Experimental investigations on a cyclone separator performance at an extremely low particle concentration

In order to evaluate the influence of extremely low particle concentration on separation performance of cyclone separator, the overall collection efficiencies and grade efficiencies of a cyclone separator with particle concentrations of 5-2000 mg/m³ and inlet velocities of 6-30 m/s have been investigated under ambient temperature and atmospheric pressure conditions. Aerosol spectrometer based on measuring particle number is used to measure the particle concentrations and particle size distributions of the inlet and outlet of the cyclone separator. The overall efficiency is equal to the ratio of the particle concentration difference between the inlet and outlet of the cyclone separator to the inlet particle concentration. The grade efficiency is obtained by comparing the particle size distributions of the inlet and outlet of the cyclone separator. The effects of particle concentration on separation performance are predicted by Smolik empirical model. Particle agglomeration, which has been found in the inlet and outlet of the cyclone separator, has a very important influence on the collection efficiencies and grade efficiencies of the cyclone separator at the particle concentration of 5-2000 mg/m³. The cut sizes for different inlet gas velocity with extremely low particle concentration can be quantitatively calculated by Barth model, Mothes and Loffer model and Muschelknautz model, respectively. Experimental results show that the overall collection efficiencies and grade efficiencies increased with the increasing particle concentrations and inlet velocities, and most of the particles with the diameter bigger than 10 μm can be removed by cyclone separator.     

Effects of separation space diameter on the performance of a novel reverse flow cyclone

ABSTRACT

A numerical study was carried out to investigate the effect of separation space diameter on the performance of a novel reverse flow tangential inlet cyclone design by using the Eulerian-Lagrangian approach. The design of this cyclone is based on the idea of increasing vortex length and decreasing pressure drop compared with traditional cyclones. This novel cyclone differs from the traditional cyclones with separation space and vortex limiter instead of the conical part. A qualitative numerical study was performed to analyze the effect of separation space diameter on the cyclone performance at different flow rates by evaluating velocity profile, pressure drop, fractional and overall efficiencies. The results show that the collection efficiency of smaller particles increases while pressure drop decreases significantly with the increase in separation space diameter for D₁/D < 0.5.     

流场形态对旋风分级器性能的影响

气流分级器性能的优劣很大程度上取决于流场分布,改变常规旋风分级器的切向进风口位置,在分级空间建立不同类型的离心流场,采用数值模拟和分级试验手段分析了分级流场形态对颗粒运动过程和分级性能的影响。结果表明,传统旋风分级器边壁下行流造成粗粉中细颗粒夹带较多,影响分级精度;新型旋风分级器内形成上下两个旋涡,上旋涡均为上行气流,其流量约占总风量的80%,下旋涡携带细颗粒较少,降低了细颗粒进入粗组分的概率;上旋涡可实现对边壁区的细颗粒的轴向淘洗、再分级,提高了分级精度。试验结果表明,入口气速从10m/s增加至22m/s。相较于传统旋风分级器,新型旋风分级器的分级性能明显改善,分级精度指标平均提高27%,压降损失为传统旋风分级器的53%~62%。     

Analysis of the efficiency of reverse flow cyclones

The efficiency of a 152 mm cyclone was determined for inlet velocities in the range 6.1 — 15.5 m/s, for particle sizes from 0.6 μm to 4.7 μm, using monodisperse methylene blue-uranine aerosol particles. The efficiency of a geometrically similar 76 mm cyclone was also measured for a few conditions of inlet velocity and particle size. These data and others were correlated by linear regression analyses on a function of cyclone Stokes number and cyclone Reynolds number. It was concluded that in the range of variables spanned by the experimental data, the flow fields within the cyclones depended on Reynolds number, and hence that contrary to the assumptions of most theoretical models, cyclone efficiency is not exclusively a function of Stokes number.     

差异旋风分离器并联性能测量及流场分析

通过改变旋向和芯管直径,设计了3种差异旋风分离器,并按中心对称方式组成了3种并联方案：相同分离器、旋向差异分离器和芯管差异分离器并联。在冷态实验装置上,测量了单分离器和并联分离器的性能,并利用FLUENT软件分析了并联分离器的流场。结果表明,并联分离器的效率均高于单分离器,且效率-气速曲线未出现“驼峰”;与相同分离器并联相比,旋向交替变化时并联总压降较小,分离效率也更低,但各分离器流量分配均匀,未发现“窜流”现象;当芯管有差异时,并联总压降增大,各分离器进口流量分配不均匀,且进、出口流量平均相差6.0%,公共灰斗中存在“窜流”,旋流稳定性变差,效率降低。为了保证并联分离器的性能,应采用相同分离器对称并联的方式。     

