Effects of helical fins on the performance of a cyclone separator: A numerical study

This study aimed to investigate the separation performance of a cyclone separator after reshaping its cylindrical body by installing the helical triangular fins. A numerical simulation based on Fluent was adopted to perform an orthogonal test to optimise the structure of the cyclone separator with helical triangular fins. Three structural parameters of the helical triangular fins were selected as optimisation variables: base width, fin size, and fin pitch, and their influences on the evaluation indices of the cut-off diameter were investigated. The optimal combination scheme was determined by range analysis, and the cyclone separator performances before and after optimisation were compared and analysed. The significant influence of the structural parameters on the cut-off diameter was in descending order as the fin pitch, fin size, and base width. For particles with diameter of 0.1, 0.5, 1, 2, and 3 μm, the separation efficiency of the cyclone separator with optimized helical triangular fins increased by 7.4 %, 15.9 %, 20.1 %, 10.9 % and 14.8 % respectively. Moreover, the cut-off diameter of the finned cyclone separator is reduced by 30.7 %, while the pressure drop is only increased by 6.6 %. The short circuit flow and back-mixing were alleviated, thereby considerably enhancing the stability of the flow field. Therefore, the finned cyclone separator was found to play a critical role in increasing the separation of fine particulate matter.     

Experimental investigation of processes in acoustic cyclone separator

This paper presents air flow velocity profiles obtained in conventional and acoustic cyclone separators. It is shown that vortex air flow is created in acoustical cyclone separator in presence of secondary countercurrent air flow. It is obtained that in acoustic cyclone separator air pressure pulses occur at frequency of 8 kHz and pressure amplitude reaches a value of 170 dB. Separation efficiency of acoustic cyclone separator was established experimentally.     

Investigation on separation performance and structural optimization of a two-stage series cyclone using CPFD and RSM

Cyclones are generally operated in series when the efficiency of a single cyclone is not sufficient for the process. This study firstly used computational particle fluid dynamics (CPFD) to simulate the gas-solid two-phase flow characteristics in a two-stage series cyclone separator. The separation efficiency and distribution of energy consumption was interpreted by analyzing particle distribution characteristics. Secondly, the structure of the two-stage cyclone separator was optimized via response surface methodology (RSM) to make up for the disadvantage that the distribution of the separation load was non-uniform. The results showed that the grade efficiency for 3 μm of the first-stage cyclone separator was increased from 45.408% to 59.932% compared to the original model. The pressure drop of the first-stage cyclone separator is about 2.147 kPa while the second-stage cyclone separator is about 2.774 kPa. It can be seen that the overall optimized two-stage cyclone separator has the advantages of high efficiency, low energy consumption and load-balanced separation performance.     

DESIGN AND CALIBRATION OF A STACK SAMPLER FOR OIL FLY ASH

A particle sampling system was developed for the collection of Fly ash the stacks of ail-fired electrical generation plants. The apparatus has a cyclone separator which is designed to provide a cutpoint of approximately 2.5 µ followed by a pulse jet fabric filter. Flow rate is a nominal 226 L/min (8 cfm).

The system was tested in the laboratory with monodisperse aerosols to determine the fractionation characteristics of the cyclone and the inlet probe. Efficiencies of three candidate filters were examined with clean media, with a dust cake and with the dust cake removed. Tests were conducted using monodisperse polystyrene aerosols of 0.50, 0.76 and 1.09 µ

The pulse Jet apparatus was checked by operating the system at a flow rate of 200 L/min, loading the filter with AC fine test dust, and determining the stable filter pressure drop as a function of pulse jet air pressure.     

DUST STRANDS IN CYCLONE SEPARATORS AT LOW DUST CONCENTRATION

State of the art in calculating a cyclone separator is the application of the equilibrium theory and taking the formation of dust strands into account as well. The latter process does not depend on particle size mainly. An ideal flow pattern for the formation of dust strands is the so called Dean-vortex: it is being realized favorably in the axial flow cyclone. A dust strand can be produced down to a raw gas concentration C₀ ≈ 10^-5. Then, it is being exhausted through one or few holes in the mantle of the axial cyclone applying bleeding of about 10 % of the volume flow Separating its dust in a bin cyclone and recirculating the binflow gas to the main, axial cyclone completes this high performance cyclone separator. Dimensional analysis shows that the clean gas concentration c₁ mainly depends on the swirl W_tan/w_ax, the raw gas concentration c₀and on Reynolds number. For usual dust conditions a clean gas concentration c₁ ≤ 50 mg/m³ is feasible.     

