Cyclone separators:

Cyclone Separators The most widely used type of dust-collection equipment is the cyclone, in which
dust-laden gas enters a cylindrical or conical chamber tangentially at one or more points and
Fileaves through a central opening (Fig. 17-36). The dust particles, by virtue of their inertia, will tend
to move toward the outside separator wall, from which they are led into a receiver. A cyclone is
essentially a settling chamber in which gravitational acceleration is replaced by centrifugal
acceleration. At operating conditions commonly employed, the centrifugal separating force or
acceleration may range from 5 times gravity in very large diameter, low-resistance cyclones, to 2500
times gravity in very small, high-resistance units. The immediate entrance to a cyclone is usually
rectangular.

Fields of Application cyclone collectors offer one of the least expensive means of dust collection
from both investment and investment viewpoint. Cyclones have been employed to remove solids
and liquids from gases and solids from liquids and have been operated at temperatures as high as
1000°C. and pressures as high as 500 atm. Cyclones for removing solids from gases are generally
applicable when particles of over 5 µ (0.0002 in.) diameter are involved, although some of the
multiple-tube parallel units attain 80 to 85 per cent efficiencies on particles of 3 µ diameter. In
collecting particles of over 200 µ diameter, cyclones may be used, but gravity settling chambers are
usually satisfactory and less sub-ject to abrasion. In special cases where the dust shows a high
degree of agglomeration, or where high dust concentrations (over 100 gr./cu.ft.) are involved,
cyclones will remove dusts having a much smaller particle size. In certain cases, efficiencies as high
as 98 per cent have been realized on dusts having an ultimate particle size of 0.1 to 2.0 µ because
of the predominant effect of agglomeration.

Flow pattern. In a cyclone the gas path involves a double vortex with the gas spiraling downward at
the outside at the outside and upward at the inside. When the gas enters the cyclone, its velocity
undergoes a redistribution so that the tangential component of velocity increases with decreasing
radius as expressed radius as expressed by Vct ˜ r*n. the spiral velocity in a cyclone may reach a value
several times the average inlet-gas velocity. Theoretical considerations indicate that n should be
equal to 1.0 in the absence of wall friction. Actual measurements [Shepherd and lapple,
Ind,Eng.chem., 31,972 (1939);32,1246 (1990)], however, indicate that n may range from 0.5 to 0.7
over a large portion of the cyclone radius. Ter linden [Inst. Mech. Engrs.j., 160,235 (1949) ] found n
to be 0.52 for tangential velocities measured in the cylindrical portion of the cyclone at positions
ranging from the radius of the gas-outlet pipe to the radius of the collector. Although the velocity
approaches zero at the wall, the boundary layer is sufficiently thin that pitot-tube measurements
show relatively high tangential velocities there, as shown in Fig.20-97. The radial velocity V, is
directed toward the center through-out most of the cyclone, except at the center, where it is
directed outward.

Superimposed on the “double spiral,” there may be a “double eddy” [Van Tongeran, Mech. Eng., 57,
753 (1935). Wellmann, feuerungstech.,26, 137 (1938)] similar to that encountered in pipe coils.
Measurements on cyclones of the type shown in Fig. 20-96 indicate, however, that such double eddy
velocities are small compared with the spiral velocity (Shepherd and Lapple, op. cit.).
Pressure Drop. The pressure drop through a cyclone as well as the friction loss is most conveniently
expressed in terms of the velocity head based on the immediate cyclone inlet area. The inlet velocity
head, expressed in inches of water, is related to the average inlet-gas velocity and density by

ℎ𝑣𝑖 = 0.0030𝜌𝑉𝑐2 …….. 20-73

The cyclone friction loss is a direct measure of the static pressure and power that a fan must develop
and is related to the pressure drop by

4𝐴𝑐 2
𝐹𝑐𝑣 = 𝛥𝑃𝑐𝑣 + 1 − ( ) ………(20-74)
𝜋𝐷𝑒2

Although there have been several attempts to calculate the friction loss or pressure drop from
fundamental considerations [Feifel, Forsch. Gebiete Ingenieurw.,9, 68, 306 (1938); 10, 212 (1939);
Arch. Warmewirt.,20,15 (1939)], none is very satisfactory, since the simplifying assumptions made
have not allowed for entrance com-pression, wall friction, and exit contraction, all of which have a
major effect. Consequently, no general correlation of cyclone pressure-drop data is available as yet.

