CYCLONE DESIGN AND ANALYSIS

by Esco Engineering

179 Lansdowne Avenue,

Kingsville, Ontario N9Y 3J2 Canada Revisions

ph 519 733 3122 ######## Corrected error in cell D14 on efficiency sheets

fax 519 733 6094 18-Jan-99 Added diagram

Contact: Neil Stone, Chief Engineer 3-Apr-99 Corrected cell O7, Efficiency 1 - thanks to Laercio Frare for pointing out this error

e-mail jnstone@mnsi.net 2-Dec-99 Added metric option, NV sketch

Website www.mnsi.net/~pas/esco.htm 13-Dec-99 Corrected error in density calc (size!E9, Efficiency 1! and 2!E19)

Copyright 1997 by John Neil Stone. All rights reserved.

May be redistributed free of charge, but may not be sold without the author's explicit permission.

Provided "as is" without warranty of any kind.

HOW TO USE THIS SPREADSHEET

NOTE: This spreadsheet is for the use of knowledgeable professionals, capable of evaluating the accuracy

of the results. The author is not responsible for the use to which these results are put.

1 The 'Cyclone size' sheet calculates dimensions for various standard cyclones.

Enter the flow rate, design inlet velocity and gas density in the colored squares

and the sheet will give dimensions for five standard cyclones - two high efficiency, and

three low efficiency. The table also gives the predicted pressure drop, but be aware that this is a

very uncertain calculation (see original references). See 'Diagram' sheet for nomenclature.

On the 'Cyclone size' sheet you specify the units you want to use - metric or US Customary (Imperial)

THIS UNITS SELECTION APPLIES TO ALL SHEETS

2 Two methods are provided for calculating cyclone efficiency. You can calculate both, and

compare the results on the chart. Both sheets are set up with the same layout, so data can be copied

between sheets easily.

3 The efficiency calculation requires particle size data, cyclone dimensions, and physical property

data for the gas and the solids. The calculation assumes that the size distribution of the particles

is log normally distributed. The sheet is set up so that you can enter either the mean and standard

deviation of the log normal distribution, or the particle size data, from which these data are then calculated.

4 Procedure for efficiency calculations:

a) Enter the cyclone dimensions in cells D4 to D11. If you have calculated these using this

spreadsheet, the values in cells 13 to 20 for the selected cyclone design can be directly copied

into D4 to D11. NOTE: Paste special the values - do not just copy the cells.

b) Enter the gas property data in cells D18 to D21.

c) Enter the particulate data in cells D26 to D29. If you enter the mean and standard deviation, and

select 'N' for cell D28, then the overall efficiency is immediately given in cell H15, and the inlet and

outlet size distributions are given in cells O21 to O41 and R21 to R41.

d) If you want to use the size distribution method, enter 'Y' in cell D28, and then the range limits starting in

cell N50 and the corresponding % in range starting in O50. If you want to use more than nine ranges, you

can extend these columns to as many rows as you want - just remember to copy the formulae

in columns M and P through T into any rows that you add.

After entering the size distribution data, You have to run the regression tool. Choose the 'Tools' menu

then 'Data Analysis' then 'Regression'. For the 'X' value pick all the values in column Q, starting in Q50;

for the 'Y' values, pick all the values in column T, starting in T50. For the 'Output range' enter V48. You will

get a message saying results will overwrite cells - pick OK.

Once the regression is done, the results are available, as described in c) above.

5 The chart sheet graphs the penetration (col P = 1 - fractional efficiency) against particle size for the two efficiency

calculation methods. CAUTION: The two efficiency sheets are not linked, so make sure they are both calculating

from the same data if you want to compare the two efficiency calculations!

6 The spreadsheet is protected in order to prevent accidental overwriting of the formulae.

However, there is no password needed to unprotect it, so you can freely adapt it to suit your purposes.

