2105382 2105382

UNIT OPERATIONS I
Separation of Particle from fluid: Cyclone
Apinan Soottitantawat
Apinan.s@chula.ac.th

Separation
There are many cases during the processing and handling of particulate solids when particles are required to be separated from suspension in a gas or a liquid. How to separate them ?
Classification of separation techniques according to p p q g phases involved

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Separation: Cyclone
One of the widely used is Cyclone.

- Gas Cyclone Separate the particle solid (aerosol) from Cyclone: the gas. - Hydrocyclone Separate the particle solid (aerosol) from Hydrocyclone: the liquid.

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LOGO

Gas Cyclone

Apinan Sootitantawat apinan.s@chula.ac.th

SolidSolid-gas separation (Dust Collection)

Purpose of the separation
1. Air-pollution control, as i fl 1 Ai ll ti t l in fly-ash removal f h l from power-plant fl l t flue gases 2. Equipment-maintenance reduction, as in filtration of engine intake air or pyrites furnace-gas treatment prior to its entry to a contact sulfuric acid plant 3. Safety- or health-hazard elimination, as in collection of siliceous and y metallic dusts around grinding and drilling equipment and in some metallurgical operations and flour dusts from milling or bagging operations 4. Product-quality improvement, as in air cleaning in the production of pharmaceutical products and photographic film 5. 5 Recovery of a valuable product as in collection of dusts from dryers product, and smelters 6. Powdered-product collection, as in pneumatic conveying; the spray drying of milk eggs and soap; and the manufacture of high purity milk, eggs, zinc oxide and carbon black
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SolidSolid-gas separation (Dust Collection)

In any application, the size of the particles to be removed from the gas determine, determine the method to be used for their separation separation. Generally speaking, particles larger than about 100 mm can be separated easily by gravity settling. For particles less than 10 mm more energy intensive methods such as filtration, wet scrubbing and electrostatic precipitation must be used.

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Cyclone

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Cyclone
> 10 m

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Cyclone
Particles in the gas are subjected to centrifugal forces which move them radially outwards, against the inward flow of gas and towards the inside surface of the cyclone on which the solids separate. The direction of flow of the vortex reverses near the bottom of the cylindrical section and the gas leaves the cyclone via the outlet in the top. The solids at the wall of the cyclone are pushed downwards by the t th outer vortex and out of th solids exit. t d t f the lid it

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Cyclone

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Cyclone: Components

(cylinder)

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Cyclone: Type of inlet

Tangential entry

Tangential entry Helical entry With deflector vanes

Involute entry

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Cyclone: Solid discharge valve

Simple manual slide gate Rotary valve Double flap value

Discharge screw feeder

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Cyclone: Outlet of cyclone

Involute scroll outlet

Rotary valve

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Cyclone: Type of Cyclone

Based on gas inlets: inlets:

1. Tangential Entry cyclone

Top inlet

Bottom inlet
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Cyclone: Type of Cyclone

Based on gas inlets: inlets:

2. Axial Entry cyclone

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Cyclone: Type of Cyclone

Based on gas inlets: inlets:

2. Axial Entry cyclone

Multiple Cyclone
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Cyclone: Type of Cyclone

Based on cyclone performance: performance:

1. Conventional cyclone 2. High efficiency cyclone

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Body diameter Height of inlet Width of inlet Diameter of gas Length of vortex Length of body Length of cone Diameter of dust outlet

D/D 1.0 1.0 1.0 H/D 0.44 0 44 0.5 05 0.8 08 W/D 0.21 0.25 0.35 0.4 0.5 0.75 De/D S/D 0.5 0.6 0.85 1.4 1.75 1.7 Lb/D Lc/D 2.5 25 2.0 20 2.0 20 Dd/D 0.4 0.4 0.4

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LOGO

Over all and Grad efficiency of collector (cyclone) ( l )

Apinan Sootitantawat apinan.s@chula.ac.th

Efficiency of separation
It is useful to represent the efficiency with which various sizes or grades of particles are distributed between the outputs of separation devices devices.

