Challenge

Cyclone Separator Challenge

DDharmesh Joshi24 Jul 2020

Introduction:

Cyclone separators are separation devices that use the principle of inertia to remove particulate matter from flue gases. Cyclone separator is one of many air pollution control devices known as pre-cleaners since they generally remove larger pieces of particulate matter. This prevents finer filtration methods from having to deal with large, more abrasive particles later on. In addition, several cyclone separators can operate in parallel, and this system is known as a multi-cyclone.

It is important to note that cyclones can vary drastically in their size. The size of the cyclone depends largely on how much flue gas must be filtered, thus larger operations tend to need larger cyclones. For example, several different models of one cyclone type can exist, and the sizes can range from a relatively small 1.21.5 meters tall (about 4-5 feet) to around 9 meters (30 feet)—which is about as tall as a three-story building.

Removed Components from Cyclone Separators:

Dust
Particles: Abrasive, Corrosive, Adhesive, Explosive

Diagram:

Process Description:

Working Principle:
Cyclone is a centrifugal separator in which particles, due to their mass, are pushed to their outer edges as a result of centrifugal force. Incoming Air is automatically forced to adopt a fast revolving spiral movement – the so called double vertex. This double spiral movement consists of an outer stream, which flows downwards in spiral and inner stream, which flows upwards in spiral. At the interchange between both streams, air passes from one stream to another. The particles which are present in the air re forced to the outer edges and leave the separator via collection device fitted to the bottom of the separator.

Air speed of the cyclone lies between 10 to 20 m/s, and the most common speed is 16 m/s. If there are fluctuations in speeds (with lower speeds), separation yield falls quite drastically.

Most cyclones are built to control and remove particulate matter that is larger than 10 micrometers in diameter. However, there do exist high-efficiency cyclones that are designed to be effective on particles as small as 2.5 micrometers. As well, these separators are not effective on extremely large particulate matter. For particulates around 200 micrometers in size, gravity settling chambers or momentum separators are a better option.
Out of all of the particulate-control devices, cyclone separators are among the least expensive. They are often used as a pre-treatment before the flue gas enters more effective pollution control devices. Therefore, cyclone separators can be seen as "rough separators" before the flue gas reaches the ne filtration stages.

Effectiveness:

Cyclone separators are generally able to remove somewhere between 50-99% of all particulate matter in the flue gas. How well the cyclone separators are actually able to remove this matter depends largely on particle size. If there is a large amount of lighter particulate matter, less of these particles are able to be separated out. Because of this, cyclone separators work best on flue gases that contain large amounts of big particulate matter.
There are several advantages and disadvantages of using cyclone separators. First, cyclone separators are beneficial because they are not expensive to install or maintain, and they have no moving parts. This keeps maintenance and operating costs low. Second, the removed particulate matter is collected when dry, which makes it easier to dispose of. Finally, these units take up very little space. Although effective, there are also disadvantages in using cyclone separators. Mainly because the standard models are not able to collect particulate matter that is smaller than 10 micrometers effectively and the machines are unable to handle sticky or tacky materials well.

Variants:

“High throughput” cyclones have a diameter greater than 1.5 m and are suitable for separating particles that are 20m or larger.
“High efficiency” cyclones (pencil cyclones) have a diameter which lies between 0.4 and 1.5m and can be used to separate particles that are 10m or larger.
Cyclones with diameter between 0.005 and 0.3 m are no longer used independently, but are constructed into multi-cyclones. In this case the inflow of gas does not take place tangential as in regular cyclones, but axially, after which the gas is made to spiral via splitter blades. A multi-cyclone requires gas to be well-distributed across the smaller cyclones. If there is insufficient distribution, this may lead to gas back-flow and blockages.

Empirical models for Cyclone Separator Efficiency:

Iozia and Leith Model:

Iozia and Leith logistic Model is a modified version of Barth (1956) model which is developed based on force balance. The model assumes that a particle carried by the vortex endures the influence of two forces: a centrifugal force Z, and flow resistance, W.

The collection efficiency _i of particle diameter d_pi can be calculated by

Li and Wang Model:

The Li and Wang model include particle bounce or re-entrainment and turbulent diffusion at the cyclone wall. A two-dimensional analytical expression of particle distribution in the cyclone is obtained. Li and Wang model was developed based on the following assumptions:

The radial particle velocity and the radial concentration profile are not constant, for uncollected particles within the cyclones.
Boundary conditions with the consideration of turbulent diffusion coefficient and particle bounce re-entrainment on the cyclone wall are:

Koch and Licht Model:

Koch and Licht collection theory recognized the inherently turbulent nature of cyclones and the distribution of gas residence times within the cyclone.