Multi-object optimization study on the performance of gas cyclones based on heterogeneous condensation and turbulent agglomeration

Improving the separation efficiency of fine particles becomes more and more critical as environmental pollution aggravates. This study aims to investigate the effects of four key parameters on the performance of gas cyclones, including cyclone body height, particle concentration, initial supersaturation degree, and inlet temperature. Then, the two-way coupling numerical model, in which is the process of heterogeneous condensation and agglomeration for insoluble fine particles, was achieved by user defined function. On this basis, the response surface analysis method and multi-objective genetic algorithm were adopted to optimize the cyclone. The results show that when the particle concentration is less than 1000 mg/m³, the separation efficiency can reach above 95%. The initial supersaturation degree has the greatest effect on the separation efficiency and vapour consumption rate, while the cyclone body height is the most critical factor on the pressure drop. As the particle concentration increases, the separation efficiency decreases at first and then keeps almost stable. With the increase of inlet temperature, the separation efficiency is enhanced, and the pressure drop reduces. These research results can provide important guidance for the optimization and engineering application of this technology.     

局部磨损对α型旋风分离器内流场及分离性能的影响

以α型旋风分离器为研究对象,基于欧拉-拉格朗日方法,采用雷诺应力模型（RSM）、颗粒离散相模型（DPM）、E/CRC磨损方程对分离器内流场与磨损特性进行数值模拟。通过分析速度矢量、切向速度、颗粒运动轨迹等参数的分布规律,研究了局部磨损对设备内流场及分离性能的影响。结果表明,α型旋风分离器入口正对壁面磨损最为严重,最大磨损率约为1.4×10^-5kg/(m²·s)。磨损引起壁面几何结构的改变,导致气流方向发生偏转,不利于主流的稳定与固体颗粒的分离。随局部磨损的加剧,排气管下口短路流急剧增大,从而导致排气管下口以下区域流体流量减少,外涡切向速度降低;细颗粒的逃逸现象更加明显,粗颗粒运动轨迹趋于重合,更易形成高浓度灰环加剧壁面磨损。与未磨损时相比,局部磨损厚度50mm时,3μm粒径颗粒的分离效率由74.38%降低至54.97%,分割粒径d₅₀由0.73μm增大至2.36μm;设备压降降低了约15.41%。     

Development of a new high‐efficiency simple structure cyclone

A novel uniflow cyclone design was evaluated using three prototype cyclones. For the first two, the efficiency and Euler number were determined using airborne solid particles with a number mean diameter of 12.5 µm. Then a larger scale prototype based on the optimized geometry was compared with an existing conventional high efficiency cyclone and a vane‐induced uniflow cyclone, using mineral oil droplets with a number mean diameter of 8.9 µm. Both sets of experiments showed that the newly designed cyclone had a higher efficiency at a higher pressure requirement, in addition to the feature of a small footprint.     

多效旋风分离器性能的实验研究

多效旋风分离器通过采用2级螺旋管预分离含尘气体、螺旋形顶盖板导流、筒体中心稳流锥稳流和吸气回流系统防止粉尘返混等措施,解决了在旋风流场中分离微米及亚微米级颗粒的难题。文中通过实验研究了直径为0.25 m的多效旋风分离器的压降、分离效率和进口风速的关系,实验物料粒径范围为0.1—23μm,平均粒径为7.59μm。结果表明:在10—14 m/s入口风速时,对0.1—3μm颗粒的分离效率大于90%,对大于5μm颗粒的分离效率接近100%,压降在500—1 000 Pa。风速大于16 m/s时,对0.1—2μm颗粒的分离效率大于75%。     

并联旋风分离器的旋流稳定性分析

分别选用2台和4台直径300 mm的相同PV型旋风分离器作为分离元件,共用进气管、集气室和排尘室,以中心对称方式组成两种并联分离器,并通过数值模拟比较单分离器与两种并联方案中各分离元件气相流动的特点. 气体介质为常温常压空气,入口气速15~30 m/s. 结果表明,2台或4台并联时各分离元件流量偏差分别不超过0.35%和0.28%,压降最大偏差为0.79%和0.43%,流量分配均匀,灰斗内窜流返混不明显,且4台并联时效果更好. 4台并联时分离元件排尘段的稳定性指数比2台并联或单分离器降低过半,旋流稳定性显著增强. 对称排列的分离元件在公共灰斗中会形成具有自稳定性的对称涡系,对分离元件内旋进涡核的摆动有约束作用,旋流稳定性增强.     

