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Separators in the cement industry
2 Cyclones
2.15 Example of calcula៝�on:
‐ We want to install cyclone(s) with following data:
‐ ven៝�la៝�on flow rate: 160 000 m3/h
‐ temperature: 90 °C
‐ al៝�tude: 1 000 m
‐ dust concentra៝�on: 80 gr/m3
‐ dust density: 1 600 kg/m3
‐ desired pressure loss: 150 mmWG
‐ Space restric៝�on: maximum height of cyclone: 9 m
‐ Typical feed of the cyclone:
‐ Calculate:
‐ number of cyclones and cyclones dimensions
‐ pressure drop
‐ efficiency
‐ check if all is OK
‐ Calcula៝�on of air density:
‐ pressure (ph) at 1000m over the sea level with the formula:
‐ air density (ρf) with the formula:
where t is the gas temperature in °C
Following the methodology:
1 Configura៝�on:
We choose: High Efficiency Stairmand
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2 Speed inlet:
We choose: 20 m/sec
3 Cyclones number first es៝�ma៝�on:
At the moment, we choose: 1 cyclone
Then, the flow rate for calcula៝�on is: 160 000 m3/h or 44,444 m3/sec
4 Cyclone diameter calcula៝�on:
With the formula:
5 Other dimensions of the cyclone:
6 Pressure drop calcula៝�on:
With the formula:
Note: we selected K = 16 in this case
7 Check if diameter and pressure drop are OK:
Pressure drop is Ok because 1380,1 Pa = 140,7 mmWG < 150 mmWG
There is a problem with the height of the cyclone: 11,280 m > 9 m
Then we calculate again for 2 cyclones, Q becomes 160 000 m3/h divided by 2 = 80 000 m3/h = 22,222 m3/sec
Using the same formula, we will have:
Note, the pressure drop is the same because dimension parameters are of the same configura៝�on!
Now, it is OK. The cyclone have a height of 8 m < max. 9m
8 Efficiencies calcula៝�on:
and:
where µ = 0,0765 kg/m.h
Then, we use the equa៝�on:
where Di is the average size of each interval
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For example, we have for 0,5 µ:
Results for all sizes:
The next step is to mul៝�ply Ƞi by the par៝�al residue of the interval (or mass),
and to make the sum for all sizes in order to have the total efficiency:
As we have a concentra៝�on of 80 gr/m3 in the inlet of the cyclone, we modify the efficiency with:
Conclusion, the efficiency is 85,66%
9 Checking of the efficiency:
If it is not enough, we have to recalculate with a higher inlet velocity
A calculator is available in the tools page:
Important note: This methodology is only useful for a first and rough es˧ma˧on
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