1. Grade or fractional efficiency 2. Overall efficiency

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Total Efficiency and Grade Efficiency Materials Balance

Mf
f mi , f
M f mi

M = M f + Mc
Component Balance

f mi ,c
Mc

f mi M = f mi , f M f + f mi ,c M c
f mi = Mass Fraction

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Total Efficiency Total efficiency

Mf

Mc Et = M

M Mc
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Grade Efficiency G(x) Grade efficiency G(x)

Mf

M Mc

G ( xi ) =

M i ,c f mi ,c M c M i, f f mi M

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Know Grade Efficiency G(x) to calculate Et

Mc Et = M
Mc Et = = M

G ( xi ) =

M i ,c M i , feed

f mi ,c M c f mi M

M
M

ic

G( x )M =
i

i , feed

= G ( xi ) f mi , feed

Et = G ( xi ) f mi , feed
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Know Et to calculate Grade Efficiency G(x)

G ( xi ) =

f mi ,c M c f mi, ffeed M i d

Mc Et = M

Grade efficiency G(x)

G ( x) = Et

f mi ,c f mi , feed
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Total & Grade Efficiency G(x)

Mc Et = M

M = M f + Mc
f mi M = f mi , f M f + f mi ,c M c

G ( x) = Et

f mii ,c f mi

f mi = f mi , f (1 Et ) + f mi ,c Et
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Example: Total & Grade Efficiency Tests on a reverse flow gas cyclone give the results shown in the t bl below: th table b l
Lower 0 5 10 15 20 25 Upper 5 10 15 20 25 30 Mass in feed (g) 10.00 15.00 25.00 25 00 30.00 15.00 5.00 Coase product size (g) 0.10 3.53 18.00 18 00 27.30 14.63 5.00

From these results determine the total efficiency of the cyclone and grade efficiency of each particle range
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Solution: Total efficiency

Lower 0 5 10 15 20 25 Upper 5 10 15 20 25 30 Total Di 2.5 7.5 12.5 12 5 17.5 22.5 22 5 27.5 Mass in feed (g) 10.00 15.00 25.00 25 00 30.00 15.00 15 00 5.00 100.00 100 00 Coase product size (g) 0.10 3.53 18.00 18 00 27.30 14.63 14 63 5.00 68.56 68 56

M c 68.56 Et = = = 0.68 M 100

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Solution: Grade efficiency

G ( x) =

M i ,c M ii, feed

f mi ,c M c f mi M
Coase product size (g) 0.10 3.53 18.00 27.30 14.63 5.00 68.56 G(x)=Mci/Mi 0.0100 0.2353 0.7200 0.9100 0.9753 1.0000

Lower 0 5 10 15 20 25

Upper 5 10 15 20 25 30 Total

Di 2.5 7.5 12.5 17.5 22.5 27.5

Mass in feed (g) 10.00 15.00 25.00 30.00 15.00 5.00 100.00

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Grade efficiency curve

1.00 G GradeEff ficiency, ,G(x) 0.80 0.60 0.40 0.20 0 20 0.00 0 10 20 30 Diameter (m)
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Example: Size distribution and cyclone efficiency

Air in a foundry is dusty because of handling sand used to make molds, shaking castings out of the sand molds, and so on. A , g g , sample of the workplace air was draw through a cyclone at a rate of 0.15 L/min for a period of 100 s. The sampled air contained 240 particles, particles which were counted and size optically on the basis of diameter as shown in the table. (density of particle = 1.74 g/cm3)

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Example: Size distribution and cyclone efficiency

It has been proposed to remove particle from the air with a cyclone whose fractional (grade) efficiency is given below. y (g ) y g

1. Plot the i distribution f the 1 Pl t th size di t ib ti of th sample i b th of normal graph l in both f l h and lognormal graph for number and mass basis. 2. Will this cyclone be able to bring the workplace air into y g p compliance with the OSHA standard that specifies that the maximum allowable concentration for nonrespirable nusance dust is 15 mg/m3?
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Solution:

Dlower Dupper Di 5 6 5.5 6 9 7.5 9 13 11 13 18 15.5 18 26 22 26 37 31.5 31 5 37 52 44.5 52 73 62.5 73 103 88

ni fi=ni/ni D 1 0 0.0000 3 0 0.0000 4 2 0.0083 0 0083 5 29 0.1208 8 54 0.2250 11 84 0.3500 0 3500 15 54 0.2250 21 14 0.0583 30 3 0.0125 Total 240 1.000

hi=fni/D 0.0000 0.0000 0.0021 0 0021 0.0242 0.0281 0.0318 0 0318 0.0150 0.0028 0.0004

niDp3 0 0 2662 107992 574992 2625494 4758541 3417969 2044416 13532065

fmi=niDp3/niDp3 hmi=fmi/D 0.0000 0.000000 0.0000 0.000000 0.0002 0 0002 0.000049 0 000049 0.0080 0.001596 0.0425 0.005311 0.1940 0 1940 0.017638 0 017638 0.3516 0.023443 0.2526 0.012028 0.1511 0.005036 1.0000

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Solution:
0.0350 Nu umberfract tion/morMassfrac ction/m 0.0300 0.0250 0 0250 0.0200 0.0150

Number fraction

Mass fraction
0.0100 0.0050 0.0000 1 10 Diameter(m) 100 S.Apinan
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Solution:
2. Will this cyclone be able to bring the workplace air into compliance with the OSHA standard that specifies that the maximum allowable concentration for nonrespirable nusance dust is 15 mg/m3? g
Step 1: Determine the initial over all dust mass concentration

Number concentration =

240 = 960 particles/L 0.15 100 / 60

Number concentration = 9.60 105 particles/m 3

Mass concentration = Number Concentration

3 Dm

6 Dm = Diameter of average mass

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Solution: Determine the diameter of average mass

Dlower 5 6 9 13 18 26 37 52 73 Dupper 6 9 13 18 26 37 52 73 103 Di 5.5 7.5 11 15.5 22 31.5 31 5 44.5 62.5 88 D 1 3 4 5 8 11 15 21 30 Total
1/ 3

ni fn,i=ni/nt 0 0.0000 0 0.0000 2 0.0083 29 0.1208 54 0.2250 84 0.3500 0 3500 54 0.2250 14 0.0583 3 0.0125 240 1.000

niDp3 0 0 2662 107992 574992 2625494 4758541 3417969 2044416 13532065

fiDp3 0 0 11 450 2396 10940 19827 14242 8518 56384

n i di 3 dm = N

( f d )
i i

3 1/ 3

= 38.34

Dm = Diameter of average mass

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Solution:
Determine the initial over all dust mass concentration

Number concentration = 9.60 105 particles/m 3

Mass concentration = Number Concentration
3 Dm

6 1740 kg/m 3 (38.34 10 6 ) 3 Mass concentration = 9.60 105 6 Mass concentration = 4.93 10 5 kg/m 3 = 49.3 mg/m 3

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Solution:
Step 2: The minimumum over all efficiency to pass the standard ( concentration for nonrespirable nusance dust is 15 mg/m3)
Mass Balance

M c = M feed M fine = 49.2 15 = 34.3 mg/m

Et ,minimum

M c 34.3 = = = 0.6957 M 49.3

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Solution:
Step 3: Determine the actual overall efficiency from grade efficiency

Et = G ( xi ) f mi , feed

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Solution:

Dlower Dupper 5 6 9 13 18 26 37 52 73 6 9 13 18 26 37 52 73 103

Di 5.5 7.5 11 15.5 22 31.5 44.5 62.5 88

ni 0 0 2 29 54 84 54 14 3 240

fi ni/ fi=ni/ni 0.0000 0.0000 0.0083 0 0083 0.1208 0.2250 0.3500 0.2250 0.0583 0.0125 1.000

fmi niDp3/ fmi=niDp3/niDp3 0.0000 0.0000 0.0002 0 0002 0.0080 0.0425 0.1940 0.3516 0.2526 0.1511 1.0000

G(xi) 0.42 0.5 0.6 06 0.68 0.72 0.8 0.83 0.93 0.98

G(xi)fmi 0.0000 0.0000 0.0001 0 0001 0.0054 0.0306 0.1552 0.2919 0.2349 0.1481 0.8662

Et = G ( xi ) f mi , feed = 0.8662
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Solution:

Et > Et ,standard

Consequently, the collector is capable of q y, p satisfying the OSHA standard.