Koch and Licht describe particle motion in the entry and collection regions with the additional following assumptions:

The tangential velocity of a particle is equal to the tangential velocity of the gas flow, i.e. there is no slip in the tangential direction between the particle and the gas.
The tangential velocity is related to the radius of cyclone by uRⁿ =constant.

Lapple Model:

Lapple model was developed based on force balance without considering the flow resistance. Lapple assumed that a particle entering the cyclone is evenly distributed across the inlet opening. The particle that travels from inlet half-width to the wall in the cyclone is collected with 50% efficiency. The semi-empirical relationship developed by Lapple to calculate a 50% cut diameter, d_pc , is

Applications:

Chemical and Petrochemical Processes
Industrial, Metallurgical and Power Generation
Food & Pharmaceutical
Cement Industry

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Methodology:

There are two different Phases as given below:

Continuous Phase
Discrete Phase

Continuous Phase:

It consists of fluid flowing within the fluid volume

Discrete Phase:

It consists of smaller particles interacting with Continuous Phase.
It can also exchange momentum, mass and energy with Fluid Phase or Continuous Phase.

To carry out this analysis,

Simulation will be done using DPM (Discrete Phase Modeling).

Discrete Phase Modeling:

It is employed when there are solid Particles in Gas, or Liquid or Lquid Droplets in Gas , or Bubbles in Liquid.

There are two ways to carry out DPM

Un-coupled Flow
Coupled Flow

Uncoupled Flow:

In this type of flow, Discrete Phase will not have any interaction with Continuous Phase.

Coupled Flow:

It will influence the flow of Continuous Phase.

Since, the size of the particles injected in to Cyclone Separator is very small, the usage of both type of flow should not matter much.

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Analysis:

In this project, we will perform an analysis on a given Cyclone model in two different manners.

By varying particle diameters
By varying particle velocities

As per condition, we will discuss theses analysis in two different parts as given below:

Part-1

For varying particle diameters, we will see the cases as given below:

CYCLONE_A1
CYCLONE_A2
CYCLONE_A3
CYCLONE_A4
CYCLONE_A5

Part-2

For varying particle velocities, we will see the cases as given below:

CYCLONE_B1
CYCLONE_B2
CYCLONE_B3
CYCLONE_B4
CYCLONE_B5

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Procedure:

Geometry:

Import the geometry in fluent SpaceClaim, named as “ Cyclone Separator.stp”
Extract the fluid volume within the geometry by selecting the inner edges at inlet and outlets.
Hide the Geometry and suppress for physics.
Save the fluid volume for further analysis.

Creation of fluid volume and geometry of Cyclone Separator as given below:

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Meshing:

Here the geometry of Cyclone Separator is simple and so we can create hexahedron elements for the fluid volume.
But with other methods like multizone and sweep, it will become so time taking process.
So, we can create good mesh with help of “Cut cell” method available in assembly option in fluent, for generation of structural mesh.
Because structural Mesh gives the best results.

Mesh settings, statistics and cell arrangements are as given below:

We can see the arrangement of cell is very nice and structured.
From above image, we can see that Maximum size of an element is about 7 mm and cell count is 64238.
We can see the “CutCell” method option available under the Assembly Meshing.

Also we have to create Named selections for different kind of behavior at inlet and outlets.

Named selections are as per given below:

Inlet
Outlet_Top
Outlet_bottom ( or Dustbin)
Wall

As we can see Inlet, Outlet_Top, Outlet_Bottom and rest of that is named as Wall.
Here we have given two Outlets purposely.
Outlet_Top is used for light gas and Outlet_bottom is used for collecting heavy particles, which drops due to gravity at the bottom.

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Case Setup:

After completing Meshing, we further go to the Setup in fluent.
Here we will see the case setup for both Part_1 and Part_2 cases.

General Settings:

Solver Type: Pressure Based

Time: Steady

Gravity: -9.81 m/s² (in –Y direction)

Viscous Model: > Model: K-Epsilon

> K-Epsilon Model: RNG

> RNG Option: Swirl Dominated Flow

> Near Wall Treatment: Standard Wall Functions

Here RNG is the slight modification of Standard K-Epsilon model.
This enhances the accuracy of the swirling flows.