旋转直流内循环式旋风分离器流场测定与分析(Ⅱ)

在流场测定的基础上，着重分析了旋转直流内循环式旋风分离器内三维速度分布和压力分布随入口气速的变化规律，回归了分离段切向速度计算的无因次经验方程，探求了压降性能的放大效应。结果表明该新型旋风分离器的流场规整，放大效应小，阻力系数比常用的反转式旋风分离器降低约30％。     

The impact of cylinder vortex stabilizer on fluctuating turbulence characteristics of a cyclone separator based on Large Eddy Simulation

The main purpose of present study is to comprehensively clarify the impact of cylinder vortex stabilizer on fluctuating turbulence structure of a Stairmand cyclone separator on basis of Large Eddy Simulation. The cylinder vortex stabilizer is easy and could be applied to any existing cyclone model without any major replacement. This novel modification in cyclone body is considered to alleviate the negative effect of entrainment of particles from the ash hopper and swing of the vortex end in swirling flow. The numerical simulations were conducted based on Stairmand cyclone separator and three new models with variation of vortex stabilizer length and diameter. The results showed that the cylinder vortex stabilizer could enhance flow instability and improve fluctuating turbulence structure to some extent. It is confirmed that cylinder vortex stabilizer could significantly reduce the tangential velocity in the inner quasi-forced vortex region of the cyclones. Comparing with Stairmand cyclone, the swirling first and second peak frequency of cyclone model with vortex stabilizer (Length L/D: 6.5, diameter d/D: 0.12) have been confirmed to get considerable reduction of 11.54% and 10.86%, respectively. This modified cyclone model is comparatively better for enhancement of flow stability, providing about 18.4% maximum reduction of normalized flow angle, 24.8% of rotational kinetic energy in dust collector and 14.2% in the main body of cyclone.     

DUST STRANDS IN CYCLONE SEPARATORS AT LOW DUST CONCENTRATION

Abstract

State of the art in calculating a cyclone separator is the application of the equilibrium theory and taking the formation of dust strands into account as well. The latter process does not depend on particle size mainly. An ideal flow pattern for the formation of dust strands is the so called Dean-vortex: it is being realized favorably in the axial flow cyclone. A dust strand can be produced down to a raw gas concentration C₀ ≈ 10^?5. Then, it is being exhausted through one or few holes in the mantle of the axial cyclone applying bleeding of about 10 % of the volume flow Separating its dust in a bin cyclone and recirculating the binflow gas to the main, axial cyclone completes this high performance cyclone separator. Dimensional analysis shows that the clean gas concentration c₁ mainly depends on the swirl W_tan/w_ax, the raw gas concentration c₀and on Reynolds number. For usual dust conditions a clean gas concentration c₁ ≤ 50 mg/m³ is feasible.     

Effect of the inlet angle on the performance of a cyclone separator using CFD-DEM

Hydrodynamic characteristics in a cyclone separator are simulated by means of DEM-CFD. Reynolds stress turbulence model (RSM) is used to capture gas turbulence. By changing the inlet angle, the distributions of pressure drop, tangential and axial velocity of gas phase are obtained within the cyclone. Simulated results indicate that the flow pattern consists of two regions: loss-free vortex region and forced vortex region. The negative inlet angle brings about a larger pressure drop comparing to positive inlet angle. The separation efficiency and trajectory of particles from simulation are obtained. The effects of inlet angle and particle size on separation efficiency are quantified. The separation efficiency is increased with an increase of particle size, while the separation efficiency firstly increases and then declined as inlet angle changes from negative to positive. An agreement between the numerical simulation and experimental results has been achieved in a cyclone separator.     