Fig.20-97. variation of tangential velocity and radial velocity at different points in a cyclone. [ Ter
Linden, Inst. Mech. Engrs. J., 160,235 (1949).]

The friction loss through cyclones encountered in practice may range from 1 to 20 inlet velocity
heads, depending on the geometric proportions (Alden, “Design of industrial exhaust system,” 3d
ed., Chap. VII, industrial press, New York, 1959. Shepherd and lapple, 𝐹𝑐𝑣 and 𝛥𝑃𝑐𝑣 are
substantially constant, independent of the actual cyclone size. The following discussion
deals with reported equations for the pressure drop or friction loss a cyclone when
handling dust-free gases.
Miller and Lissman [“calculation of cyclone pressure drop,” paper presented at
December,1940, meeting of A.S.M.E., New York (not published)], investigating cyclones
with an involute entrance, obtained the following empirical expression:

𝐷𝑐 2
𝛥𝑃𝑐𝑣 = 𝑘 ( ) … … … … . (20 − 75)
𝐷𝑒
The value of k was found to be substantially constant with a value of 3.2 over the following
range proportions: (𝐵𝑐 /𝐷𝑐 ) = 1/8 to 3/8; (𝐻𝑐 /𝐷𝑒 ) = 1.0; (𝐷𝑒 /𝐷𝑐 ) = 1/4 𝑡𝑜 3/4. 𝐹𝑜𝑟
smaller values of (𝐷𝑒 /𝐷𝑐 ), the values of k increased, while for smaller values of (𝐵𝑐 /𝐷𝑐 ), it
decreased. In these tests 𝐷𝑐 , 𝐷𝑒 , and 𝐵𝑐 were varied but not 𝐻𝑐 . Shepherd and Lapple (0p.
cit), investigating cyclones of the general type shown in Fig.20-96, obtained the following
empirical expression:
 𝑘 𝐵𝑐 𝐻𝑐
𝐹𝑐𝑣 = … … . . (20 − 76)
𝐷2𝑒
These tests covered the following range in proportions: (𝐵𝑐 /𝐷𝑐 ) = 1/12 𝑡𝑜 1/4; (𝐻𝑐 /𝐷𝑐 ) =
1/4 𝑡𝑜 1/2; (𝐷𝑒 /𝐷𝑐 ) = 1/4 𝑡𝑜 1/2. With the normal arrangement in which the
rectangular inlet terminates at the outer elements of the cyclone body or cylinder, K was
found to have a value of 16.0. If the inner side of the inlet duct was extended past the
cyclone cylinder wall and into the annular space halfway to the oppsite wall to form an
“inlet vane,” the friction loss was reduced by over 50 per cent and K was found to be 7.5.
pressure-drop values calculated by means of Eq. (20-76) for a value of K of 13.0 will check
the miller and Lissman data whithin +/- 30 per cent for the most part. For the specific
proportios shown in Fig.20-96, 𝐹𝑐𝑣 = 8.0 and the pressure drop is given by
2
𝛥𝑃𝑖 = 0.024𝜌𝑉𝑐 … . . (20 − 77)
Data reported in the trade literature for the type of cyclone shown in Fig. 20-98b can be
closely represented by Eq. (20-76) for a value of K of 18.4. the proportions covered by this
design are approximately: (𝐵𝑐 /𝐷𝑐 ) = 5/8; 𝐻𝑐 /𝐷𝑐 ) = 5/8; (𝐷𝑒 /𝐷𝑐 ) = 1/2 𝑡𝑜 1.The term
𝐷𝑐 , as specified here, is the diameter of the main or upper cylinder. The large diameter of
5
the upper cone is 1 8 times as large. The cyclone shown in Fig. 20-98a has a reported (trade
literature) pressure drop as follows:
2
𝛥𝑃𝑖 = 0.013𝜌𝑉𝑐 … . . (20 − 78)
Linoya [Mem. Faculty Eng., Nagoya Univ., 5(2) (September,1953)] investigated the effect of
wall roughness on pressure drop and found that pressure drop decreased with increased
with increased surface roughness. He pasted and particles of various sizes on the wall of the
cyclone and obtained pressure-drop data as shown in Table 20-35. First (“Fundamental
Factors In the Design of Cyclone Dust Collectors,”Doctoral thesis, Harvard University, may,
1950) independently concluded that wall friction was a negligible part of the total pressure
drop. Wall friction apparently reduces the vortex intensity, thereby decreasing pressure
drop.
Collection Efficiency. Various authors [ Davies, proc.Inst.Mech.engrs., B1B, 185 (1952).
Lapple and shepherd, Ind.Eng.Chem.,32, 605 (1940)] have investigated the theoretical time
of movement of particles of dust toward the wall of the cyclone, and Ter Linden [Proc. Inst.
Mech. Engrs., 160, 233 (1949)] has attempted a theoretical prediction of cyclone
performance, but at the present time there is no generally accepted accepted fundamental
relationship. The most satisfactory expression for cyclone performance is till the empirical
one by Rosin, Rammler, and Intelmann [ Z. Ver deut. Ing., 76,433-437 (1932)].
Table 20-35. Effect of surface roughness on cyclone pressure drop