DPM Settings:

Here we will see the setting for both Part_1 and Part_2 cases as given below:

As per above image, enable the “Interaction with Continuous Phase”. This will enable the Coupled Flow.
Also enable “Update DPM Sources Every Flow Iteration”. Enabling this option, gives the chance to calculate the Particle Source Terms at every Iteration. (For Unsteady Simulation, it is recommended, and given by-default.)
Set “DPM Iteration Interval = 10”. This option allows us to control the frequency at which particles attract.
Here “Tracking Parameters = 1500000”. It is maximum number of Time Steps, to compute a single trajectory of Particle. In case, the fluent exceeds the maximum number of Time Steps, it will automatically cancel the report of Trajectory. For Steady case, Time Steps number = 50,000 given by default. But for calculation of all possible particles, we have set it to 1500000.
“Step Length Factor = 5”. This is used to control the size of Time Step. Larger the Factor, smaller the Time Step will be.
Here, we have not used “Specify Length Scale”, which is also used for controlling the Time Step size, by dividing Length Scale with Velocity of Discrete Particle and Velocity with Velocity of Continuous Phase.

Particle Injection:

Particle injections setting for Part_1 and Part_2 cases are as given below:

For injection of particle in Cyclone Separator, select “Injection” option shown in above image

Here in Injection, select “Create”.

From above image, give appropriate “Injection name” as per different cases.

Common settings for all cases are as given below:

Injection Type: Surface

Release From Surface: Inlet

Particle Type: Inert

Material: Anthracite

Flow Rate: 1e^-20 Kg/s

Other settings for variables for cases of Part_1 & Part_2 are as given below:

As per above table, Diameter of Particle and X-Velocity will be different for all cases.
In the Cases of Part_1, X-Velocity = 3 m/s will be same for all cases and Diameter of Particle will be different.
In the Cases Part_2, Diameter of the Particle = 5 e^-6 m will be same for all cases and the X-Velocity will be different.
In all cases of Part_1 & Part_2, Velocity of the Particle and the Velocity of the Flow will be same.

Boundary Condition:

Boundary Condition for analysis can be set as given below:

As we can see in above image, that value of velocity and DPM Type has been set according to type of boundary.

Similarly, we can set all the parameters for different boundaries of Cyclone Separator as given below:

Inlet: > Type: Velocity-Inlet > Velocity Magnitude: > 3 m/s (For Part_1 Cases)

> 1 to 5 m/s (For Part_2 Cases Respectively)

> DPM: Reflect

Outlet_Top: > Type: Pressure-outlet

> Gauge Pressure: 0 Pa

> DPM: Escape

Outlet_Bottom: > Type: Pressure-outlet

> Gauge Pressure: 0 Pa

> DPM: trap

Wall: > Type: Wall

> Wall motion: Stationary wall, Shear Condition: No slip Condition

> DPM: Reflect

Here in above all boundary conditions, we have given different DPM conditions like Reflect, Escape and Trap.

Reflect: It is the Particle Rebound off the boundary in question with a change in its momentum as defined by the coefficient of restitution.
Escape: The particle is reported as having “escaped”, when it encounters the boundary in question. Trajectories calculated are terminated.
Trap: The Trajectory calculated is terminated and the fate of the particle is recorded as “trapped”. In the case of evaporating droplet, their entire mass instantaneously passes into the vapor phase and enters the Cell adjacent to the boundary. IN the case of combusting particle, the remaining volatile mass is passed into the vapor phase.

Solution Methods:

Apart from all default settings, we have changed some of the settings as suggested in above image, for this type of analysis.
Here, we have set Momentum of “Turbulent Kinetic Energy” & “Turbulent Dissipation Rate” to Second Order Upwind scheme.
For this type of analysis, it can give us more accurate results.

Solution Initialization:

Here, as per above image, we have set the “Standard initialization”. Also computing option has been set to “Compute From = Inlet”.
If we have Inlets and Outlets, than we can go for Standard Initialization, and it is best suited for this type of Analysis.

Run Calculation:

Give Number of Iteration = 1000 and Time Scale Factor = 1
Select Calculate.

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Results:

Now we will see the Results of all cases of Part_1 and Part_2 respectively.

Here we will see the Results of Part_1 and Part_2 and calculate the Separation Efficiency and Pressure Drop for each case.

Separation efficiency:

It is defined as the fraction of particles of a given size collected in the cyclone, compared to those of that size going into the cyclone. Experience shows that the separation efficiency of cyclone separator increases with increasing particle mean diameter and density; increasing gas tangential velocity; decreasing cyclone diameter; increasing cyclone length; extraction of gas along with solids through the cyclone legs.

