Separation of Gas-Solid Mixtures using a Cyclone Separator

Leo B. Besa
Quesie P. Norada

ChE 136
Feb. 16, 2019

I. Introduction

A cyclone separator is a vertical cylinder with the inlet stream introduced

tangentially near the top, giving the suspension a spinning motion in the cylinder. The
centrifugal force acting on the particles tends to grow them radially to the sides of the
cylinder as they spiral downward to a conical bottom where they are removed (Brown,
1950).

Figure 1. A standard tangential inlet vertical reverse flow cyclone separator

(Davis, 2000).

On entering, the air in the cyclone flows downward in a spiral or vortex adjacent
to the wall. When the air reaches near the bottom of the cone it spirals upward in a
smaller spiral in the center of the cone and cylinder. Hence, a double vortex is present
(Geankoplis, 1993).
The particles are thrown toward the wall and fall downward, leaving out the
bottom of the cone. A cyclone is a settling device in which the outward force on the
particles at high tangential velocities in many times the force of gravity. Hence, the
cyclones accomplish much more effective separation than gravity settling chambers
(Geankoplis, 1993).
Cyclone separators are usually used for removing particles 10 μm in size and
larger. However, conventional cyclones seldom remove particles with an efficiency
greater than 90% unless the particle size is 25 μm or larger. High-efficiency cyclones
can remove particles down to 5 μm. Regardless of the design, the fractional removal
efficiency of any cyclone drops significantly beyond a certain particle size (Wark et. al.,
1998).
Cyclone collection efficiency increases with increasing particle size, particle
density, inlet gas velocity, cyclone body length, number of gas revolutions, and
smoothness of the cyclone wall (Flagan and Seinfeld, 1988).
Cyclone efficiency decreases with increasing cycling diameter, gas outlet
diameter, and gas inlet area. The design of a cyclone represents a compromise among
collection efficiency, pressure drop, and size. Higher efficiencies require higher
pressure drops and larger unit sizes. As the particle laden gas enters the cyclone, it spins
through Ne revolutions in the main outer vortex before entering the inner vortex and
passing upward toward the exit of the cyclone. As an approximation, Ne is given by:

Equation 1.

where Lc is the height of the main upper cylinder, Zc is the height of the lower cone,
and H is the height of the rectangular inlet (Green and Perry, 2007).
Similarly, cyclone efficiency will decrease with increases in the parameters such
as gas viscosity; cyclone body diameter; gas exit diameter; gas inlet duct area; gas
density; leakage of air into the dust outlet (nptel.ac.in).
There are many factors that can affect cyclone performance. A cyclone must be
airtight for proper performance. Any leakage in a cyclone can cause a loss in collection
efficiency. Erosion can affect cyclone performance by altering the flow patterns.
Erosion can also lead to cyclone failure by eroding welds or areas of concentrated solids
impingement. Fouling of a cyclone by plugging the dust outlet or the buildup of dust on
the walls affect flow patterns and cause ash reentrainment. Cyclone roughness (e.g.,
large weld beads) reduces cyclone efficiency. Cyclone efficiency is a strong function of
particle size and if the particle size decreases from the design specifications then
cyclone efficiency will also decrease. Similarly, cyclone efficiency is a function of
particle density, and if the particle density decreases from that for which the cyclone
was designed, collection efficiency will decrease. Dust collection increases with
increasing dust loading. If the dust loading should decrease from the design parameter,
cyclone efficiency will decrease. Physical properties of the gas can have some effect on
the cyclone performance. Increasing the gas temperature decreases its density and
increases its viscosity thereby reducing collection efficiency (Miller, 2017).

II. Objectives

This experiment is generally aimed at the determination of the cyclone

separator’s collection efficiency to various sample particles. Specifically, this
experiment aims to fulfill the following objectives:
 1. to relate particle density to the collection efficiency of the cyclone separator
and,
2. to relate particle size distribution to the collection efficiency of the cyclone
separator

III. Scope and Limitations

1. Since the blower has only one power setting, the input gas velocity will
be assumed as constant.
2. Entrained solids, which were not properly flushed out of the cyclone
separator prior to the trial, are expected to cause error in the collection
efficiency.
3. The sample particles will be flour and saw dust.

IV. Methodology

Figure 2. Cyclone Separation Set-up (Retrieved from

https://www.indiamart.com/proddetail/cyclone-separator-8146129530.html)

A. Equipment and Materials

1.) Cyclone Separation Set-up
2.) Sample 1 (Rice Flour)
3.) Sample 2 (Sawdust)
4.) Mechanical Sieve Shaker
5.) Top Loading Balance
6.) Stopwatch
7.) Beakers
8.) Funnel
9.) Clean Cloth
 B. Procedure

For the first part of the experiment, two different samples with different
densities, specifically rice flour and saw dust, were prepared for the experiment.
To obtain same particle size, each sample was sieved using mesh no. 10. Two
replicates weighing 40 grams each were prepared. For the second part of the
experiment, samples with different particle size were prepared. The sample, rice
flour, was sieved using mesh no. 25 and mesh no. 45 to obtain different particle
size. Each particle size was then weighed to 30 grams each and two replicates
were prepared.

