Rapid Performance Evaluation and Optimal Sizing of Dry Cyclone Separators

Abstract

Cyclones are generally less efficient than other kinds of equipment, but their simple construction, low energy requirements, and ability to operate at high temperatures and pressures make them attractive for cleaning up gases. Despite the simplicity in construction and operation, complex mathematical formulations are used for predicting the collection efficiency of particles of a given diameter. These must be numerically integrated, along with the inlet particle-size-distribution functions that are appropriate in each application, in order to obtain the overall cyclone efficiency. In this paper, the above cumbersome procedure is simplified through nomographs allowing rapid, yet rigorous, estimation of the overall cyclone efficiencies based on two alternative and well-established approaches and on the sole assumption of a lognormal particle-size distribution. Along with the above, pressure drop and limiting inlet velocity correlations are also considered, and each of the above nomographs is combined with others, providing direct graphical representation of the so far obscure relationships among cyclone diameter, overall efficiency, and gas pressure drop or flow rate. The paper thus affords an overview of cyclone behavior over a wide range of conditions, offering direct solutions to both cyclone performance and optimal cyclone design problems.