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Collectors in series

M feed
Cyclone 1

M f1
Cyclone 2

M f 2 M f ,n 2
Cyclone n-1

M f ,n 1
Cyclone n

Mf

M c1 M c1 Et1 = M feed
1 Et1 = M f1 M feed

M c2

M c ,n 1
Et ,n 1 =
1 Et ,n 1 =

M c ,n
Et ,n =
1 Et ,n =

M c2 Et 2 = M f1
1 Et 2 = Mf2 M f1

M c ,n 1

M c ,n M f ,n 1
M f ,n M f ,n 1
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M f ,n 2
M f ,n 1 M f ,n 2

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Collectors in series

M c1 Et1 = M feed
1 Et1 = M f1 M feed

M c2 Et 2 = M f1
1 Et 2 = Mf2 M f1

Et ,n 1 =
1 Et ,n 1 =

M c ,n 1 M f ,n 2
M f ,n 1 M f ,n 2 n

Et ,n =
1 Et ,n =

M c ,n M f ,n 1
M f ,n M f ,n 1 n

Mass Balance

M feed = M ci +M f ,n
1 Et = 1 Et = M f ,n M feed M f1 M feed Mf2 M f1 ... M f ,n 1 M f ,n 2 M f ,n M f ,n 1
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Et

M =

c ,i

M feed

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Collectors in series
Therefore

1 Et =

M f1 M feed

Mf2 M f1

...

M f ,n 1 M f ,n 2

M f ,n M f ,n 1

1 Et = (1 Et1 ) (1 Et 2 ) ... (1 Et ,n 1 ) (1 Et ,n )

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Collectors in parallel:

M c1
M f1
Cyclone 1

M feed ,1 f
M feed

Mf

M feed , 2

Cyclone 2

Mf2

M c2
Mass Balance

M feed = M fi + M ci = M f + M ci
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Collectors in parallel:

M c1
M f1
Cyclone 1

M feed ,1 f
M feed

Mf

M feed , 2

Cyclone 2

Mf2

Et

M =

M c2
ci

M feed

M feed M f M feed

= 1

Mf M feed
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Collectors in parallel:

M c1
M f1
Cyclone 1

M feed ,1 f
M feed

Mf

M feed , 2

Cyclone 2

Mf2

M c2

M f1 Mf2 M c1 M c2 Et1 = = 1 Et 2 = = 1 M feed 1 M feed 1 M feed 2 M feed 2

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Collectors in parallel:

M f 1 = M feed 1 (1 Et1 ) Et = 1 Mf M feed

M f 2 = M feed 2 (1 Et 2 )

M = 1
feed f d ,i

fi

M feed

Et

M = 1

(1 Eti )

M ffeed d
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Grade efficiency curve

1.00 G GradeEff ficiency, ,G(x) 0.80 0.60 0.40 0.20 0 20 0.00 0 10 20 30 Diameter (m)
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Cyclone Grade Efficiency in Practice There are the another way to show the efficiency of collector/separator as cut diameter (critical size critical size, diameter, xcrit, dpcirt) For cyclone, the grade efficiency curve for g cyclones is y , g y gas y usually S-shaped. The particle size for which the grade efficiency is 50%, cut size, x50, is often used as a single number measurement of the efficiency of the cyclone. x50 is sometimes simply referred to as the cut size of the cyclone (or other separation device). p y The concept of x50 cut size is useful where the efficiency of a cyclone is to be expressed as a single number independent of the feed solid size distribution, such as in scale-up calculation.
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Cut size/ Cut diameter in cyclone

1.00 G GradeEff ficiency, ,G(x) 0.80 0.60 0.40 0.20 0 20 0.00 0 10 20 30 Diameter (m)

Cut size = D p 50 = x50

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LOGO

Prediction of collection efficiency

Apinan Sootitantawat apinan.s@chula.ac.th

Prediction of collection efficiency

Theoretical approach (Laminar flow) Cut diameter approach (Lapple`s method) Leith and Licht`s method