CFD analysis of flow field in square cyclones

In this study, computational fluid dynamic method is used to predict and evaluate the flow field inside a square cyclone. The flow field is calculated using 3D Reynolds-averaged Naveir-Stokes equations. The Reynolds stress transport model (RSTM) is used to simulate the Reynolds stresses. The Eulerian-Lagrangian computational procedure is implemented to predict particle trajectory in the cyclone. The Newton's second law is used to study the particle trajectory with modeling the drag and gravity forces acting on the particles. The velocity fluctuations are simulated using the discrete random walk (DRW). Two square cyclones which have different geometries are studied. The cyclones are simulated at different flow rates. The details of the flow field are studied in the cyclones and the effect of varying the flow rates is observed. Tangential velocity is investigated in different sections inside the square cyclone. Contour of pressure and turbulence intensity is shown for different inlet velocities inside the cyclones. It is observed that different geometries, also different inlet velocities, could affect on the pressure drop. The collection efficiency and the flow patterns obtained numerically are compared with the experimental data and good agreement is observed.     

双循环旋风分离器除尘机理的数值模拟

双循环旋风分离器通过将主进口设置在筒体中部,将顶部进气口设置为回流口,消除了进气口附近的二次流,避免了短路流,将大于3μm颗粒的分离效率提高至接近100%,并避免了少量11—15μm颗粒的短路逃逸。为了探索该设备的除尘机理,借助CFD软件,通过数值模拟研究的方式,辅助分析了2种进气口在分离性能上不同,传统旋风分离器不能完全分离3—8μm和11—15μm颗粒的机理,以及消除二次流的方法。计算结果表明:当回流气速低于主进气速时,会产生类似于顶端进气口的现象,即二次流、灰环和短路流,降低了小于6μm颗粒的分离效率。当回流气速略大于主进气速时,可以完全消除主进气口附近的二次流,使得所有粒径颗粒的分离效率都较高。模拟结果与实验结果从定性的角度符合较好。     

Effect of inlet particle arrangement on separating property of a cyclone separator

Different arrangements of particles on the inlet section exert different effects on the separation property of a cyclone separator. Sorting classifier with different heights was connected in series with a conventional cyclone, positive rotation cyclone, and reverse rotation cyclone respectively, to investigate the effect of particle arrangement on the separation property and inner flow field. Results indicate that the implementation of a sorting classifier increases the pressure drop and energy consumption of a cyclone separator. The taller the sorting classifier, the larger the flow is. The energy consumption in positive rotation cyclone is closer to that in reverse rotation cyclone. Meanwhile, the tangential velocity in inner flow field is higher and the separating property is enhanced. The reverse rotation cyclone relieves the fishhook effect, whereas the positive rotation cyclone eliminates such effect. The reverse and positive rotation cyclones demonstrate an improved separating property for particles smaller and greater than 1 μm, respectively. Moreover, the reverse rotation cyclone demonstrates superior overall separation, but the positive rotation cyclone demonstrates a greater classification effect than the reverse rotation cyclone.     

Characteristics of the collection efficiency for a double inlet cyclone with clean air

Two single inlet cyclones and a double inlet cyclone were designed and fabricated to evaluate, and compare, their collection efficiencies. Two single inlet cyclones had different inlet sizes and vortex finder diameters. The double inlet cyclone had two inlet parts that divided the cyclone inlet in two. Clean air was introduced to the inlet near the cyclone wall, and particle-laden air was introduced to the inlet away from the cyclone wall. This double inlet made the clean air swirl in the region near the vortex finder, and the particle-laden air swirl in the region close to cyclone wall. The performance of the double inlet cyclone was evaluated at various clean air flow rates, keeping the particle-laden air flow rate constant.The collection efficiency of the double inlet cyclone was found to be 5–15% greater than that of the single inlet cyclone with the same inlet size and vortex finder diameter. As the flow rate of clean air was increased, the collection efficiency increased. This result indicates the possibility of achieving higher collection efficiencies with a double inlet cyclone.     

Hydrodynamic characteristics of fine particles in the riser and standpipe of a circulating fluidized bed

The hydrodynamic properties in the riser and standpipe. and the cyclone efficiency have been determined in a circulating fluidized bed (CFB) unit consisting of a riser (0.05 m-IDX3.8 m high), a standpipe (0.068 m-IDX2.5 m high) as a primary cyclone/bubbling fluidized bed, and a secondary cyclone. Silica gel powder (mean diameter = 46 μm) was used as the bed material. The effects of gas velocity in the riser and initial solid loading on the solid circulation rate, and the solid holdups in the riser and standpipe have been determined. The effects of gas velocity in the standpipe on the efficiencies of primary and secondary cyclones have been also determined as functions of solid circulation rate and solid entrainment rate. The solid circulation rate increases with increases in the gas velocity in the riser and in the initial solid loading. The efficiencies of primary and secondary cyclones increase with an increase in the gas velocity in the riser. However, the efficiency of primary cyclone decreases and that of secondary cyclone increases slightly, with an increase in the gas velocity in the standpipe.     