9/24/2013 174911189.xls.ms_office

DEFINITION OF CYCLONE DIMENSIONS

D

b De

a S

h

H

NV = Neutral vane

Extension of inner

side if inlet to centerline

of cyclone

B ELEVATION PLAN

9/24/2013 174911189.xls.ms_office

Cyclone size

CALCULATE DIMENSIONS FOR CYCLONE NOTES Sheet 1 is for sizing

Sheets 2/3 are for efficiency (alternates)

Sheet 4 are charts of results of sheets 2/3

SPECIFY UNITS (U = US CUSTOMARY[IMPERIAL], M = METRIC) m This setting applies to the whole spreadsheet

Input Working

Flow rate Q m^3/h 82702.43 48657 cfm

Design inlet vel vi m/s 45.94 151 fps

Gas density rg kg/m^3 0.0740 0.005 pcf

Inlet area 5.38 sf

PD parameter 0.80 cm water

Dimensions Type of cyclone

Stairmand Swift Lapple Swift Peterson/Whitby

HE HE LE LE LE

Dia D m 2.24 2.33 2.00 2.00 2.03

Inlet ht a m 1.12 1.02 1.00 1.00 1.18

Inlet width b m 0.45 0.49 0.50 0.50 0.42

Outlet length S m 1.12 1.16 1.25 1.20 1.18

Outlet dia De m 1.12 0.93 1.00 1.00 1.02

Cylinder ht h m 3.35 3.26 4.00 3.50 2.71

Overall ht H m 8.95 9.07 8.00 7.50 6.44

Dust outlet dia B m 0.84 0.93 0.50 0.80 1.02

# vel hds Nh 5.14 4.87 4.49 4.69 4.77

Press drop, no NV cm water 4.11 3.89 3.59 3.75 3.81

Press drop, with NV cm water 1.92 1.83 1.68 1.76 1.79

Cyclone data from "New design approach boosts cyclone efficiency", W.H.Koch and W.Licht, Chem Eng Nov 7 1977, 80

Pressure drop vel head correlation from "A better way to calculate cyclone pressure drop" J.Casal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99

Page 3

Cyclone size

Sheets 2/3 are for efficiency (alternates)

Sheet 4 are charts of results of sheets 2/3

This setting applies to the whole spreadsheet

Copy one col of outline

data (copy values only)

to efficiency sheet.

Cyclone data from "New design approach boosts cyclone efficiency", W.H.Koch and W.Licht, Chem Eng Nov 7 1977, 80

Pressure drop vel head correlation from "A better way to calculate cyclone pressure drop" J.Casal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99

Page 4

Efficiency 1

CALCULATE EFFICIENCY FOR CYCLONE (method 1)

CALCULATIONS ARE IN METRIC UNITS

Geometry Input Working Limits/warnings

Dia D m 2.58 8.47 INLET HT GREATER THAN OUTLET LENGTH - CAUSES SHORT-CIRCUITING

Inlet ht a m 15.49 609.92 INLET WIDTH TOO GREAT - CONTRACTION AT INLET

Inlet width b m 6.20 243.97

Outlet length S m 1.29 4.23

Oulet dia De m 15.49 609.92 VORTEX OUTSIDE CYCLONE

Cylinder ht h m 3.87 12.70

Overall ht H m 10.33 33.88

Dust outlet dia B m 11.62 457.44

Natural length L m 14.65 48.04

# vel hds Nh 37532.13

Press drop, no NV cm water 0.00

Press drop, with NV cm water 0.00 Overall efficiency

Gas data

Flow rate Q m^3/h 2000 1176.67 19.61111 cfs

Density rg kg/m^3 0.0740 0.0046 0.066 air @ 1 atm, spec'd temp

Viscosity u cP 0.010 0.010 6.72E-06 lb/f-s

Temperature T C 60 140

Salt. temp fact fT 1.00 1

Salt dens. fact fp 1.00 1

Particle data Value used

Log mean dia dp m 12 11.905565

Log SD sd m 3 3.1077764

Use distribution? (Y/N) y If yes, run regression - adjust input ranges (cols Q,T) to suit data

Specific gravity 0.8 49.92 pcf

References

Efficiency from "New design approach boosts cyclone efficiency",

W.H.Koch and W.Licht, Chem Eng Nov 7 1977, 80

Pressure drop vel head correlation from "A better way to calculate cyclone pressure

drop" J.Casal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99

Statistical correlation constants

2.515517

0.802853

0.010328

1.432788

0.189269

0.001308

Min

0

2

3

Page 5

Efficiency 1

5

10

20

30

40

50

Page 6

Efficiency 1

Calculated data

Log SD 1.133907

INLET HT GREATER THAN OUTLET LENGTH - CAUSES SHORT-CIRCUITING Inlet velocity fps 0.018979