Study and optimization of flow field in a novel cyclone separator with inner cylinder

This paper presents a study of gas-solid flow in a novel cyclone separator with inner cylinder, compared with that in a conventional cyclone. The Reynolds stress model (RSM) is used to simulate fluid flow, and the discrete phase model (DPM) is selected to describe the motion behavior of particles. The experimental data measured by particle image velocimetry (PIV) is used to verify the reliability of the numerical model. The results show that in the novel cyclone, the cleaned gas can be quickly discharged from the vortex finder, the movement distance and residence time of fine particles are prolonged, the short-circuit flow and vertical vortex under the vortex finder are eliminated, the mutual interference between upflow and downflow in the cylinder is eliminated, and the region of quasi-free vortex in the cone is enlarged. Compared with the conventional cyclone, the novel cyclone has higher collection efficiency and lower pressure drop.     

旋风分离器减阻杆减阻的PIV实验研究

采用先进的PIV实验技术对Stairmand型旋风分离器中安装减阻杆前后的强湍流场进行了测量。通过速度场、湍流强度、Reynolds应力等物理量的对比分析,表明减阻杆降低了中心涡核区的旋转动能和湍流强度。对减阻杆减阻机理进行了更深入的探讨。     

Modification of the cyclone separator geometry for improving the performance using Taguchi and CFD approach

ABSTRACT

The cyclone separator performance has been affected by its high-pressure drop. The main geometric ratios such as outlet diameter, inlet width and inlet height and total height have been preferred to reduce the pressure drop and improve the performance of cyclone separator. These standard geometric values have been altered with the aid of design of experiment technique by Taguchi method for reducing the pressure drop. This changed new design produce low-pressure drop compared with the standard cyclone separator. Moreover, the collection efficiency of the new design is high when compared with standard cyclone separator. The pressure drop, Euler number, cut-off diameter and efficiency of the standard and new cyclone separator have been compared with the results of mathematical and computational fluid dynamics technique (CFD). The Reynolds stress turbulence model and discrete phase model have been used for simulating the cyclone separator in CFD. An acceptable agreement has been obtained between these results.     

旋风分离器内颗粒运动阻力的特征

分析了旋风分离器内颗粒运动阻力的特性，计算了某些工况下的颗粒雷诺数，进而分析说明了在旋风分离器内固体颗粒运动的的阻力不仅有粘性力的作用，而且有体形力的作用。     

导叶式旋风管内短路流颗粒夹带的研究

采用数值模拟方法,结合试验与理论分析,研究Shell型导叶式旋风管内短路流颗粒夹带问题。结果表明:Shell型旋风管直筒芯管下口存在短路流现象,计算得知短路流量占进口总流量的39.3%。理论分析发现,短路流主要夹带粒径小于9μm的颗粒,短路流夹带颗粒临界粒径为9μm。另外,数值模拟跟踪颗粒逃逸的轨迹证明,Shell型旋风管能将粒径大于9μm的颗粒全部除尽;粒径小于9μm的颗粒既有经排尘口返混逃逸,又有短路流夹带逃逸,其中短路流夹带逃逸占主要部分,且随着粒径的增加,经芯管下口短路夹带逃逸的数目减小。     

DESIGN GUIDELINES FOR CYCLONE IMPROVEMENT

ABSTRACT

There is a potential for improving cyclone separators by design and operating conditions. Secondary flow detrimental to dust separation can be avoided by proper gas inlets, dimensioning of body and swirl, or by use of a flow guide in the area of separation. Cyclone and bin are to be treated as one unit. Scavenging of the bin is most effective for high effiency. Cut sizes smaller than 1 μm can be realized with a cyclone separator unit consisting of a preseparator, a battery of small cyclones, and a scavenging cyclone with gas recirculation. Such arrangements are capable to cope with dust streaks and to make positive use of dust agglomeration. These principles are applicable also for big cyclone batteries as used behind rotary dryers for wood chips, etc.     

