An Introduction to Air Pollution

Chapter 3. Cyclones
Ph.D 25th September 2012

Cyclones
The particulate-laden gas stream is forced to spin in a cyclonic manner.

The mass of the particles causes them to move toward the outside of the vortex. Most of the large-diameter particles enter a hopper below the cyclonic tubes while the gas stream turns and exits the tube.

 There are two main types of mechanical collectors: (1) large-diameter cyclones, and (2) small-diameter multicyclones. Large-diameter cyclones are usually one to six feet in diameter; while small-diameter multi-cyclones usually have diameters between 3 and 12 inches. A typical large-diameter cyclone system is shown in Figure 1. The gas stream enters the cyclone tangentially and creates a weak vortex of spinning gas in the cyclone body.

 Large-diameter particles move toward the cyclone body wall and then settle into the hopper of the cyclone. The cleaned gas turns and exits the cyclone. Large-diameter cyclones are used to collect particles down to 1/16 inch (1.5 mm) diameter and above.

Standard Cyclone

 In systems where the large-diameter cyclone is located after the fan (positive pressure), the treated gas is usually discharged directly from the cyclone. In systems where the cyclone is located before the fan (negative pressure), the gas stream is either exhausted from a separate stack or from the discharge of the fan itself. In negative pressure systems, a solids discharge valve is used to prevent air infiltration up through the hopper area.

 A small-diameter cyclone tube is shown in Figure 2.

Vanes located on the inlet of each of the tubes create the spinning movement of the gas stream.
Most of the commercial tubes are six, nine, or twelve inches in diameter.

Due to the limited gas handling capacity of each tube, large numbers of tubes are mounted in parallel in a single collector.

 Small-diameter multi-cyclones, such as the one shown in Figure 2 are capable of removing particles having diameters down to 5 micrometers. Small-diameter multi-cyclones are not generally used for very large diameter material, such as 3 mm and above, because large particles may plug the spinner vanes in the multi-cyclone tubes. Some mechanical collectors are specially designed to provide high-efficiency PM collection down to a particle size of one micrometer.

 The small-diameter of the cyclone tube creates more rapid spinning of the gas stream than in large-diameter cyclones.
The particles moving outward in the spinning gas stream have a relatively shorter distance to travel in a small-diameter multi-cyclone tube before they reach the cyclone body wall. These features allow small-diameter multi-cyclones to collect considerably smaller particles than largediameter cyclones can.

 Mechanical collectors are used whenever the particle size relatively large (> 5 micrometers) and/or the control efficiency requirements are in the low-to-moderate range of 50 to 90%.
They are also used as the pre-collector of large-diameter embers generated in some combustion systems.

Removal of the embers is necessary to protect highefficiency particulate control systems downstream from the mechanical collectors. Most mechanical collectors are not applicable to industrial sources that generate sticky and/or wet particulate matter.
These materials can accumulate on the cyclone body wall or the inlet spinner vanes of conventional multi-cyclone collectors.

Advantages and Disadvantages of cyclones

Advantages of cyclones are: 1. Low capital cost 2. Ability to operate at high temperatures 3. Low maintenance requirements because there are no moving parts. Disadvantages of cyclones are: 1. Low efficiencies (especially for very small particles) 2. High operating costs (owing to power required to overcome pressure drop).

Generalized efficiency curves for three types of cyclones

Collection Efficiency
(4.1)

Collection Efficiency

d p ( p g )Vi Vt 18R
2

(4.6)

Collection Efficiency
(4.7)

(4.8)

Design Considerations

Design Considerations

Applications

Applications

Problem
A cyclone with a flow rate of 150 m3/min has an efficiency of 80%. Estimate the efficiency if the flow rate is doubled. Step 1 Q1 = 150 m3/min Q2 = 300 m3/min Pt1 = 100% - 80% = 20% Pt2/Pt1 = (Q1/Q2)0.5 Step 2 Final Efficiency = 1- Pt2 = 86%

Pressure Drop

(4.12)

Pressure Drop and Power

(4.13)

Power Requirement

(4.14)

Detailed Design Process

Given - particle size distribution and densities and gas flow rate, temp, pressure, viscosity Specify - desired removal efficiency and pressure drop Select desired design geometry Select body diameter Calculate other dimensions from geometry use Table 4.1 p.127 From inlet area, calculate inlet velocity, Vi = Q/(WH)

Detailed Design part II

Calculate number of turns, Ne from eqn 4.1 From inlet velocity, 50% particle removal diameter eqn 4.6
Using particle diameters - calculate particle collection efficiency for each size eqn 4.7 Using mass fraction mj in size class dj, calculate mass removed right side eqn 4.8

Calculate overall removal efficiency by summing eqn 4.8 If set terms in spreadsheet, can rapidly calculate overall removal efficiency from several body diameter diameters and plot a curve!

Design part III: Pressure Drop

Calculate number of velocity heads eqn 4.12 Calculate pressure drop eqn 4.13 Calculate power requirement, eqn 4.14 See example 4.4 for pressure drop using English units (k = 0.0001575) w f kQP If have in spreadsheet can calculate pressure drop vs body diameter

Cyclone inner vortex core dimensions

Assumed that Vt equals the average air stream inlet velocity Vin when r equals the radius of the cyclone wall (R)

Stokes Equation

Stokes Law
Newtons drag (Re > 1000) applies to particle motion for which the viscous effects of the gas can be neglected compared with the inertial effects. In 1851, George Gabriel Stokes (1819-1903) derived an expression for the drag force on spherical objects with very small Reynold's numbers (e.g., very small particles) by solving the generally unsolvable Navier-Stokes equations. Stokes' law for drag force is expressed as:

FD 3Vd p

Stokes Law
Rep < 1 The net force acting on the particle is obtained by integrating the normal and tangential forces over the surface of the particle.

Normal Force
Frictional Force

Fn Vd p
F 2Vd p

Total resisting force

FD 3Vd p

Stokes Law
By equating Newton's resistance law and Stokes' law, the drag coefficient can be solved for (applicable when Rep < 1):

FD 3Vd p CD g
24 24 CD gVd p Re p

d V

2 p

Theoretical Analysis of Cyclone Collection Efficiency

The particle motion in the cyclone outer vortex can be modeled by Newtons law

For flows in which Stokes law applies, the drag force on a spherical particle may be determined by the Stokes law and the centrifugal force is determined

In the cyclone outer vortex fluid field, there are only two forces (centrifugal force Fc & drag force FD) acting on the particle in the radial direction. When Fc > FD, the particle moves towards the cyclone wall to be collected. Whereas, when Fc < FD, the particle will move to the inner vortex and then to penetrate the cyclone. The force balance (Fc = FD) gives the particle a 50% chance to penetrate and a 50% chance to be collected. The force balance differential equation can be setup by letting equation 4 equal to equation 5, i.e. Fc = - FD, it yields equation 6.