SOLUTIONS TO CHAPTER 9 EXERCISES: GAS CYCLONES EXERCISE 9.

1: A gas-particle separation device is tested and gives the results shown in the table below:
Size range (m) Range mean (m) Feed mass (kg) Coarse product mass (kg) 0 - 10 5 45 1.35 10 - 20 15 69 19.32 20 - 30 25 120 99.0 30 - 40 35 45 44.33 40 - 50 45 21 21.0

a) Find the total efficiency of the device. b) Produce a plot of the grade efficiency for this device and determine the equiprobable cut size. SOLUTION TO EXERCISE 9.1: (a) From the test results: Mass of feed, M = 45 + 69 + 120 + 45 + 21 = 300 grams. Mass of coarse product, Mc = 1.35 + 19.32 + 99 + 44.33 + 21 = 185 grams. Therefore, from Text-Equation 9.5, total efficiency, E T =

Mc = 0.617 (or 61.7 %) M

mc m

(b) In this case, G(x) may be obtained directly from the results table as G(x) =
For example, for the size range 0-10 m, G(x ) = ranges:
Size range (m) G(x) 0 - 10 0.03 10 - 20 0.28 20 - 30 0.825 30 - 40 0.985 40 - 50 1.000

1.35 = 0.3. For the remaining size 45

Plotting this data gives x50 = 19.4 m, as may be seen from Solution-Manual-Figure 9.1.1.

SOLUTIONS TO CHAPTER 9 EXERCISES: GAS CYCLONES

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EXERCISE 9.2:

A gas-particle separation device is tested and gives the results shown in the table below:
Size range (m) feed size distribution Coarse product size distribution 6.6 - 9.4 9.4 - 13.3 13.3 - 18.7 18.7 - 27.0 27.0 - 37.0 37.0 - 53.0 0.05 0.016 0.2 0.139 0.35 0.366 0.25 0.30 0.1 0.12 0.05 0.06

If the total mass of feed is 200 kg and the total mass of coarse product collected is 166.5 kg, a) Find the total efficiency of the device b) Determine the size distribution of the fine product. c) Plot the grade efficiency curve for this device and determine the equiprobable size. d) If this same device was fed with a material with the size distribution below, what would be the resulting coarse product size distribution?
Size range (m) 6.6 - 9.4 9.4 - 13.3 13.3 - 18.7 18.7 - 27.0 27.0 - 37.0 37.0 53.0 feed size distribution 0.08 0.13 0.27 0.36 0.14 0.02

SOLUTION TO EXERCISE 9.2: (a) From the test results: Mass of feed, M = 200 kg and mass of coarse product, Mc = 166.5 kg.

Therefore, from Text-Equation 9.5, total efficiency, E T =

Mc = 0.8325 (or 83.25 %) M (b) Text-Equation 9.9 gives us the relationship between the size distributions of feed, coarse product and fine product: (dF/dx) = ET (dFc/dx) + (1-ET) (dFf/dx) Rearranging, 1 dF E T dFc dF dF dF f = = 5.97 4.97 c dx dx 1 E T dx 1 E T dx dx
Hence, we can calculate the fine product distribution from a knowledge of the feed distribution and the coarse product distribution:

SOLUTIONS TO CHAPTER 9 EXERCISES: GAS CYCLONES

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Size range (m) Feed: dF/dx Coarse: dFc/dx

Hence, Fine: dFf/dx

6.6 - 9.4 9.4 - 13.3 13.3 - 18.7 18.7 - 27.0 27.0 - 37.0 37.0 - 53.0 0.05 0.016
0.219

0.2 0.139
0.503

0.35 0.366
0.270

0.25 0.30
0.0015

0.1 0.12
0.0006

0.05 0.06
0.0003

dF dFc M c c dx dx = ET (c) Grade efficiency, G(x) = dF dF M dx dx

For example, for the size range 6.6-9.4 m, G(x ) = 0.8325

0.016 = 0.2664 0.05

And for the remaining size ranges:

Size range (m) Feed: dF/dx Coarse: dFc/dx
Hence, G(x):

6.6 - 9.4 9.4 - 13.3 13.3 - 18.7 18.7 - 27.0 27.0 - 37.0 37.0 - 53.0 0.05 0.016
0.2664