Size of sand particles on wall Pressure Drop, No. of Inlet Velocity Heads
None………………………………………………………. 8.0
147 to 175 microns, light coat………………… 5.8
147 to 175 microns, heavy coat ……………… 4.9
500 to 1000 microns ………………………………. 4.1

They derived the following equation for the minimum diameter particle that should be
completely separated from the gas stream in a cyclone:
0.5
9µ𝐵𝑐
𝐷𝑝,𝑚𝑖𝑛 = [ ] … … … … … . . (20 − 79)
𝜋 𝑁𝑡𝑐 𝑉𝑐 (𝜌𝑠 − 𝜌)
Smaller particles are removed to an extent proportional to the initial distance of the
particles from the wall. Their derivation is based on Stokes´s law, assuming the gas stream
undergoes a fixed number of turns at constant spiral velocity without any mixing action or
turbulence. The Rosin, Rammler, and Intelmann relationship can be conveniently
presented in the form shown in Fig.20-99, which gives the collection efficiency to be
expected for a gives particle size, expressed as a ratio to the cut size 𝐷𝑝𝑐 , where 𝐷𝑝𝑐 is
defined by
0.5
9µ𝐵𝑐
𝐷𝑝𝑐 = [ ] … … … … … . . (20 − 80)
2𝜋 𝑁𝑒 𝑉𝑐 (𝜌𝑠 − 𝜌)
This type of plot is essentially a generalized form of the “fractional” efficiency plot
frequently found in commercial literature, and the cut size 𝐷𝑝𝑐 is the particle size
corresponding to a fractional efficiency of 50 per cent. For the Rosin, Rammler, and
Intelmann curve, the term 𝑁𝑒 is identical witch 𝑁𝑡𝑐 . Actually, as previously described,
however, the flow pattern is considerably more complex, and the separation or
classification efficiency curve is not nearly so sharp as would be predicted by this curve.
Consequently, an experimental determination of this relationship must be relied upon. In
the absence of reentrainment, such a curve, as well as the value of the term 𝑁𝑒 , should be
unique for a cyclone of given geometric proportions, and the value of 𝑁𝑒 may be regarded
as an approximate measure of the effectiveness of a given type of cyclone design. Where
reentrainment is appreciable, the value of 𝑁𝑒 will tend to decrease with increasing gas
ᶯvelocity and density.
In Fig.20-99 is given a curve, based on experimental data for a variety of dusts, for a cyclone
of the proportions given in Fig.20-96. In this case reentrainment appeared to be minor, and
based on a few plant and laboratory data, 𝑁𝑒 has been found to be approximately 5.0.
Although these data were not very accurate, the value given is probably conservative since
some of the data indicated the value of 𝑁𝑒 to be as high as 10. If an inlet vane, as described
above, is used with this cyclone, reentrainment becomes appreciable, and the apparent
value of 𝑁𝑒 has been found to be approximately 2 for cyclone inlet velocities on the order
of 50 ft./sec. with air at atmospheric pressure. The above values of 𝑁𝑒 were determined
under conditions for which relatively little flocculation of dust in the gas stream would be
expected.
Figure 20-99 gives the separation efficiency to be expected for a given particle size, whereas
any dust or mist encountered in practice is comprised of particles covering a range of sizes.
Consequently, the over-all collection efficiency is a summation of the efficiency on each
particle size prorated according to the fraction of the total dispersoid in that size range. If
the particle-size distribution is known, the over-all collection efficiency can be calculated
graphically by plotting values of 𝑛 and ɸ , corresponding to the same particle size, as a
ordinate and abscissa, respectively, on arithmetic graph paper as shown in Fig.20-100. The
over-all collection efficiency is then given by the mean ordinate of the plot, I,e., the ordinate
for which the two shaded areas are equal.

