Exploratory Study on Cyclones of Modified Designs

This paper introduces a new design of cyclone, named triple cyclone, created by adding two more cylinders to the conventional cyclone. The performance of the triple cyclone was evaluated systematically together with the previously reported double cyclone. The tests showed that the collection efficiencies of double and triple cyclones were lower than those of the conventional cyclone with the same body diameter and identical gas inlet and outlet size. Of the three designs, the collection efficiency of the triple cyclone was the lowest. Accordingly, the highest pressure drop was observed for the conventional cyclone, and the pressure drop for the triple cyclone was the lowest. These results are probably attributed to the relatively weak vortices formed within triple and double cyclones.     

Numerical simulation of flow field in three types of standard cyclone separators

The numerical simulation of the fluid flow and particle dynamics is presented by CFD techniques to characterize the performance of the three types of standard cyclones. The three types of cyclones named 1D3D, 2D2D and 1D2D. The length of cylindrical part of the body is equal to 1, 2 and 1 times of the body diameter, respectively; and the length of the conical part is 3, 2 and 2 times of the body diameter. The Reynolds averaged Navier–Stokes equations with Reynolds stress turbulence model (RSM) are solved by use of the finite volume method based on the SIMPLE pressure correction algorithm in the computational domain. The Eulerian–Lagrangian computational procedure is used to predict particles tracking in the cyclones. The velocity fluctuations are simulated using the Discrete Random Walk (DRW). The dependency of cyclone characteristics on its diameter is investigated and D₅₀ (Cut-Point) is calculated for different Particle Size Distributions (PSDs). The numerical results are compared with the experimental data and the theoretical model and good agreement is observed.     

Numerical study of flow field in new design cyclones with different wall temperature profiles: Comparison with conventional ones

In this paper, numerical study of flow field in the new design cyclones with five different wall temperature profiles are investigated. The new design cyclone is based on the idea of improving cyclone collection efficiency and pressure drop by increasing the vortex length. In this paper, the five wall temperature profiles are as follows: (A) cooling with uniform distribution, (B) without temperature change, (C) heating with uniform distribution, (D) incremental linear heating, (E) reduction linear heating. Results are compared in new design and conventional cyclones. The Reynolds averaged Navier–Stokes equations with Reynolds stress turbulence model (RSM) are solved. The Eulerian-Lagrangian computational procedure is used to predict particles tracking in the cyclones. The velocity fluctuations are simulated using the Discrete Random Walk (DRW).Results show that generally, heating the bottom zone of the cyclones can improve the collection efficiency and reduce the pressure drop while heating the top zone of the cyclones marginally affects the flow field. Moreover, cooling the cyclones reduces the efficiency and causes a higher pressure drop. Among five different wall temperature profiles, C and E profiles can increase the efficiency about 8% and profile C reduces the pressure drop by about 9%. The mentioned values in different conditions including particle diameter, flow rate, etc. can be different.     

Effects of Exit Tube Diameter on the Flow Field in Cyclones

A number of cyclones with different exit tube diameters have been simulated with CFD in this study. Results show that the exit tube diameter influences not only the velocity magnitude, but also the shape of the velocity profiles within cyclones. Depending on the diameter of the exit tube, the axial velocity profiles can exhibit a either maximum or a minimum on the axis. If the exit tube diameter is small, the central flow has a jet-like appearance. On the other hand, axial velocity dip in the profile can be observed near the center in a cyclone with a large gas exit tube. In addition, the well-known double vortexes, which commonly are present in a cyclone of practical design, do not exist in a cyclone with an excessively large exit tube. Quantitative comparison of velocity distribution shows that the tangential velocity increases as the exit tube diameter is reduced, giving rise to higher particle collection efficiency. Usually, the pressure drop decreases with increasing exit tube diameter. However, if the exit tube size is excessively large, the pressure drop may start to increase. Practically, cyclone with an excessively large exit tube should be avoided.     

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.     