Evaluation of natural gas dehydration in supersonic swirling separators applying the Discrete Particle Method

The natural gas flow fields and particles separation characteristics were numerically calculated with the RNG k ? ε turbulence model and Discrete Particle Method (DPM) in the supersonic swirling separator. An experimental system was set up for testing the separation efficiency of three new designed separators with wet air. The numerical results showed that the new annular nozzle not only expanded the natural gas to supersonic velocity with resulting in low temperature (?72 °C), but also strengthened the swirling flow with the centrifugal field of 640 000g (g is the acceleration of gravity), both of which created good conditions for natural gas dehydration. Under the strong swirling flow field, most particles collided with the walls or entered into the liquid-collection space directly, while only few particles escaped together with the gas flow. The separation efficiency reached over 95%, when the length of the cyclone separation section was about 10 times of the diameter of the wall at throat. The experimental results indicated that the water can be efficiently removed from the wet air. The numerical results were in good agreements with the experimental findings, which demonstrated that the Discrete Particle Method (DPM) was accurate and stable enough to evaluate the dehydration characteristics of the supersonic swirling separator.     

DESIGN GUIDELINES FOR CYCLONE IMPROVEMENT

There is a potential for improving cyclone separators by design and operating conditions. Secondary flow detrimental to dust separation can be avoided by proper gas inlets, dimensioning of body and swirl, or by use of a flow guide in the area of separation. Cyclone and bin are to be treated as one unit. Scavenging of the bin is most effective for high effiency. Cut sizes smaller than 1 μm can be realized with a cyclone separator unit consisting of a preseparator, a battery of small cyclones, and a scavenging cyclone with gas recirculation. Such arrangements are capable to cope with dust streaks and to make positive use of dust agglomeration. These principles are applicable also for big cyclone batteries as used behind rotary dryers for wood chips, etc.     

A minichannel aluminium tube heat exchanger – Part I: Evaluation of single-phase heat transfer coefficients by the Wilson plot method

A prototype liquid-to-refrigerant heat exchanger was developed with the aim of minimizing the refrigerant charge in small systems. To allow correct calculation of the refrigerant side heat transfer, the heat exchanger was first tested for liquid-to-liquid (water-to-water) operation in order to determine the single-phase heat transfer performance. These single-phase tests are reported in this paper. The heat exchanger was made from extruded multiport aluminium tubes and was designed similar to a shell-and-tube heat exchanger. The heat transfer areas of the shell-side and tube-side were approximately 0.82 m² and 0.78 m², respectively. There were six rectangular-shaped parallel channels in a tube. The hydraulic diameter of the tube-side was 1.42 mm and of the shell-side 3.62 mm. Tests were conducted with varying water flow rates, temperature levels and heat fluxes on both the tube and shell sides at Reynolds numbers of approximately 170–6000 on the tube-side and 1000–5000 on the shell-side, respectively. The Wilson plot method was employed to investigate the heat transfer on both the shell and tube sides. In the Reynolds number range of 2300–6000, it was found that the Nusselt numbers agreed with those predicted by the Gnielinski correlation within ±5% accuracy. In the Reynolds number range of 170–1200 the Nusselt numbers gradually increased from 2.1 to 3.7. None of the previously reported correlations for laminar flow predicted the Nusselt numbers well in this range. The shell-side Nusselt numbers were found to be considerably higher than those predicted by correlations from the literature.     

Thermohydraulic performance and effectiveness of a mini shell and tube heat exchanger working with a nanofluid regarding effects of fins and nanoparticle shape

The influence of varied nanoparticle shapes on thermal–hydraulic efficacy of a boehmite nanofluid (BNF) in a mini shell and tube heat exchanger (MSTHX) in the cases of with and without fin is investigated. The five nanoparticle shapes with 90 °C inlet temperature at Reynolds number of 500 for the warm fluid side, and four Reynolds numbers of 500, 1000, 1500, and 2000 with 20 °C inlet temperature for the cold fluid side are considered. The warm fluid is the nanofluid that moves in the tube side, whilst the cool fluid is common water inside the shell side. With elevating Reynolds number, the heat transfer rate (q), overall heat transfer coefficient (U), pressure drop, effectiveness, and number of transfer unit (NTU) increase, while the performance index reduces. By increasing the Reynolds number from 500 to 2000 in the nanofluid having the oblate spheroid nanoparticles, the effectiveness rises 20%, and the performance index reduces 21.7%. The BNF with the platelet additives results in the largest q, whilst the smallest pressure loss is achieved for the Os-shaped additives. Also, the heat transfer rate, U, effectiveness, NTU, performance index, and pressure loss for the MSTHX with fin are larger than those for the MSTHX without fin.