Fig. 20-99. Separation efficiency of cyclones.

In many cases a good approximation is obtained if the over-all collection efficiency is taken
as equal to the cumulative percentage of material ɸ larger than the cut size 𝐷𝑝𝑐 in the dust
fed to the cyclone. Equation (20-80) allows for operating temperature in the viscosity term,
which means that, for a given inlet velocity, increased temperature results in a larger cut
size, corresponding to a lower efficiency. As another good approximation, it should be
noted that a given size of cyclone will have substantially the same collection efficiency at
any temperature, provided that the pressure drop is the same, because of counterbalancing
effects of gas density and viscosity.
Table 20-36 gives experimental collection-efficiency data reported by Anderson for
geometrically similar cyclones of the type shown in Fig. 20-98. These will serve to illustrate
the order of magnitude of the collection efficiency to be expected for various particle sizes.
Cyclone Design Factors. Cyclones are generally designed to meet specified pressure-drop
limitations. For ordinary installations, operating at approximately atmospheric pressure, fan
limitations generally dictate a maximum allowable pressure drop corresponding to a
cyclone inlet velocity in the range of 20 to 70 ft. /sec. Consequently, cyclones are usually
designed for an inlet velocity of 50 ft./sec., though this need not be strictly adhered to.
In the removal of dusts, the collection efficiency can be changed by only a relatively small
amount by a variation in the operating conditions. The primary design factor that can be
utilized to control collection efficiency is the cyclone diameter, a smaller-diameter unit
operating at a fixed pressure drop having the higher efficiency [ Anderson,Chen. Met., 40,25
(1933). Drijver, Warme, 60,333 (1937). Whiton, Power, 75,344 (1932); Chem. Met., 39,150
(1932)]. Small-diameter cyclones, however, will require a multiple of units in parallel for a
specified capacity. In such cases the individual cyclones can discharge the dust into a
common receiving hopper [Whiton, Trans. Am. Soc.Mech. Engrs., 63,213 (1941)].

Fig. 20-100. Calculation of over-all collection efficiency.

Table 20-36. experimental cyclone collection Efficiencies

Cyclone inlet velocity: 44ft./sec.
Cyclone pressure drop: 4 in./water
Inlet dust concentration: 2-5 grains/cu. Ft.
Specific gravity of dust: 3.0 g./cc.
𝐷𝑒
Cyclone proportions: 𝐵𝑒 = 6

Gas: atmospheric air

Inlet Dust particle-size Analysis
Particle Cumulative %
Diam., µ Larger Than Size
5 74
10 64
20 43