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Prediction of collection efficiency 1. Theoretical approach (Laminar flow)

N e p d V G ( x) = = 9 W

2 p g

Lc 1 N e = Number of turns of vortex ( Lb + ) H 2

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Prediction of collection efficiency Number of turns of vortex (Ne)

N e = Number of turns of vortex f f

Lc 1 N e ( Lb + ) H 2

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Prediction of collection efficiency 2. Cut diameter approach

A semiempirical approach developed by Lapple used larminar flow treatment but introduced the concept of a cut size, dp50. Therefore he could fine the cut diameter as

N e p d V = 0. 5 = 9 W
d p 50 9 W = 2N e pVg

2 p g

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Prediction of collection efficiency Lapple`graph

G (dpi ) =

1 + (d p 50 / d pi ) p

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Prediction of collection efficiency 3. Leith & Licht s modelTheoretical approach Licht (Laminar flow)
The laminar flow model has limitations, as gas flow in a cyclone is not simply laminar (nor is it fully turbulent, because the boundary layer has a significant depth). Leith&Licht have derived the equation which was in the form q

G ( Dp) = = 1 exp(2(C ) p p(
G(Dp) C n

1/ 2 n + 2

dp Configuration parameter Impaction parameter Vortex V t exponentt

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Parameter of cyclone

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Prediction of collection efficiency

( D) T n =1 2.5 283
0.14 0.3

D T
D C= 21 e WH D

Cyclone diameter () ()

D 2

S H 1 S + k Lb d d 2 Lb De 2 k S 1 + + + + D D 2D 3 D D D D D D

D, W, H, De, Lb, D W H De Lb S 2 1/ 3 k D
k = 2.3De WH
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Prediction of collection efficiency

( D) T n =1 2.5 283
0.14 0.3

D T
D 2

Cyclone diameter () ()
2

D C= 21 e WH D

S H 1 S + k Lb d d 2 Lb De 2 k S 1 + + + + D D 2D 3 D D D D D D

D, W, H, De, Lb, D W H De Lb S k is the farthest distance that the vortex extends below the gas exit duct calculate from

D2 k = 2.3De WH
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Prediction of collection efficiency

And d is the diameter of conical section at k

d = D ( D Dd )(S + k Lb ) / Lc
In addition

p d Vg (n + 1) = 18 g D
2 p

p dp Vg g

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Prediction of collection efficiency

The accuracy of each model/approach

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Prediction of pressure drop

1 2 P = gVi H v 2
P g Vi Hv , Pa , kg/m3 , m/s iinlett velocity head l l it h d
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Prediction of pressure drop

HW Hv = K 2 De
Hv the number of velocity head K 16 (tangential inlet), 7.5 (vane) H , m W , m De , m
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Pressure drop in gas cyclone

Common ranges of pressure drops are as follows

Low-efficiency cyclones Medium-efficiency cyclones High-efficiency cyclones

2-4 in. water 4-6 in. water 8-10 in. water

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Factors that affect to the cyclone efficiency

(D) (Lb&Lc) (De) () () /

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Cyclones in series Connecting cyclones in series is often done in practice to increase recovery. Usually the primary cyclone would be of medium or low efficiency design and the secondary and subsequent cyclones of progressively more efficient design or smaller diameter.

Series S
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Cyclones in parallel The x50 cut size achievable for a given cyclone geometry and operating pressure d d ti drop d decreases with d ith decreasing i cyclone size. The size a single cyclone for treating a given volume flow rate of gas is determined by that gas flow rate. For large g flow rates the resulting cyclone may be so g gas g y y large that the x50 cut size is unacceptably high. The solution is to split the gas flow into several smaller cyclones operating i parallel. l ti in ll l In this way, both the operating pressure drop and x50 cut size requirements can be achieved achieved.

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Cyclones in series and parallel

Clean gas

Parallel

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- - - - - - - 10 - -

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