In preparation of the experiment, a test run was conducted on the

equipment without samples to flush out particles from previous experiments and
to make sure the equipment operates efficiently. The sample was then put in the
feed opening and the lid was tightly closed. The switch was turned on and the
equipment then operated for 2.5 minutes. After 2.5 minutes, samples were
collected and weighed. The needed data was then recorded. Before putting the
next sample, a test run was again done to get rid of the remaining samples stuck
in the equipment. Two trials were done for samples with different densities and
different particle sizes. After the experiment, the equipment was turned off and
the experimentation area was cleaned.

V. Results

A. Particles with different densities

Sample Initial Weight Trial 1 Trial 2 Percent

(g) (g) (g) Efficiency

Sample 1 30 22.4 22.1 74.17%

(Rice Flour)

Sample 2 30 17.7 16.6 57.17%

(Sawdust)

Based on the results from Table A, it shows that the efficiency of the
separator increases as the density of the particles increases. The particles used
have the same particles size which came from mesh no. 10 or particles with size
greater than 2 mm. Sample 1 which was rice flour has a density of 667.83 kg/m3
while Sample 2 which was sawdust has a density of 210 kg/m3(AV Calc LLC,
2019). When the particle density decreases, the drag force act on the particles
also decreases. This result to an increase in centrifugal force and number of
swirling rotations which means that more amount of particles get accumulated
inside the cyclone separator (Mothilal & Pitchandi, 2016).
B. Particles with different sizes

Sample 1 Initial Weight Trial 1 Trial 2 Percent

(Rice Flour) (g) (g) (g) Efficiency

No. 25 40 26.1 23.6 82.83%

No. 45 40 22.2 25.6 79.67%

This table shows the collection efficiency of the cyclone separator with
the particle size being varied. Based on the data calculated, the efficiency of the
cyclone separator has a linear relationship with particle size. The sample that
came from mesh no. 25 has a particle size greater than 0.707 mm but less than
2mm while sample that came from mesh no. 45 has a particle size greater than
0.354 mm but less than 0.707 mm. This means that as the particle size increases,
the collection efficiency increases. This is because of the forces acting on the
particles. Centrifugal force increases as the particle size also increases. Thus, the
possibility of particles with larger size to move to the wall of the cyclone
separator and down to the dust outlet also increases (Liu et al., 2016).

VI. Discussion

Collection efficiency of a cyclone separator depends on the particles and

the gas movement. Design parameters such as scaling and dimensions of the
cyclone separator, and particle parameters such as density and size also
contribute to the performance of the cyclone separator. In this experiment,
particles with different densities and different sizes were used to test the
efficiency of the cyclone separator. To obtain the efficiency of the cyclone
separator, the following equation was used.

There are errors that may have contributed to the results of the
experiment. One source of error that may affect the results were the objects like
dead insects, spider webs, and other unidentified objects that came with our
collected samples (see Appendices). Another source of error is the design of the
cyclone separator, it prompts the samples from escaping the cyclone separator
and, some of the samples have stuck inside the equipment.
VII. Conclusion and Recommendation

In summary, this experiment was able to determine the cyclone

separator’s collection efficiency at various sample particles. From post-
experimental calculations, the relationship between collection efficiency and
particle size, and collection efficiency and particle density were established to
be linear.
From observations, the cyclone separator’s design should be improved.
The T-shaped pipe fitting that connects to the pipe leading to the cyclone
separator was retaining a significant amount of samples due to the differences in
pipe diameters (Figure 1, Appendices). The collector under the cyclone
separator was not well fitted, some of the samples was blown away at start-up of
the blowers (Figure 3, Appendices).
The major source of error could be attributed to the dead insects and
insect eggs collected with the samples in the bin. Despite the experimenters’
best effort to make the experiment as accurate as possible by running the
blowers every after trial to blow away the residues left, this was an unforeseen
error.
A thorough clean-up of the interior of the cyclone separator as well as
repair of the leaks and changing of the T-shaped fitting to prevent sample
accumulation are highly recommended.
VII. Appendices

A. Photos

Figure 1. Samples retained at T-shaped pipe

Figure 2. Dead insects and insect eggs collected

with the samples

Figure 3. Leaks in cyclone separator’s

collecting bin
VIII. References

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Geankoplis, C. (1993). Transport Processes and Separation Process Principles.
Upper Saddle River, NJ : Prentice Hall Professional Technical Reference,
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Liu, L., Dou, H., & Chen, X. (2016). Effect of particle diameter and injection
position on the separation performance of cyclone separators, 8(March), 40–
47. https://doi.org/10.1177/1757482X16634199
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