0.2 0.139
0.5786

0.35 0.366
0.8706

0.25 0.30
0.999

0.1 0.12
0.999

0.05 0.06
0.999

Plotting this data gives x50 = 10.5m, as may be seen from Solution-Manual-Figure 9.2.1. (d) To calculate the coarse product size distribution with the new feed to the same G(x) dF dF device, we rearrange Text-Equation 9.8 to give: c = E T dx dx hence, for the size range 6.6-9.4 m, remaining size ranges:
Size range (m) 6.6 - 9.4 9.4 - 13.3 13.3 - 18.7 18.7 - 27.0 27.0 - 37.0 37.0 53.0 New feed: dF/dx G(x) G(x) / ET
Hence, dFc/dx

dFc 0.2664 = 0.08 = 0.0256. And for the dx 0.8325

0.08 0.2664 0.32

0.0256

0.13 0.5786 0.6950

0.090

0.27 0.8706 1.046

0.282

0.36 0.999 1.2

0.432

0.14 0.999 1.2

0.168

0.02 0.999 1.2

0.024

SOLUTIONS TO CHAPTER 9 EXERCISES: GAS CYCLONES

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EXERCISE 9.3: a) Explain what a "grade efficiency curve" is for a gas-solids separation device and sketch an example of such a curve for a gas cyclone separator.

b) Determine the diameter and number of Stairmand HR gas cyclones to be operated in parallel to treat 3 m3/s of gas of density 0.5 kg/m3 and viscosity 2 x 10-5 Pas carrying a dust of density 2000 kg/m3. A x50 cut size of at most 7 m is to be achieved at a pressure drop of 1200 Pa. (For a Stairmand HR cyclone: Eu = 46 and Stk50 = 6 x 10-3.) c) Give the actual cut size achieved by your design. d) A change in process conditions requirements necessitates a 50% drop in gas flowrate. What effect will this have on the cut size achieved by your design?
SOLUTION TO EXERCISE 9.3: (b) From Text-Equation 9.1: Eu = p ( f v2 / 2 ), with p = 1200 Pa, f = 0.5 kg/m3

and Eu = 46: characteristic velocity, v = 10.215 m/s Assuming that n cyclones in parallel are required and that the total flow is evenly split, then for each cyclone the flow rate will be q = Q/n = 3.0/n. Text-Equation 9.2 defines the characteristic velocity: v = 4q (D2 ) 0.6115 Substituting q and v, gives: D = n

Substituting this expression for D together with the required cut size in Text-Equation 9.21, x2 p v 50 Stk 50 = , gives: 18D
7 10 6 ) 2000 10.215 3 ( 6 10 =
2

18 2 105 0.6115

hence, n = 1.74. We will therefore need 2 cyclones. Now with n=2, we recalculate the cyclone diameter from D = 0.6115/n0.5 and the actual achieved cut size from Text-Equation 9.21.

SOLUTIONS TO CHAPTER 9 EXERCISES: GAS CYCLONES

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Thus, D = 0.6115/ 2 = 0.432 m. Using this value for D in Text-Equation 9.21 together with required cut size and v = 10.215 m/s (which is dictated by p and the cyclone geometry), we find that the actual cut size is 6.76 m. Therefore, two 0.432 m diameter Stairmand HR cyclones in parallel will give cut size of 6.76 m using a pressure drop of 1200Pa. (d) To determine the influence of gas flowrate, we inspect Text-Equation 9.21, which 0.5 1 1 0.5 shows that if all else is constant, x 50 and so x 50 v q hence, if x represents the new cut size and q represents the new flow rate, 50 0.5 x 50 q = x 50 q
1 and so, x 50 = 0 .5
0. 5

6.76 = 9.56 m.