Gas-solid separation performance and structure optimization in 3D printed guide vane cyclone separator

Low separation efficiency and large pressure drop are two common problems of cyclones. In this paper, a 3D printed guide vane cyclone separator was designed to study the separation efficiency, turbulent kinetic energy, and particle movement of particle group by experiment and simulation. The results shown that the tangential velocity was the major influence of separating. The bottom of the exhaust pipe was the main region of gas–solid separation and pressure drop. The separation efficiency and pressure drop were positively correlated with the inlet velocity and the particle radius of the fluid. The distribution of turbulent kinetic energy that leaded to the pressure drop loss was concentrated on the inlet of the exhaust pipe. The swirl has external and internal two directions. The optimized cyclone has a longer and narrower blade flow path to obtain higher separation efficiency, especially at low inlet velocity.     

Numerical simulation of square cyclones in small sizes

The idea of using square cyclones was first introduced in early 1990s because of some problems of big conventional (round) cyclones in Circulating Fluidized Bed (CFB) industries, such as huge volume and long start-stop time of cyclones. Now there is this question, in spite of the main reason for making square cyclones, how square cyclones behave in small sizes.In this paper, two small cyclones with the same hydraulic diameter, which one is square and the other one is round, are numerically compared. The Reynolds averaged Navier–Stokes equations with Reynolds Stress Turbulence Model (RSTM) are solved by use of the finite volume method based on the SIMPLE pressure correction algorithm in the computational domain. The Eulerian–Lagrangian computational procedure is used to predict particles tracking in the cyclones. The velocity fluctuations are simulated using the Discrete Random Walk (DRW).The results show that the pressure drop in small square cyclone is less than the pressure drop in small round one. Also at each flow rate collection efficiency of small square cyclone is less than round one, but by increasing flow rate this difference decreases.     

Effects of the prolonged vertical tube on the separation performance of a cyclone

This article aims at the gas flow into the dustbin of conventional cyclones, the prolonged cyclone (attaching a vertical tube at the bottom of the dust outlet) is proposed by some researchers, which can make flow with dust enter into the tube and separate further. The Reynolds stress transport model (RSTM) has been employed to predict the gas flow fields of the conventional and prolonged cyclones. The tangential velocity, axial velocity profiles and turbulent kinetic energy profiles are presented, and the downward flow rates into the dustbin of the three cyclones are compared. The separation performances of these three cyclones are tested. The result indicates that the tangential velocity, axial velocity and turbulent kinetic energy in the dustbin reduce greatly when the prolonged vertical tube attaching into the dust outlet, which can avoid the re-entrainment of already separated dust effectively. Furthermore, the prolonged vertical tube increases the separation space of dusts. The downward flow rate into the dustbin of the prolonged cyclone decreases compared with the conventional cyclone. The experimental results show that the prolonged vertical tube can improve the separation efficiency by a slightly increased pressure drop. However, for an even longer tube, the separation efficiency is slightly reduced. Thus, there is an optimal tube length for a given cyclone.     

Experimental and CFD study on effects of spiral guide vanes on cyclone performance

This paper presents an experimental and numerical study on a tangential inlet cyclone separator with a spiral guide vane which is not often researched. Numerical pressure drop results were in close agreement with the experimental data. The spiral guide vane was also found to considerably influence the velocity distribution, turbulence intensity, pressure drop and collection efficiency in the cyclone. A critical value of spiral guide vane turns appeared below or above which there was a marked increase in collection efficiency, pressure drop, and tangential velocity. Compared to a cyclone with zero spiral guide vane turn, the maximal decrease in collection efficiency in the cyclone with the critical spiral guide vane turns (one turn) was 2% approximately. The maximum-efficiency inlet velocity appeared to exist independent of spiral guide vane turns, as inlet velocity affected the radial distance traveled by the rebounded particles from the inner wall. The analysis of flow field in cyclones indicated that the flow field was improved with the spiral guide vanes employed to some extent. The results presented here may provide a workable reference for the effects of spiral guide vanes on the flow field and corresponding performance in cyclone separators.     