INLET WIDTH TOO GREAT - CONTRACTION AT INLET Ratio inlet/salt vel -0.01011

Corrected L ft 29.64123

Core dia ft 38.11984

VORTEX OUTSIDE CYCLONE Eff vol cf 26594.11

Inlet vol cf 41777.45

Cycl const Kc 90.67049

G 3.494537

Vortex exp n+1 1.754356

17.8 %

Efficiency calcs

Dia, um

air @ 1 atm, spec'd temp Min Max Inlet mass frn

fraction

0 0.4 0.0020

0.4 0.6 0.0028

0.6 1.2 0.0168

1.2 1.8 0.0260

1.8 2.4 0.0309

2.4 3 0.0330

3 3.6 0.0336

If yes, run regression - adjust input ranges (cols Q,T) to suit data 3.6 4.2 0.0333

4.2 4.8 0.0324

4.8 7 0.1080

7 10 0.1197

10 13 0.0926

13 16 0.0724

16 22 0.1052

22 28 0.0698

28 34 0.0486

34 40 0.0351

40 49 0.0372

49 64 0.0384

64 79 0.0220

79 94 0.0136

0.9736

Overall efficiency

Distribution data

Size, um Cum %

Min Max

0 2 6

2 3 11

3 5 22

Page 7

Efficiency 1

5 10 44

10 20 67

20 30 80

30 40 85

40 50 90

50 100 97

Page 8

Efficiency 1

Int calcs

Distribution Relax time Penetration

Penetration Outlet amt Outlet mass fl fh tl th pl

fraction

0.9890 0.0020 0.0024 0 0.009991 0 7.11E-07 1

0.9751 0.0028 0.0033 0.009991 0.018218 7.11E-07 1.6E-06 0.977949

0.9657 0.0162 0.0198 0.018218 0.037832 1.6E-06 6.4E-06 0.972296

0.9540 0.0248 0.0302 0.037832 0.048784 6.4E-06 1.44E-05 0.959149

0.9444 0.0291 0.0355 0.048784 0.054068 1.44E-05 2.56E-05 0.948804

0.9360 0.0309 0.0376 0.054068 0.056018 2.56E-05 4E-05 0.93996

0.9285 0.0312 0.0380 0.056018 0.05603 4E-05 5.76E-05 0.932099

0.9216 0.0307 0.0373 0.05603 0.054921 5.76E-05 7.84E-05 0.924949

0.9153 0.0297 0.0361 0.054921 0.053178 7.84E-05 0.000102 0.918345

0.9022 0.0975 0.1186 0.053178 0.04504 0.000102 0.000218 0.912179

0.8810 0.1055 0.1283 0.04504 0.034769 0.000218 0.000444 0.892282

0.8600 0.0797 0.0969 0.034769 0.026983 0.000444 0.000751 0.869646

0.8417 0.0609 0.0741 0.026983 0.021255 0.000751 0.001137 0.850272

0.8183 0.0861 0.1048 0.021255 0.013811 0.001137 0.00215 0.833119

0.7906 0.0552 0.0672 0.013811 0.009455 0.00215 0.003483 0.803387

0.7666 0.0373 0.0453 0.009455 0.006743 0.003483 0.005136 0.777883

0.7452 0.0262 0.0319 0.006743 0.004969 0.005136 0.007108 0.75535

0.7214 0.0268 0.0327 0.004969 0.003297 0.007108 0.010667 0.735057

0.6883 0.0265 0.0322 0.003297 0.00183 0.010667 0.018197 0.707827

0.6520 0.0144 0.0175 0.00183 0.001106 0.018197 0.027727 0.668731

0.6206 0.0085 0.0103 0.001106 0.000711 0.027727 0.039256 0.635282

0.8217 1.0000

Overall efficiency 17.8 %

% in ln dia max SUMMARY OUTPUT

range

6 0.693147 2.372092 1.555097 -1.5551 Regression Statistics

5 1.098612 2.101083 1.226669 -1.22667 Multiple R 0.999874

11 1.609438 1.740188 0.77197 -0.77197 R Square 0.999749

Page 9

Efficiency 1

22 2.302585 1.28139 0.150652 -0.15065 Adjusted R Square0.999713

23 2.995732 1.489069 0.43948 0.43948 Standard Error0.022894

13 3.401197 1.794123 0.841457 0.841457 Observations 9

5 3.688879 1.947881 1.036431 1.036431

5 3.912023 2.145966 1.281729 1.281729 ANOVA

7 4.60517 2.648229 1.881213 1.881213 df SS

Regression 1 14.59118