In this case, depending upon the particle history data - Separation Efficiency is defined as the ratio of concentration that has been removed from the feed stream to the initial concentration in the feed stream. For this case ratio of the number of trapped particles to the total number of particles tracked.

Pressure Drop:

Pressure drop across the cyclone is of much importance in a cyclone separator. The pressure drop significantly affects the performance parameters of a cyclone. The total pressure drop in a cyclone will be due to the entry and exit losses, and friction and kinetic energy losses in the cyclone. Normally the most significant pressure drop occurs in the body due to swirl and energy dissipation.

Pressure drop is defined as the difference in total pressure between two points of a fluid carrying network.

Pressure drop = Total inlet pressure - Total Outlet Pressure

As the “escape” DPM condition is given to the outlet-top in this case, so outlet-top is considered in pressure drop calculation.

Results of Part_1:

CYCLONE_A1:

Residuals:

Particle Resident Time:

Particle Tracking:

Separation Efficiency in % = (52 / 98) * 100

Separation Efficiency = 53.06 %

CYCLONE_A2:

Residuals:

Particle Resident Time:

Particle Tracking:

Separation Efficiency in % = (63 / 98) * 100

Separation Efficiency = 64.28 %

CYCLONE_A3:

Residuals:

Particle Resident Time:

Particle Tracking:

Separation Efficiency in % = (75 / 98) * 100

Separation Efficiency = 76.53 %

CYCLONE_A4:

Residuals:

Particle Resident Time:

Particle Tracking:

Separation Efficiency in % = (87 / 98) * 100

Separation Efficiency = 88.77 %

CYCLONE_A5:

Residuals:

Particle Resident Time:

Particle Tracking:

Separation Efficiency in % = (98 / 98) * 100

Separation Efficiency = 100 %

Pressure Drop:

For Pressure Drop, plotting of the Pressure curves for Inlet and Outlet_Top are as given below:

Inlet:

Outlet_Top:

Total Pressure:

Now,

Pressure drop = Total inlet pressure - Total Outlet Pressure

= 33.93 – 4.099

Pressure drop =29.83 Pa

NOTE: The fluid velocity and particle velocity is 3m/sec for all particle sizes varied in Part_1;

therefore the pressure drop remains constant for all cases of Part_1.

Pressure & Velocity contours for Part_1:

Pressure Contours:

Velocity Contours:

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Results of Part_2:

CYCLONE_B1:

Residuals:

Particle Resident Time:

Particle Tracking:

Separation Efficiency in % = (7 / 98) * 100

Separation Efficiency = 7.14 %

Pressure Drop:

Inlet:

Outlet_Top

Total Pressure:

Pressure drop = Total inlet pressure - Total Outlet Pressure

= 3.15 – 0.36

Pressure drop =2.79 Pa

Pressure Contour:

Velocity Contour:

CYCLONE_B2:

Residuals:

Particle Resident Time:

Particle Tracking:

Separation Efficiency in % = (52 / 98) * 100

Separation Efficiency = 53.06 %

Pressure Drop:

Inlet:

Outlet_Top

Total Pressure:

Pressure drop = Total inlet pressure - Total Outlet Pressure

= 14.31 – 1.71

Pressure drop =12.6 Pa

Pressure Contour:

Velocity Contour:

CYCLONE_B3:

Residuals:

Particle Resident Time:

Particle Tracking:

Separation Efficiency in % = (98 / 98) * 100

Separation Efficiency = 100 %

Pressure Drop:

Inlet:

Outlet_Top

Total Pressure:

Pressure drop = Total inlet pressure - Total Outlet Pressure

= 33.93 – 4.09

Pressure drop =29.83 Pa

Pressure Contour:

Velocity Contour:

CYCLONE_B4:

Residuals

Particle Resident Time:

Particle Tracking:

Separation Efficiency in % = (98 / 98) * 100

Separation Efficiency = 100 %

Pressure Drop:

Inlet:

Outlet_Top

Total Pressure:

Pressure drop = Total inlet pressure - Total Outlet Pressure

= 62.057 – 7.5364

Pressure drop =54.52 Pa

Pressure Contour:

Velocity Contour:

CYCLONE_B5:

Residuals

Particle Resident Time:

Particle Tracking:

Separation Efficiency in % = (98 / 98) * 100

Separation Efficiency = 100 %

Pressure Drop:

Inlet:

Outlet_Top

Total Pressure:

Pressure drop = Total inlet pressure - Total Outlet Pressure

= 98.93 – 12.04

Pressure drop =86.89 Pa

Pressure Contour:

Velocity Contour:

Cyclone efficiency generally increases with the increase in inlet velocity. The efficiency of a cyclone separator is related to the pressure drop across the separator.