高温高压旋风分离器流场模拟及性能试验

提出一种圆形径向进口、筒体段扩径的拱顶旋风分离器新结构;并与PV型分离器进行了流场和分离性能对比。结果表明:在相同处理气量下,新型分离器外旋流区切向速度显著大于PV型,中心涡核区轴向速度小于PV型;用中位粒径为9μm的滑石粉进行冷模试验,新型旋风分离器分离效率比PV型高约1%;新型旋风分离器结构强度和分离性能优良,适合高温、高压的工况下应用。     

Performance evaluation of a new micro gas cyclone using simulation and experimental studies to capture indoor fine particles

The aim of this study was evaluating a micro gas cyclone performance with a body diameter of 10?mm to collect indoor fine particles. The design of a cyclone requires minimizing the pressure drop and maximizing the separation efficiency. Overall and grade efficiencies, pressure drops, and cut sizes have been investigated through a theoretical model, simulation, and experimental studies. The experimental part was conducted using an Electrical Low-Pressure Impactor (ELPI) device to measure particle concentration for flow rates of 10–13.3 (l/min). In order to study the pressure drop and velocity behavior for different flow rates, COMSOL software was utilized. The obtained results from experimental work have met the theoretical and simulation outcomes adequately. It has been confirmed by all the obtained results that by increasing the flow rate and subsequently inlet velocity, the particle collection efficiency and pressure drop increase while the cut size decreases.     

多效旋风分离器压降的实验研究

为了有效提高新型多效旋风分离器对粒径为0.1~3μm颗粒的分离效率,获取该设备的阻力性能,采用实验方法研究该新型多效旋风分离器压降与进口气速的关系,并与Lapple型旋风分离器进行比较。结果表明:进口风速为5~30m/s时,主体直径为0.25m的多效旋风分离器总阻力系数为7.29,其中,一级和二级预分离螺旋管的阻力系数分别为1.04和1.73;主体的阻力系数为4.52。直径为0.25m的Lapple型旋风分离器的阻力系数为7.21。     

Effect of Operating Pressure on the Application of Multiple Cyclones in Dense Medium Separation (DMS) Plant

In order to meet the market demands for minerals, it is necessary that large volumes of ores be treated at a rapid rate, and this has led to the use of multiple cyclones (in parallel) in the dense medium separation (DMS) plant since the single largest efficiently used cyclone (710 mm in diameter) can only process approximately 400 m³/h of material. However, the use of multiple cyclones came with a few problems that are all centered on the split of the ore feed and transport medium amongst the number of cyclones used. Poor splits often lead to poor separations, especially when treating ores with a high quantity of near-gravity material. This study therefore, focuses on the effects of operating pressure on the stability and efficiency of the cyclones. The effects of pressure on the stability and distribution of the ore in the cyclones were also investigated in this study. The analyses of the results obtained indicate that the circulating medium was stable with percentage stability in the range of 3 to 12%, with average medium stability of 8.3%. The results also show that changes in the circulating medium density and mixing box operating level had little effect on the cyclone pressure. The simulated results indicate that changes larger than 5% may adversely affect cyclone pressures. Tracer analysis was used to determine the efficiency, and its results show that the cyclones were cutting at a very high density cut point, which was due to the high operating head of the cyclones at 16D. It was discovered that operating the cyclone at maximum head of 12D to bring down the cut point reduce the wear rate on the cyclones. The tromp curves obtained from operating the cyclones at a lower pressure gave an average mean probable error of 0.048 (0.05 approximately) and an average cut point of 3.13. This indicates that the cyclones operate fairly similarly with very good separation efficiencies.     

Effect of Vortex Finder Diameter on Flow Field and Collection Efficiency of Cyclone Separators

In this study, aerocyclone separators, with five different vortex finder diameters are simulated using commercially available computational fluid dynamics code Fluent 6.3.26 to analyze flow field pattern and the collection efficiency. It is found that a decrease in vortex finder diameter results in an increase in pressure drop by 47.84% and an increase in the collection efficiency by 9.54%, whereas, the increase in vortex finder diameter leads to a reduction in pressure drop by 23.87% and a decrease in the collection efficiency by 7.70% as compared to the Stairmand high efficiency cyclone. It is also observed that a decrease in vortex finder diameter leads to about 33% increase in axial velocity and about 25% increase in tangential velocity, whereas, an increase in vortex finder diameter results in about 23% decrease in axial velocity and about 12% decrease in tangential velocity as compared to the Stairmand high efficiency cyclone.     