Residual 7 0.003669

Total 8 14.59485

CoefficientsStandard Error

Intercept 2.477006 0.007748

X Variable 1 1.133907 0.006796

Page 10

Efficiency 1

Penetration

ph

0.977949

0.972296

0.959149

0.948804

0.93996

0.932099

0.924949

0.918345

0.912179

0.892282

0.869646

0.850272

0.833119

0.803387

0.777883

0.75535

0.735057

0.707827

0.668731

0.635282

0.605957

Page 11

Efficiency 1

MS F Significance F

14.59118 27837.76 7.33E-14

0.000524

t Stat P-value Lower 95%Upper 95%Lower 95.000%Upper 95.000%

319.6806 7.74E-16 2.458684 2.495328 2.458684 2.495328

166.8465 7.33E-14 1.117837 1.149978 1.117837 1.149978

Page 12

Efficiency 2

CALCULATE EFFICIENCY FOR CYCLONE (method 2)

CALCULATIONS ARE IN METRIC UNITS

Geometry Input Working Limits/warnings

Dia D m 3.33 10.93 INLET HT GREATER THAN OUTLET LENGTH - CAUSES SHORT-CIRCUITING

Inlet ht a m 20.00 787.40 INLET WIDTH TOO GREAT - CONTRACTION AT INLET

Inlet width b m 8.00 314.96

Outlet length S m 1.67 5.47

Oulet dia De m 20.00 787.40 VORTEX OUTSIDE CYCLONE

Cylinder ht h m 5.00 16.40

Overall ht H m 13.33 43.73

Dust outlet dia B m 15.00 590.55

Natural length L m 18.91 62.02

# vel hds Nh 37532.13

Press drop, no NV cm water 0.00

Press drop, with NV cm water 0.00 Overall efficiency

Gas data

Flow rate Q m^3/h 2000 1176.67 19.61111 cfs

Density rg kg/m^3 0.0740 0.0046 0.066 air @ 1 atm, spec'd temp

Viscosity u cP 0.010 0.010 6.72E-06 lb/f-s

Temperature T C 60 140

Salt. temp fact fT 1.00 1

Salt dens. fact fp 1.00 1

Particle data Value used

Log mean dia dp um 24 11.905565

Log SD sd um 3 3.1077764

Use distribution? (Y/N) y If yes, run regression - adjust input ranges (cols Q,T) to suit data

Specific gravity 5 312 pcf

Re-entrainment coeff alpha 0 default = 0 (see original paper for definition)

References

Efficiency from "A new collection theory of cyclone separators",

L.Enliang & W Yingmin, AIChEJ Vol 35, #4 April 1989, 666

Pressure drop vel head correlation from "A better way to calculate cyclone pressure

drop" J.Casal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99

Statistical correlation constants

2.515517

0.802853

0.010328

1.432788

0.189269

0.001308

Min

0

2

3

Page 13

Efficiency 2

5

10

20

30

40

50

Page 14

Efficiency 2

Calculated data

Log SD 1.133907

INLET HT GREATER THAN OUTLET LENGTH - CAUSES SHORT-CIRCUITINGInlet velocity fps 0.011387

INLET WIDTH TOO GREAT - CONTRACTION AT INLET Ratio inlet/salt vel -0.00455

Vortex exp 1-n 0.065925

theta 6.462466

VORTEX OUTSIDE CYCLONE rw 5.466667

rn 32.80833

uw -0.07186

Dr 0.005108

2.6 %

Efficiency calcs

Dia, um

air @ 1 atm, spec'd temp Min Max Inlet mass frnPenetration Outlet amt

fraction

0 0.4 0.0020 1.0000 0.0020

0.4 0.6 0.0028 1.0000 0.0028

0.6 1.2 0.0168 1.0000 0.0168

1.2 1.8 0.0260 1.0000 0.0260

1.8 2.4 0.0309 1.0000 0.0309

2.4 3 0.0330 1.0000 0.0330

3 3.6 0.0336 1.0000 0.0336

If yes, run regression - adjust input ranges (cols Q,T) to suit data 3.6 4.2 0.0333 1.0000 0.0333