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Vertex Core Region:

Vertex Core Regions for Anthracite Particles at different time are as given below:

> Absolute Helicity:

> Swirling Strength:

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COMPARISION:

Part_1:

Part_2:

We can see from above tables that in Part_1 cases, efficiency of separation increases with increasing Particle Diameter and in Part_2 cases, with increment of Velocity.
Also we can observe that, in Part_1 cases, separation efficiency increases in gradual manner with increases in Particle Diameter.
But in Part_2 cases, separation efficiency increases rapidly with increases in velocity. It is because the Pressure Drop has more impact in cyclone separator efficiency.
In Part_1 cases, Particle Resident Time decreases with increases in Particle Diameter.
In Part_2 cases, Particle Resident Time decreases with increases in Particle Velocity.
We can see from the Pressure contours in all cases that Velocity is high at the Inlet, because the Particles are being injected forcefully by the Inlet.
Also Pressure is high at Inlet and at the Outer surface of the and low at the axial portion, because, when Particles travels in a swirl motion, they are being imparted on the outer surface of the cyclone. So most of the Particles are thrown from axial to radial direction and due to that pressure at the outer surface will always be high.

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Conclusion:

From the observations of Part_1 & Part_2 cases, we can conclude that Separation efficiency of Cyclone Separator depends on both Diameter of Particles and also on the Velocity of the Particles.
Also we can conclude that in cases of Part_2, there are more efficient results. So the Velocity is more effective variable for higher efficiency.
Efficiency of a Cyclone Separator has direct effect on the Pressure Drop.
Higher efficiency Cyclones has highest Pressure Drops.
Higher the Velocity, higher the Pressure Drop and highest the Efficiency.
Also, with increases in Diameter of Particle and Velocity of Particle, Particle Resident Time decreases.
So, when less Resident Time taken by the Particles, efficiency of the Cyclone Separator can be high.

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References:

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NOTE: Links for the video animations for Part_1 cases as A1,A2,A3,A4 & A5 as well as for Part_2 cases as B1, B2, B3, B4 & B5 are given as below:

Part_1

A1:https://drive.google.com/file/d/1xvKe98OMgK-cyMR4YjECKT8hpTH3oFXz/view?usp=sharing

A2:https://drive.google.com/file/d/1w3piJFhYnliOiie2xBhzXLiJmp665WDL/view?usp=sharing

A3:https://drive.google.com/file/d/1XVx3TSMYUs2jDB1bu2FTzkW0O8shRsPR/view?usp=sharing

A4:https://drive.google.com/file/d/1aVzWzSknw1_wzKhShoKekIhikCcojgOD/view?usp=sharing

A5:https://drive.google.com/file/d/1ydG_AMuNa1Q_B8ArCgLg-McOhrbCxzzC/view?usp=sharing

Part_2

B1:https://drive.google.com/file/d/1Z4RuSgll0qf7pbzl7RkAh7SrEU-PYPJ4/view?usp=sharing

B2:https://drive.google.com/file/d/1REV6RH53Lbd9-sar-35LyW8kEMPvU0HE/view?usp=sharing

B3:https://drive.google.com/file/d/1NG6qpfKNXX1T9gnQtN6wlveIjlEaGasv/view?usp=sharing

B4:https://drive.google.com/file/d/1XHIGDPkjgeD5rAkeCMmcXZxG4PvA1ULO/view?usp=sharing

B5:https://drive.google.com/file/d/1G7CqrhV8eEiKiSabjgag81ckO3D4pgEY/view?usp=sharing

Also link for the Report in Ducument and Pdf version given as below

DOC:https://drive.google.com/file/d/1841fGkbulLxI30VAXFTolZ0QZqHlD8xB/view?usp=sharing

PDF:https://drive.google.com/file/d/1X7vrjnlGsuLwSgk_DtjU6ne5ybp24oLI/view?usp=sharing

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Thanks & Regards,

Dharmesh Joshi

Cyclone Separator Challenge

Ship work like this
in your own course.

Talk to a career counsellor

Ship work like thisin your own course.

Talk to a career counsellor

Ship work like this
in your own course.