The effect of magnetic field on the performance of new design cyclone separators

In this paper it is attempted to improve the performance of the gas–solid new design cyclones with imposing magnetic fields. First, Eulerian-Lagrangian method is used to model the flow and to track the solid particles within the new design cyclones. The Reynolds averaged Navier–Stokes equations with Reynolds stress turbulence model (RSM) are solved by use of the finite volume method based on the SIMPLE pressure correction algorithm in the computational domain. The velocity fluctuations are simulated using the Discrete Random Walk (DRW). Then, to investigate the possible influence of the magnetic field, horizontal and vertical distances of the magnetic source from the coordinate origin as influential parameters are investigated. Solid particles with three different diameters and with different materials including polystyrene, ferrous and nickel are used. Results show that applying a magnetic field can improve the collection efficiency for all different particles’ materials. Analysis of results proves that there is a strong correlation between cyclone performances. It is observed that the collection efficiency is very sensitive to vertical distance of the magnetic source from the origin. Moreover, providing higher efficiency without imposing pressure drop is the advantage of implication of a magnetic field.     

Study of inlet temperature effect on single and double inlets cyclone performance

In this paper, a comprehensive study is performed in order to demonstrate the effect of the flow and particle temperature on cyclone performance. Three main characteristics of the low-mass-loading gas-solid cyclone separators, including: pressure drop, particle separation efficiency and natural vortex length are investigated. Eulerian-Lagrangian approach is employed to solve the unsteady Navier-Stokes and energy equations to model the flow of particles. Because of the strong swirling flow in cyclone, Reynolds stress transport model (RSTM) is used to calculate the Reynolds stresses. Numerical simulation is accomplished at a temperature range of 293–700 K and four inlet velocities. Also, a comparison is conducted between two Stairmand high efficiency cyclones with the same dimensions, one with single inlet and the other with double inlets to declare the effect of the second inlet on cyclone performance. The analysis of results shows that the swirling flow becomes weaker for higher temperature cases and thus, flow pressure drop and particle separation efficiency is noticeably decreased. Increasing in temperature causes decrease in natural vortex length. Also, study of natural vortex length is performed for the studied range of temperature.     

Experimental study on the separation performance of a novel gas–liquid separator

A novel two-stage dynamic separator called high-gravity cyclone separator (HGCS) has been designed for gas–liquid separation. It is mainly composed of a cyclone chamber and rotary drum. In this study, its performance, including the separation efficiency and pressure drop, is experimentally investigated, and the effects of the operating conditions and drum parameters are evaluated. For droplets with a mean diameter of 7 μm, the results indicate that the optimal gas inlet velocity and high-gravity factor are 12 m/s and 59.4, respectively, and the separation efficiency reaches 98 %. The effect of liquid concentration is sensitive to the high-gravity factor. At a liquid concentration of 57 g/m³, the maximum efficiency will be 98.75 % when increasing the high-gravity factor to 85.6. Furthermore, a smaller radial height is preferable when the gas inlet velocity is greater than 12 m/s, and a better separation efficiency can be obtained by increasing the drum length to 190 mm. However, when the length is 235 mm, the efficiency will be poor because of the Kelvin–Helmholtz and Rayleigh–Taylor instabilities. Compared with the predominant roles of gas inlet velocity, drum length and radial height in pressure drop, the effects of liquid concentration and high-gravity factor are small.     

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.     

页岩灰与催化裂化催化剂细粉旋风分离性能的对比试验研究

试验测定和对比页岩灰和流化催化裂化三旋灰(FCC三旋灰)的旋风分离器性能,考察入口气速、入口浓度对分离效率和分离器压降的影响.结果表明,在相同操作条件下,同一台旋风分离器上,粒度小于75 μm的页岩灰与FCC三旋灰的分离效率和分离器压降曲线差别显著;页岩灰的分离效率与分离器压降都明显低于FCC三旋灰,且入口浓度增大,页岩灰分离器压降的下降幅度高于FCC三旋灰;页岩灰分离效率最高的入口气流速度也低于FCC三旋灰.颗粒特性对旋风分离器的分离性能有明显影响,页岩灰和三旋灰的颗粒特性与形状差别是导致其旋风分离特性不同的一个基本原因;油页岩旋风分离器的设计应当考虑油页岩颗粒特性的影响.     

三维旋转流场特征与压力损失关系的研究

本文以Stairmand高效旋风分离器为实验模型，利用五孔球形探针测试了典型三维旋转流动的速度和压力分布。并结合减阻杆的研究发现，测试了安装不同类型减阻杆后速度和压力分布的变化，从而在分析减阻杆减阻机理的同时，认识了三维旋转流场特征与压力损失的关系。