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GC 2: Cyclones

GC 2: Cyclones
     Part 1: Introduction
         1 INTRODUCTION
     Part 2: State of the Art
         1 INTRODUCTION
         2 TYPES OF CYCLONE
         3 CYCLONE PERFORMANCE
             3.1 Defining performance
             3.2 Effect of cyclone geometry
                 3.2.1 Reverse flow cyclones
                 3.2.2 Uniflow cyclones
                 3.2.3 Multicyclones
             3.3 Effect of operating conditions
                 3.3.1 Particle size
                 3.3.2 Particle shape
                 3.3.3 Particle density
                 3.3.4 Gas flow rate
                 3.3.5 Aerosol concentration
         4 CYCLONE SIZING PROCEDURES
             4.1 Stairmand's sizing procedure
             4.2 Barth's sizing procedure
             4.3 Other sizing procedures
             4.4 Scoping design method
         5 PRACTICAL CONSIDERATIONS IN CYCLONE DESIGN
             5.1 Fabrication
                 5.1.1 Manufacturing tolerances
                 5.1.2 Mechanical design
                 5.1.3 Abrasion protection
                 5.1.4 High temperature design
                 5.1.5 Refractory linings
                 5.1.6 Explosion venting
             5.2 Cyclone installations
                 5.2.1 Cyclones in series
                 5.2.2 Cyclones in parallel
                 5.2.3 Effect of inlet ducting
                 5.2.4 Cyclones for limited headroom
             5.3 Ancillary equipment
                 5.3.1 Gas outlet devices
                 5.3.2 Dampers
                 5.3.3 Hoppers
                 5.3.4 Dust removal valves
                 5.3.5 Vortex stabilisers
             5.4 Problems
                 5.4.1 Low efficiency
                 5.4.2 High pressure drop
                 5.4.3 Erosion
                 5.4.4 Solids build up
                 5.4.5 Handling friable materials
                 5.4.6 Vibration
         6 SPECIALISED EQUIPMENT
             6.1 Novel devices
                 6.1.1 Shave-off cyclone
                 6.1.2 Recirculating cyclone
                 6.1.3 Rotary flow cyclone
                 6.1.4 Baffles
                 6.1.5 Vortex pocket collectors
             6.2 Demisting cyclones
                 6.2.1 Liquid re-entrainment
             6.3 Sampling cyclones
     Part 3: State of the Science
         1 INTRODUCTION
         2 FLOW MODELLING IN CYCLONES
             2.1 Experimental studies
             2.2 Inlet configuration
             2.3 The Meissner-Muschelknautz flow models
             2.4 The length of the vortex within a cyclone
             2.5 Other cyclone types
                 2.5.1 Uniflow cyclones
                 2.5.2 Multicyclones
             2.6 Small cyclones
             2.7 Computational fluid dynamics
         3 GEOMETRY INDEPENDENT MODELLING OF CYCLONE GRADE EFFICIENCY CURVES
             3.1 The Leith and Licht Model
                 3.1.1 Gas residence time
                 3.1.2 Particle distribution and collection
             3.2 The equilibrium orbit model and the definition of S
             3.3 The Dietz Model
             3.4 The Mothes and Loffler Model
             3.5 Prediction of experimental grade efficiency curves
             3.6 Particle concentration profiles
             3.7 Effect of solids loading
             3.8 Uniflow cyclones
         4 PRESSURE DROP PREDICTION
             4.1 Empirical expressions
             4.2 Theoretical models
             4.3 The SPS pressure drop model
             4.4 Effect of solids loading
         5 GEOMETRY INDEPENDENT SCALING
             5.1 Grade efficiency
             5.2 Pressure drop
     Part 4: The SPS Reverse Flow Gas Cyclone Design Procedure
         1 INTRODUCTION
         2 A DESIGN PROCEDURE FOR GAS CYCLONES
             2.1 Design data
             2.2 Selection of the required sharpness of cut
             2.3 Select cyclone vortex length and dust exit diameter
             2.4 Decide on need for a disengagement hopper and dust exit sealing arrangements
             2.5 Selection of standard cyclones of appropriate geometry
             2.6 Select an inlet velocity.
             2.7 Calculate the flow rate through an individual cyclone
             2.8 Calculate the required vortex finder diameter.
             2.9 Calculate the remaining cyclone dimensions
             2.10 Determine the empirical and theoretical cyclone performance
             2.11 Determine the wall friction factor.
             2.12 Calculate velocity at cyclone wall.
             2.13 Check the Swirl Reynolds Number and Centrifugal Acceleration criteria
             2.14 Calculate the velocity at the control surface diameter.
             2.15 Calculate the relationship between and particle diameter
             2.16 Calculate the theoretical grade efficiency curve
             2.17 Compare grade efficiency curves
             2.18 Perform grade efficiency calculation to determine the overall efficiency
             2.19 Compare efficiency with design value
             2.20 Consider changes to cyclone geometry
                 2.20.1 Pressure Drop
                 2.20.2 Inlet dimensions.
                 2.20.3 Inlet configuration and radius.
                 2.20.4 Vortex finder diameter.
                 2.20.5 Barrel diameter.
                 2.20.6 Vortex length and dust exit diameter.
                 2.20.7 Barrel height.
                 2.20.8 Vortex finder length.
             2.21 Practical considerations in cyclone design
                 2.21.1 Manufacturing Tolerances
                 2.21.2 Abrasion Protection
                 2.21.3 Grouping of Cyclones
         3 CYCLONE, THE SPS CYCLONE DESIGN PROGRAM
             3.1 Design data
             3.2 Select required ranges.
             3.3 Calculate the flow rate through each cyclone
                 3.3.1 Number of cyclones and inlet velocity
                 3.3.2 Number of cyclones and cut diameter
                 3.3.3 Number of cyclones and pressure drop
                 3.3.4 Inlet velocity and cut diameter
                 3.3.5 Cut diameter and pressure drop
             3.4 Calculate remaining cyclone dimensions
             3.5 Compare design geometry with geometrical constraints
             3.6 Check the Swirl Reynolds Number
             3.7 Check the Centrifugal Acceleration criteria
             3.8 Calculate the pressure drop across the cyclone
             3.9 Calculate the overall efficiency
             3.10 Results of the design
             3.11 Modifying designs
             3.12 Using CYCLONE to assess cyclones of arbitrary geometry
     Part 5: Appendices
         1. APPENDIX 1 THE ANALYTICAL CUT DIAMETER
         2. APPENDIX 2 GRADE EFFICIENCY INFORMATION ON STANDARD CYCLONE TYPES
         3. APPENDIX 3 EQUATIONS FOR CALCULATION OF THE DIMENSIONLESS RATIOS IN TABLE 4.2.1
         4. APPENDIX 4 GRADE EFFICIENCY CALCULATIONS
         5. NOMENCLATURE
         6. REFERENCES
     Terms and Conditions