Thus if the flow rate drop by 50%, the cut size increases to 9.56 m.
EXERCISE 9.4: (a) Determine the diameter and number of Stairmand HE gas cyclones to be operated in parallel to treat 1 m3/s of gas of density 1.2 kg/m3 and viscosity 18.5x10-6 Pas carrying a dust of density 1000 kg/m3. An x50 cut size of at

most 5 m is to be achieved at a pressure drop of 1200 Pa. (For a Stairmand HE cyclone: Eu = 320 and Stk50 = 1.4 x 10-4.) b) Give the actual cut size achieved by your design.
SOLUTION TO EXERCISE 9.4: (a) From Text-Equation 9.1: Eu = p ( f v2 / 2 ), with p = 1200 Pa, f = 1.2 kg/m3

and Eu = 320: characteristic velocity, v = 2.5 m/s Assuming that n cyclones in parallel are required and that the total flow is evenly split, then for each cyclone the flow rate will be q = Q/n = 1.0/n. Text-Equation 9.2 defines the characteristic velocity: v = 4q (D2 ) 0.7136 Substituting q and v, gives: D = n Substituting this expression for D together with the required cut size in Text-Equation 9.21,
SOLUTIONS TO CHAPTER 9 EXERCISES: GAS CYCLONES Page 9.5

Stk 50 =

x2 p v 50 18D

, gives: 5 10 6

1.4 10 4 =

18 18.5 10 6 0.7136

) 1000 2.5
2

hence, n = 0.283. We will therefore need only one cyclone. Now with n=1, we calculate the cyclone diameter from D = 0.7136/n0.5 and the actual achieved cut size from Text-Equation 9.21. (b) Thus, D = 0.7136/1= 0.7136 m. Using this value for D in Text-Equation 9.21 together with required cut size and v = 2.5 m/s, we find that the actual cut size is 3.65 m. Therefore, one 0.714 m diameter Stairmand HE cyclone will give cut size of 3.65 m using a pressure drop of 1200Pa. Stairmand HR cyclones are to be used to clean up 2.5 m3/s of ambient air (density 1.2 kg/m3 and viscosity 18.5 x 10-6 Pas) laden with dust of particle density 2600 kg/m3. The available pressure drop is 1200 Pa and the required cut size is to be not more than 6 m. (a) What size of cyclones are required? (b) How many cyclones are needed and in what arrangement? (c) What is the actual cut size achieved?
EXERCISE 9.5: SOLUTION TO EXERCISE 9.5: 2 From Text-Equation 9.1: Eu = p ( f v / 2 ), with p = 1200 Pa, f = 1.2 kg/m3 and

Eu = 46 (see Text-Figure 9.5):

characteristic velocity, v = 6.594 m/s

Assuming that n cyclones in parallel are required and that the total flow is evenly split, then for each cyclone the flow rate will be q = Q/n = 2.5/n. Text-Equation 9.2 defines the characteristic velocity: v = 4q (D2 ) 0.695 Substituting q and v, gives: D = n

SOLUTIONS TO CHAPTER 9 EXERCISES: GAS CYCLONES

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Substituting this expression for D together with the required cut size in Text-Equation 9.21 (noting that Stk50 = 6 x 10-3), x2 p v 50 , gives: Stk 50 = 18D 6 10 6 ) 2600 6.594 3 ( 6 10 =
2

18 18.5 10 6 0.695

hence, n = 5.06.

Since the required number of cyclones is only slightly greater than 5, we will try five cyclones in parallel. With n=5, we calculate the cyclone diameter from D = 0.695/n0.5 and the actual achieved cut size from Text-Equation 9.21. Thus, D = 0.695/ 5 = 0.3108 m. Using this value for D in Text-Equation 9.21 together with required cut size and v = 6.594 m/s (which is dictated by p and the cyclone geometry), we find that the actual cut size is 6.1 m. Therefore, five 0.311 m diameter Stairmand HR cyclones in parallel will give cut size of 6.1 m using a pressure drop of 1200Pa. (Six cyclones may be used if felt necessary, in which case, D = 0.284 m and x50 = 5.75 m).

SOLUTIONS TO CHAPTER 9 EXERCISES: GAS CYCLONES

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Figure 9.1.1: Grade efficiency curve for Exercise 9.1.

SOLUTIONS TO CHAPTER 9 EXERCISES: GAS CYCLONES

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Figure 9.2.1: Grade efficiency curve for Exercise 9.2.

SOLUTIONS TO CHAPTER 9 EXERCISES: GAS CYCLONES

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