04
0.03
0.02
0.01
0
0
0.05
0.1
0.15
0.05
0.2
0.04
0.03
0.02
0.01
0
0
0.05
0.1
0.15
0.05
0.2
0.04
0.03
0.02
0.01
0
0
0.05
0.1
0.15
0.05
0.2
0.04
0.03
0.02
0.01
0
0
0.05
0.1
0.15
0.2
x
Fig. 11. Particle trajectory of various particles (110 lm) with increase of vortex nder length (collection eciency:
(a) 78%, (b) 87%, (c) 87%, (d) 86%).
1833
0.05
0.04
0.03
0.02
0.01
0
0
0.05
0.1
0.15
0.2
0.05
0.04
0.03
0.02
0.01
0
0.05
0.1
0.15
0.2
0.05
0.04
0.03
0.02
0.01
0
0.05
0.1
0.15
0.2
x
Fig. 12. Trajectory of particles (110 lm) with increase of tangential velocity (collection eciency: (a) 67%, (b) 79%,
(c) 87%).
In Fig. 10 calculation results show the eect of diameter of vortex nder on particle trajectory.
As shown in the gure, the increase of the diameter of vortex nder reduces the collection eciency since the eect of increased static pressure inside the vortex tube overwhelms the increased
centrifugal force outside the vortex tube caused by the decreased area by the increase of tube
diameter. A similar result can be also found by the experimental work by Bryant et al. [2].
The calculation results of particle trajectory for various length of vortex nder, S is shown in
Fig. 11. The vortex nder length has insignicant eect on collection eciency s over a certain
range but excessively short (less than S/Dc = 0.2) length reduces the collection eciency due to
early exposure of low pressure region near vortex nder.
Collection eciency signicantly increases with the increase of tangential velocity as shown in
Fig. 12. Higher tangential velocity causes higher centrifugal force and results in a reduction of the
cut size of collected particles. Furthermore, the calculation data show that cyclones have an essential ability to remove ne particles at high tangential velocity. Contrary to conventional idea that
cyclones are not suitable for removing particles smaller than 1 lm, this study shows that it has a
1834
sucient ability to collect particles whose diameters are much smaller than 1 lm at high tangential velocity.
5. Conclusion
Based on a series of numerical investigation and experiment, a number of useful conclusions
can be drawn for the case of extreme operating condition caused by high temperature and pressure condition.
The calculated results predict well the general trend and its magnitude of the experimentally
measured pressure drop with the condition of increased pressure and temperature as a function
of ow rate. Further, experiment shows that the increase of pressure and temperature generally
aect signicantly the collection eciency of ne particle less than 10 lm but the eect of pressure
and temperature appears contrary each other. That is, the increase of pressure increases the collection eciency, while the increase of the temperature results in the decrease of the eciency over
a certain range of ow rate.
In order to investigate in more detail the eect of extreme condition on the physics of collection
eciency, a series of parametric numerical investigations are performed in terms of major cyclone
design or operational parameters such as tangential velocity, vortex nder length and diameter.
Tangential velocity plays the most important eect on the particle collection even for the elevated
temperature and pressure condition. But in general there is no remarkable dierence noted between
reference and extreme condition. Therefore, the decrease of fractional collection eciency by the
operating condition of high temperature can be remedied by the increase of operating pressure.
The incorporation of a proper turbulence model of the nonlinear term appeared by relative
velocity between gas and particle phase for drag calculation of particle trajectory is considered
as one of the important tasks for the more accurate resolution of physical feature for elevated temperature and pressure condition in near future.
References
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[2] H.S. Bryant, R.W. Silverman, F.A. Zenz, How dust in gas aects cyclone pressure drop, Hydrocarbon Process. 62
(1983) 8790.
[3] J. Dirgo, D. Leith, Performance of theoretically optimized cyclones, Filterat. Separat. 22 (1985) 199225.
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Industry, Marcel Dekker, New York, 1993.
[5] S.H. Rongbiao, K.W. Xiang, K.W. Park, K.W. Lee, Eects of cone dimension on cyclone performance, Aerosol
Sci. 32 (2001) 549561.
[6] C.H. Kim, J.W. Lee, A new collection eciency model for small cyclones considering the boundary layer eect,
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1835
[10] M. Morweiser, M. Bohnet, Design calculation of aerocyclones for extreme operating conditions, in: 12th
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