分流型芯管对导叶式旋风管内颗粒逃逸的控制

Experimental and computational fluid dynamics was used in this study to predict the escape particles and evaluate the performance of PSC type cyclone tube with slotted vortex finder.The simulation results showed that the PSC type cyclone tube could remove the particles with a diameter greater than 5 μm.The PSC type cyclone tube increased the grade efficiency of particles with a diameter greater than 2 μm as compared with the Shell type cyclone tube.Short circuit flow occurred around the vortex finder slots and there was almost no short circuit flow under the vortex finder inlet.Most small particles escaped from vortex finder slots of the PSC type cyclone tube.The slotted vortex finder could develop “upwards flow” near the vortex finder inlet outside wall and control the escape particles under the vortex finder inlet.The force analysis of particles near the slotted vortex finder slots showed that gas flow carried the particles with a diameter smaller than 3 μm out the separator.     

双循环旋风分离器阻力性能的实验研究

双循环旋风分离器通过将主进气口设于简体中部,将顶部进气口设为回流口,消除了传统旋风分离器顶部进气口存在的二次流和短路流,进而使大于3μm颗粒的分离效率接近100%.基于工程设计理论的需求,研究了该新设备的阻力性能.利用直径为0.250 m的实验设备,测定了其压降与进口气速的关系,考察了不同结构和操作条件对其阻力性能的影...     

Wetted wall cyclone — A novel concept

Wetted wall cyclone is based on a novel concept of having a gravity fed water film flowing down along the inner walls of a cyclone. This equipment can be used for simultaneous cooling and cleaning - both particulate and gaseous impurities - of a gas. This work encompassed planning and designing of infrastructural equipment, like orifice meter, venturi feeder, rotary air lock and wetted wall cyclone carrying out intensive experimental work and detailed analysis of data thereof. The particulate matter removal under both dry and wet conditions is studied at different air velocities. Experiments were performed by introducing fly ash and talc as pollutants. The overall and grade efficiencies have been obtained under both dry and wet conditions at varying inlet velocity at constant solid loading. Wetting the cyclone walls increased the overall collection efficiency marginally by about 2% when talc was used as the contaminant. However, analysing the grade efficiency data showed a marked improvement of up to 33% in the collection efficiency for fine particles in the range of 1 to 3 μm.     

EXPERIMENTAL STUDY ON SMALL CYCLONES OPERATING AT HIGH FLOWRATES

A new set of experimental data on the particle collection efficiency of small cyclones operating at high flowrates is reported. Seven different cyclones were studied systematically covering a flowrate range 60–110 l min^-1 and a particle size range 0.026–3.6 μm. Special emphasis was given to the effects of the cylinder height and of the exit tube length on the particle collection efficiency. The length ratios of the cylinder height and exit tube length to the cyclone body diameter were varied from 0.75 to 4.5 and from 0.5 to 1.5, respectively. The experimental results suggest that the flowrate plays a significant role in cyclone collection efficiency. High flowrate can help to collect fine particles. As the cylinder height is increased, the collection efficiency increases. However, when the cylinder height is increased excessively, the collection efficiency appears to decrease to certain extent. An optimized exit tube length was also observed. Pressure drop decreased substantially either as the cylinder height became longer or as the exit tube length became shorter. It was also found that the difference between the cyclone cylinder height and the exit tube length affects the particle collection characteristics significantly.     

Collection efficiencies of various designs of post‐cyclone

Post‐cyclone (PoC) is a novel secondary dust separator, which collects a certain fraction of the particles escaping through the vortex finder of a reverse flow cyclone. Due to the residual swirl in the vortex finder, the particles in the effluent air are concentrated at the wall of the vortex finder in an outer annulus. The particles in the outer annulus are split from the main stream and collected in a bleed flow. This paper presents the experimentally determined collection efficiencies of various designs of PoC. Depending on the design, operating conditions and the size and density of the particles, PoC can reduce the emission of the parent cyclones by 5% to 50%. In some experiments, the bleed flow from PoC is recycled back to the inlet of the cyclone. Significant improvement in the removal of fines occurs when the bleed flow is recycled to the inlet.