Volume II provides a reference manual for all aspects of cyclone technology, science and design.

Practical aspects of cyclone installations are covered together with a balanced assessment of the current state of scientific knowledge and methods of predicting equipment performance and operation.

Gas cyclones are amongst the most commonly used types of gas cleaning equipment. They are cheap to build and easy to operate. They can be made from most structural materials to give them protection from a wide range of adverse process conditions. They suffer from the significant disadvantage that their efficiency falls off rapidly as the particle size drops below about 10 micrometers. As a result, it is necessary to have precise design procedures available so that decisions on whether to take advantage of the economic benefits of cyclones may be made with certainty.

Volume GC II  Part 1 Introduction.

Part 1 gives a brief introduction on how to use the rest of the volume.


Volume GC II  Part 2 State of the art.

This part gives details of the different types of cyclones and discusses the operating practices employed. It also examines the practical aspects of cyclone installations and provides information which allows problems associated with cyclones to be diagnosed and corrected.


Volume GC II  Part 3 State of the science.

This part contains an in-depth review of models, both theoretical and empirical, used for cyclone performance. It discusses how these models can be used in semi-empirical design procedures using scaling techniques. Relevant experimental work is also discussed.


Volume GC II  Part 4 The SPS reverse flow gas cyclone design procedure.

This report provides, for the first time, an accurate, scientifically based, design procedure which, to a large extent, is independent of the geometry of the unit being considered. A new theoretical approach to cyclone design is outlined which builds upon the best of the previously available theories. This approach is then used to show how the grade efficiency results obtained from one geometry of cyclone can be scaled to other geometries. Agreement of the 50% efficiency point is generally good. Differences in the slope of the grade efficiency curves are accounted for and used to construct a phase diagram which allows an engineer the opportunity to match the geometry of the cyclone to his process requirements. Several standard sets of geometries are provided to enable prediction of the likely pressure drop.

This part also gives details of how this is implemented in the CYCLONE design microcomputer program, which has now been updated and rewritten as Windows AEA-ToolKit application.