4.2 4.8 0.0324 1.0000 0.0324

4.8 7 0.1080 1.0000 0.1080

7 10 0.1197 1.0000 0.1197

10 13 0.0926 1.0000 0.0926

13 16 0.0724 1.0000 0.0724

16 22 0.1052 1.0000 0.1052

22 28 0.0698 1.0000 0.0698

28 34 0.0486 1.0001 0.0486

34 40 0.0351 1.0001 0.0351

40 49 0.0372 1.0003 0.0372

49 64 0.0384 1.0007 0.0385

64 79 0.0220 1.0018 0.0221

79 94 0.0136 1.0039 0.0137

0.9736 0.9737

Overall efficiency 2.6

Distribution data

Size, um Cum % % in ln dia max

Min Max range

0 2 6 6 0.693147

2 3 11 5 1.098612

3 5 22 11 1.609438

Page 15

Efficiency 2

5 10 44 22 2.302585

10 20 67 23 2.995732

20 30 80 13 3.401197

30 40 85 5 3.688879

40 50 90 5 3.912023

50 100 97 7 4.60517

Page 16

Efficiency 2

Int calcs

Distribution Penetration

Outlet mass fl fh kh wh lh pl ph

fraction

0.0021 0 0.009991 -1.6E-06 4.19E-09 -2.6E-13 1 1

0.0029 0.009991 0.018218 -3.5E-06 9.43E-09 -1.3E-12 1 1

0.0173 0.018218 0.037832 -1.4E-05 3.77E-08 -2.1E-11 1 1

0.0267 0.037832 0.048784 -3.2E-05 8.48E-08 -1.1E-10 1 1

0.0317 0.048784 0.054068 -5.6E-05 1.51E-07 -3.4E-10 1 1

0.0339 0.054068 0.056018 -8.8E-05 2.36E-07 -8.3E-10 1 1

0.0345 0.056018 0.05603 -0.00013 3.39E-07 -1.7E-09 1 1

0.0342 0.05603 0.054921 -0.00017 4.62E-07 -3.2E-09 1 1

0.0333 0.054921 0.053178 -0.00022 6.03E-07 -5.4E-09 1 1

0.1110 0.053178 0.04504 -0.00048 1.28E-06 -2.5E-08 1 1

0.1229 0.04504 0.034769 -0.00097 2.62E-06 -1E-07 1 1.000001

0.0951 0.034769 0.026983 -0.00165 4.43E-06 -2.9E-07 1.000001 1.000002

0.0743 0.026983 0.021255 -0.00249 6.7E-06 -6.7E-07 1.000002 1.000004

0.1080 0.021255 0.013811 -0.00471 1.27E-05 -2.4E-06 1.000004 1.000015

0.0717 0.013811 0.009455 -0.00763 2.05E-05 -6.3E-06 1.000015 1.000041

0.0499 0.009455 0.006743 -0.01126 3.03E-05 -1.4E-05 1.000041 1.000088

0.0361 0.006743 0.004969 -0.01558 4.19E-05 -2.6E-05 1.000088 1.000169

0.0382 0.004969 0.003297 -0.02338 6.29E-05 -5.9E-05 1.000169 1.000381

0.0395 0.003297 0.00183 -0.03989 0.000107 -0.00017 1.000381 1.001108

0.0227 0.00183 0.001106 -0.06077 0.000163 -0.0004 1.001108 1.002574

0.0141 0.001106 0.000711 -0.08604 0.000231 -0.0008 1.002574 1.005167

1.0000

%

SUMMARY OUTPUT

2.372092 1.555097 -1.5551 Regression Statistics

2.101083 1.226669 -1.22667 Multiple R 0.999874

1.740188 0.77197 -0.77197 R Square 0.999749

Page 17

Efficiency 2

1.28139 0.150652 -0.15065 Adjusted R Square0.999713

1.489069 0.43948 0.43948 Standard Error0.022894

1.794123 0.841457 0.841457 Observations 9

1.947881 1.036431 1.036431

2.145966 1.281729 1.281729 ANOVA

2.648229 1.881213 1.881213 df SS MS F

Regression 1 14.59118 14.59118 27837.76

Residual 7 0.003669 0.000524

Total 8 14.59485

CoefficientsStandard Error t Stat P-value

Intercept 2.477006 0.007748 319.6806 7.74E-16

X Variable 1 1.133907 0.006796 166.8465 7.33E-14

Page 18

Efficiency 2

Page 19

Efficiency 2

Significance F

7.33E-14

Lower 95%Upper 95%Lower 95.000%Upper 95.000%

2.458684 2.495328 2.458684 2.495328

1.117837 1.149978 1.117837 1.149978

Page 20

charts

0.0000

0.2000

0.4000

0.6000

0.8000

1.0000

1.2000

0 5 10 15 20 25

Pen

etr

ati

on

Particle dia um

EFFICIENCY

Koch and Licht Enliang

Page 21

charts

25 30

Page 22