Settling Under Combined Forces

It is sometimes convenient to combine more than one force to effect a mechanical separation. In
consequence of the low velocities, especially of very small particles, obtained when gravity is the only
external force acting on the system, it is well worthwhile to also employ centrifugal forces. Probably
the most common application of this is the cyclone separator.

Cyclone
Cyclonic separation is a method of removing particulates from an air, gas or water stream,
without the use of filters, through vortex separation. Rotational effects and gravity are used to
separate mixtures of solids and fluids.
Although the aim of cyclone operation is to separate particles by size, particle density, particle
shape and other factors also affect the settling rate of particles and hence cyclone performance.
Cyclones are used in preference to screens as a means of size separation in the grinding circuit
as they are more efficient at fine separation sizes.
A high speed rotating (air)flow is established within a cylindrical or conical container called a
cyclone. Air flows in a spiral 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 center 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, falling then 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,
separating smaller and smaller particles. The cyclone geometry, together with 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.

CYCLONE

CYCLONE is the most widely used Centrifugal Separation Equipment for

separating dust or mist from gases. The feed enters the cyclone tangentially
near the top and is given a spinning motion as it enters the cylindrical
chamber. Due to spiral motion of the fluid, there is some radial acceleration

of the particle and the gravitational force imparts downward acceleration.

The result is a downward and spiraling path of increasing radius until the
particles reach the boundary. Therefore, the particles continue a spiraling
path down the wall, and the gas freed of solids, moves upward in the
Central Core. Due to high tangential velocities, large centrifugal force is
developed.
In cyclone separator, the two different density particles are separated by
the action of centripetal force. The feed is mixed with the air in the air pipe
and then entered into the separator due to density difference lighter
particles goes with air and heavier particle fall down .

Application
Large scale cyclones are used in sawmills to remove sawdust from extracted
air. Cyclones are also used in oil refineries to separate oils and gases, and in
the cement industry as components of kiln preheaters. Cyclones are
increasingly used in the household, as the core technology in bagless types
of portable vacuum cleaners and central vacuum cleaners. Cyclones are
also used in industrial and professional kitchen ventilation for separating the
grease from the exhaust air in extraction hoods. [1] Smaller cyclones are used
to separate airborne particles for analysis. Some are small enough to be
worn clipped to clothing, and are used to separate respirable particles for
later analysis.
An alternative cyclone design uses a secondary air flow within the cyclone
to keep the collected particles from striking the walls, to protect them from
abrasion. The primary air flow containing the particulates enters from the
bottom of the cyclone and is forced into spiral rotation by stationary spinner
vanes. The secondary air flow enters from the top of the cyclone and moves

downward toward the bottom, intercepting the particulate from the primary
air. The secondary air flow also allows the collector to optionally be mounted
horizontally, because it pushes the particulate toward the collection area,
and does not rely solely on gravity to perform this function.

Cyclone dimensions

advantages

Disadvantages

Low capital cost.

High operating costs (due to pressure

drop).

Ability to operate at high temperatures.

Low efficiencies (particularly for small

particles).

Can handle liquid mists or dry materials.

Unable to process "sticky" materials.

Low maintenance requirements (no moving parts).

Small footprint - requires relatively small space.

A large diameter cyclone has a much lower separation factor at the same velocity.
We cannot increase the velocirty too much as it leads to abrasive wear.
Multiple-cyclone separators consist of a number of small-diameter cyclones, operating in
parallel and having a common gas inlet and outlet, as shown in the figure, and operate on the
same principle as single cyclone separators -- creating an outer downward vortex and an
ascending inner vortex.
Multiple-cyclone separators remove more dust than single cyclone separators because the
individual cyclones have a greater length and smaller diameter. The longer length provides
longer residence time while the smaller diameter creates greater centrifugal force. These two
factors result in better separation of dust particulates. The pressure drop of multiple-cyclone
separators collectors is higher than that of single-cyclone separators, requiring more energy to
clean the same amount of air. A single-chamber cyclone separator of the same volume is more
economical, but doesn't remove as much dust.