EXPERIMENT 3

CYCLONE SEPARATOR

1.0 0BJECTIVES

1.1 To demonstrate the cyclone separation operation and measure the pressure drop
against input velocity.

1.2 To determine the cyclone separation efficiency on different air flow rate.

1.3 To evaluate the relationship between separation efficiency and air flow rate.

2.0 INTRODUCTION

Cyclonic separation is a typical solid-gas or liquid-solid separation device. It consists 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.

Collection Efficiency

The collection efficiency typically depends on the movement of gas and particles and
also the particles sizes.

1. Cyclone fractional efficiency

Cyclone fractional efficiency is the weight of stated size of particles collected in the
hopper divided by the total weight of same size particles entering the cyclone. Referring
the paper proposed previously, the collection efficiency increase as:

The increase of particle size and density.

Increasing speed of cyclone rotation in the cyclone vortex.
Decreasing cyclone diameter.
Increasing cyclone length.

2. Cyclone grades efficiency

A cyclone grade efficiency curve related the particle sizes to the cyclones efficiency on
particle of that size going to the cyclone. The grade efficiency curve for Stairmans high
efficiency cyclone (Figure 1) shown that efficiency continuously increase with increasing
the particle diameter, and approach to 100% asymptomatically for a sufficient large
particle. Efficiency is generally good for dusts where particle diameters are larger than 5
m.

Figure 1: Cyclone grade efficiency, high efficiency standard design and optimized design

The efficiency of cyclone often related to its critical size or its cut size. A critical size is
defined as the size of particles calculated to be collected with 100% efficiency. Cut size
defined as the aerodynamics equivalent diameter of the particle collected with 50%
efficiency. Lapple (1951) related the cyclones efficiency with particle cut size. From the
studies, the actual efficiency of cyclone increase gradually with increase in the ratio of
dp/dpc as shown in Figure 2. dpc represent the cut size of the particle, which can be
calculated by:

where,

G = gas viscosity, kg/ms

b = cyclone body diameter, m
p = Particle density, kg/m3
vg = Gas velocity, m/s
Ne = number of turn the gas makes in the cyclone. Friedlander et.al (1952) proposed
that, this value can be a constant varying from 0.5 to 1, with typical value of 5.
 Figure 2: Cyclone efficiency versus dp/dpc, from Lapple (1951)

Theodera and DePaola (1980) then fitted an algebraic equation into the curve proposed
by Lapple (1951) as below:

where,

j = collection efficiency of particle in the jth size range (0<i <1)

dpj = characteristic diameter of the particle size range (m)

The overall cyclone efficiency defined as,

where,

mj = mass of particles in the j

M = total mass of particle

The performance of cyclone can be improved with drawing some gas from cyclone by
the exit duct or wetting the cyclones wall.
Pressure Drop

Pressure drop is a important parameter in order to evaluate the cyclone performance.

The pressure drop in a cylinder only considered at the inlet and outlet location. It
contributed by:

1. Loss due to the expansion gas when it enters the cyclone chamber
2. Loss as kinetic energy of rotation in the cyclone chamber
3. Losses due to wall friction in the cyclone chamber
4. Any additional friction losses in the exit duct, resulting from swirling flow above and
beyond those incurved by straight flow
5. Any regain rotational kinetic energy as pressure energy

Many models have been developed to estimate the pressure drop in cyclone separator,
among them, Shepherd and Lapple (1939) and Stairmand (1949,1951) are most
common used. However these model are either empirical or theoretical; none of them
predicts the pressure drop accurately. It is know that pressure drop is a function of the
cyclone dimensions, particles properties and its operating conditions such as inlet air
velocity. Shepherd and Lapple (1939,1940) converted inlet velocity heads into pressure
drop in term of static pressure head, P with the equation derived below:

where,

vg = gas velocity through cyclone inlet, m/s

G = gas density
H = pressure drop in inlet velocity head
G = acceleration of gravity
L = liquid density

CJ. Stairmand assume that the total energy loss is due to losses in the cyclone vortex,
plus entrance and exit losses. The empirical pressure drop equation given by Stairmand
(1949) is,

where ,
Here, G is a friction factor approximately equal to 0.005 and A is the inside surface of the
cyclone exposed to the spinning gas. A value for A can be calculated from:

3.0 MATERIALS & APPARATUS

3.1 Cyclone separation trainer

3.2 Filter bag

3.3 Acrylic resins

3.4 Dust particle (or other test samples)

 Figure 3: Cyclone Separator Trainer

LEGEND
A Dust tank F Air blower
B Cyclone A G Water tank
C Cyclone B H Control panel
Pressure different meter for Cyclone
D Cyclone C I
B and Cyclone D
E Cyclone D J Duct
4.0 PROCEDURE

4.1 Measurement of Pressure Drop Against Input Velocity

1. Place the cyclone separation trainer apparatus on ground.

2. Plug the 3 phase 5 pin plug to the main power supply. Turn on the power supply.

3. Switch ON the power supply unit in front of the control panel.

4. Close the entire cyclone inlet valve except cyclone B valve.

 5. Tare zero the digital differential meter by pressing the zero button.

6. Switch ON the blower by pressing the run button. Set the frequency to say 10
Hz. Record the reading from the differential pressure meter.

7. Increase the blower speed with every 5Hz increment until 25 Hz. Off the air
blower. Close the cyclone B valve and switch ON the cyclone D valve. Repeat
step 6 to 8.

8. Calculate the air speed in the cyclone for each different frequency.

9. Plot the graph of air peed against blower frequency for both of the cyclone.

Note:
Relationship between the frequency of the motor and the velocity:

where,

V = Air speed (m/s)

Pstagnation= Stagnation or total pressure (Pa)
Pstatic = Static pressure (Pa)
= Air density (kg/m3) = 1.165 kg/m3 @ 30oC
Pstagnation Pstatic = Reading from digital differential meter

4.2 Measurement of Cyclone Separation Efficiency on Different Air Flow Rate

1. Place the cyclone separation trainer apparatus on ground.

2. Plug the 3 phase 5 pin plug to the main power supply. Turn on the
power supply.

3. Switch ON the power supply unit in front of the control panel.

4. Close the entire cyclone inlet valve except cyclone A valve. Close the
feed tank valve.

5. Measure 50 g of acrylic resin (initial sample) and pout into tank A

(feed tank).

6. Fix the filter bag to the bottom outlet of the cyclone. Measure the
weight of the filter bag before fix into the bottom outlet of the cyclone.

7. Switch ON the blower by pressing the run button. Set the frequency to
say 10 Hz. Allow the air to circulate for about 2 minutes.
 8. Open the feed tank valve. Investigate the air flow pattern in the
cyclone.

9. Ensure the dust is all completely channel into the cyclone.

10.Stop the blower by press the stop button.

11.Remove the filter bag and measure the weight of the filter paper.

12.Repeat the experiment by vary the air flow rate.

13.Calculate the separation efficiency for each different flow rate.

14.Repeat the experiment by using different test sample.

15.Repeat the experiment by using the 200 mm cyclone.

16.Plot the graph of separation efficiency against blower speed for both
of the cyclones.

Note:
Final sample weight = Final filter bag weight - Initial filter bag weight
Separation efficiency, n = (final sample weight - initial sample
weight)/initial sample weight

5.0 RESULTS

5.1 Measurement of Pressure Drop Against Input Velocity

P (Pa)
Frequency (Hz)
100 mm Cyclone 200 mm Cyclone
10
15
20
25

Speed in Cyclone (m/s)

Frequency (Hz)
100 mm Cyclone 200 mm Cyclone
10
15
20
25
5.2 Measurement of Cyclone Separation Efficiency on Different Air Flow Rate

100 mm Cyclone
Blower Initial Filter Final Filter Final Initial Separation
Speed Bag Weight Bag Weight Sample Sample Efficiency
(Hz) (g) (g) Weight (g) Weight (g) (%)

200 mm Cyclone
Blower Initial Filter Final Filter Final Initial Separation
Speed Bag Weight Bag Weight Sample Sample Efficiency
(Hz) (g) (g) Weight (g) Weight (g) (%)

6.0 DISCUSSION

(Include a discussion on the result noting trends in measured data, and comparing
measurements with theoretical predictions when possible. Include the physical interpretation of
the result, the reasons on deviations of your findings from expected results, your
recommendations on further experimentation for verifying your results, and your findings.)

7.0 CONCLUSION

(Based on data and discussion, make your overall conclusion.)

5.0 QUESTIONS

8.1 Discuss the finding from the graph obtained.

8.2 Explain the working principle of cyclone separation unit. How does the particle can
be separated away from the air in the cyclone?

8.3 State two (2) methods / steps to increase the efficiency the cyclone separator.

8.4 State the application and where the cyclone separator in normally installed.