Cyclone diam., in. Dust collected, %

6 Total 90 -5 µ 66 +5 µ 98
9 Total 83 -10 µ 60 +10 µ 99
24 Total 47 -20 µ 47 +20 µ 98

The final design involves a compromise between collection efficiency and complexity of
equipment. It is customary to design a single cyclone for a given capacity, resorting to
multiple parallel units only if the predicted collection efficiency is inadequate for a single
unit. Cyclones is series may be justified in cases where the dust has the following properties:
1. It has a broad size distribution including a sizable portion of particles finer than 15
microns, in which case a single large-diameter cyclone is used to collect the coarse
fraction and reduce the loading to a small-diameter multiple-tube unit.
2. It has a high tendency to flocculate in the equipment preceding the cyclones as well
as in the cyclone themselves.
In the latter case efficiencies predicted on the basis of ultimate particle-size
distribution will be highly conservative. Also, although efficiency is normally
increased by increasing the gas through-put (Drijver, op. cit.), in such cases the
reverse may be true because of the deflocculating effect of higher velocities.
Similarly, design proportion variations that result in increased collection afficiency
with dispersed dust may be detrimental in the case of flocculated dusts. Insufficient
data are available to permit any generalization for this case, however. The
flocculation factor is probably also the chief cause for inconsistency of data reported
in the literature.
Reducing the gas-outlet duct diameter will increase both collection efficiency and
pressure drop. Increasing the length of cyclone is generally conceded to increase
collection efficiency, though there are no reliable supporting data. There is also no
reliable information on the effect of inlet proportions, although the Rosin, Rammler,
and Intelmann relationship indicates that for a given cyclone inlet velocity the inlet
width should be minimized. The cyclone developed by the Mill Mutual Fire
Prevention Bureau has a relatively narrow rectangular inlet which is sized on the
basis of the particle size of dust to be collected. The expense of fabricating the
transition duct for a cyclone inlet having a high depth-to-width ratio must be
weighed against the possible improvement in efficiency. It is essential that the
transition be relatively gradual in order to avoid excessive pressure drop due to gas
jetting into the cyclone chamber. There is disagreement among cyclone designers
regarding the optimum cone angle, but most “high-efficiency” cyclones have cone
lengths in the range of 1.6 to 3.0 cyclone diameters.
A cyclone will operate equally well on the suction or pressure side of a fan if the dust
receiver is airtight. Probably the greatest single cause for poor cyclone performance,
however, is the leakage of air into the dust outlet of the cyclone. A slight air leak at
this point can result in a tremendous drop in collection efficiency, particularly with
fine dusts. For a cyclone under pressure, air leakage at this point is objectionable
primarily from the local dust nuisance created. For batch operation, an airtight
hopper or receiver may be used. For continuous withdrawal of collected dust, a
rotary star valve, a double-lock valve, or a screw conveyor may be used, the latter
only with fine dusts. A collapsible, open-ended rubber tube can be used (see p. 20-
70). Special pneumatic unloading devices can also be used with dusts. Figure 20-101
shows a cyclone in which the gas and solids discharge at the same end. The solids
are removed at the gas periphery together witch a gas-purge rate of 5 to 20 per cent
of the inlet-gas flow. In any case it is essential that sufficient unloading and receiving
capacity be provided to prevent collected material from accumulating in the
cyclone.
Generally, cone-and-disk baffles, helical guide vanes, etc., placed inside a cyclone,
will have a detrimental effect on performance.
A few of these devices do have some merit, however, under special circumstances.
Although an inlet vane will reduce pressure drop, it causes a correspondingly greater
reduction in collection efficiency. Its use is recommended only where collection
efficiency is normally so high as to be a secondary consideration and where it is
desired to decrease the resistance of an existing cyclone system for purposes of
increased air-handling capacity or where floor-space or headroom requirements are
controlling factors. If an inlet vane is used, it is advantageous to increase the gas-
exit-duct length inside the cyclone chamber. A disk or cone baffle located beneath
the gas-outlet duct may be beneficial if air in-leakage at the dust outlet cannot be
avoided. A heavy chain suspended from the gas-outlet duct has been found
beneficial to dust build-up on the cyclone walls. Such a chain should be suspended
from a swivel so that it is free to rotate without twisting. At present there are no
known devices that will recover the gas spiral-velocity energy in the gas-outlet duct.
Substantially all devices that have been reported to reduce pressure drop do so by
reducing spiral velocities in the cyclone chamber and consequently result in reduced
collection efficiency.
At low dust loadings the pressure in the dust receiver of a single cyclone will
generally be lower than in the gas-outlet duct. Increased dust loadings will increase
the pressure in the dust receiver. Such devices as cones, disks, and inlet vanes will
generally cause the pressure in the dust receiver to exceed that in the gas-outlet
duct. A cyclone will operate as well in a horizontal position as in a vertical position.
However, departure from the normal vertical position result in an increasing
tendency to plug the dust outlet. If the dust outlet becomes plugged, collection
efficiency will, of course, be low. If the cyclone exit duct must be reduced to tie in
with proposed duct sizes, the transition should be made at least five diameters
downstream from the cyclone and preferably after a bend. In the event that the
transition must be made closer to the cyclone, a Greek cross should be installed in
the transition piece in order to avoid excessive pressure drop.
Increased dust loadings will result in both decreased pressure drop and increased
collection efficiency (Drijver, op. cit.;shepherd and lapple, op. cit). At dust loading of
over 200gr./