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International Journal of the Physical Sciences Vol. 5 (6), pp. 804-813, June, 2010
Available online at http://www.academicjournals.org/IJPS
ISSN 1992 - 1950 ©2010 Academic Journals
Full Length Research Paper
The effects of vortex finder on the pressure drop in
cyclone separators
Ferit Ficici*, Vedat Ari and Murat Kapsiz
Technical Education Faculty, Sakarya University, Sakarya, Turkey.
Accepted 25 May, 2010
In this study, three cylinder-shaped vortex finders with diameters of 80, 120 and 160 mm were designed
and manufactured to find out the pressure drop of the cyclones by experimentally investigating the
effects of gas inlet velocity, the vortex finder diameter and length on the cyclone performance at
different gas concentration. As a result of this experimental analysis, a critical diameter of vortex finder
is obtained as 120 mm. Furthermore, analyzing the experimental findings with a statistical regression
method indicated that there was a linear relationship between length of vortex finder and pressure loss.
Then, according to the analysis results, relevance values were obtained as 98.87, 98.37 and 97.59% for
these vortex finders (with diameters of 80, 120 and 160 mm), respectively.
Key words: Cyclone, vortex finder, pressure drop.
INTRODUCTION
Cyclones are devices that employ a centrifugal force
generated by a spinning gas stream to separate particles
from the carrier gas (Gimbun et al., 2005). Cyclone
separators operate under the action of centrifugal forces.
Fluid mixture enters the cyclone and makes a swirl
motion and, due to centrifugal forces, the dense phase of
the mixture gains a relative motion in the radial direction
and is separated from main flow (Avci and Karagoz,
2003). In this design, particle-laden gas enters the
cyclone at the top of the cylinder and makes several
revolutions due to the shape of the entry forming a vortex
with a high tangential velocity which accelerates particles
outward to the wall for collection. Below the bottom of the
gas exit tube, the spinning gas gradually migrates inward,
to a “central core” axially along the cylinder centerline,
and from there up, finally out exit tube (Zhu and Lee,
1999). Their simple design, low capital cost and nearly
maintenance-free operation make them ideal for use as
pre-cleaners for more expensive final control devices
such as baghouses or electrostatic precipitators.
Cyclones are particularly well suited for high temperature
and pressure conditions because of their rugged design
and flexible components materials. Cyclone collection
efficiencies can reach 99 % for particles bigger than 5 µm,
*Corresponding author. E-mail: fficici@sakarya.edu.tr.
and can be operated very high dust loading. Cyclones
are used for the removal of large particles for both air
pollution control and process use (Silva et al.,2003).
Application in extreme condition includes the removing of
coal dust in power plant, and the use as a spray dryer or
gasification reactor (Gimbun, 2005).
Engineers are generally interested in two parameters in
order to carry out an assessment of the design and
performance of a cyclone. These parameters are the
collection efficiency of particle and pressure drop through
the cyclone (Dirgo and Leith, 1985). An accurate predict-
tion of cyclone pressure drop is very important because it
relates directly to operating costs. Higher inlet velocities
give higher collection efficiencies for a given cyclone, but
this also increases the pressure drop across the cyclone.
Therefore, a trade off must be made between higher
collection efficiency and low pressure drop across the
cyclone (Griffiths and Boysan, 1996).
The vortex finder size is an especially important
dimension, which significantly affects the cyclone
performance as its size plays a critical role in defining the
flow field inside the cyclone, including the pattern of the
outer and inner spiral flows. The vortex finder affected the
collection efficiency and pressure drop of cyclones, and
proposed an energy-effective cyclone design (Lim et al.,
2003).
The purpose of this study is to help in understanding of
the pressure drop of cyclones by experimentally exploring
Ficici et al. 805
Figure 1. Reverse flow cyclone.
Table 1. Dimensions of the Tests Cyclone.
Sizes (m)
Dc 0.340 h1 0.272
Dw 0.126 h2 0.374
Dp 0.068 h3 0.05
Hc 0.647 be 0.075
ht 0.0961 hi 0.550
the effects of gas inlet velocity, the vortex finder diameter
and length, at different gas concentration, on the cyclone
performance. The pressure drop of cyclones with 3
different vortex finders diameters have been evaluated
and compared. This study focused on the effects of the
vortex finder diameter on the pressure drop as little work
has been performed on cyclones in relation to this
dimension.
EXPERIMENT
Cyclone geometry
There are a number of different forms of cyclone but the reverse
flow cyclone represented in Figure 1 is the most co mmon design
used in the industry. The cyclone consists of four main parts: the
inlet, the separation chamber, the dust chamber and the vortex
finder. Tangential inlets are preferred for the separation of solid
particles from gases (Atmeyer et al., 2004). Cyclone dimension
used in this simulation are as shown in Table 1. Cyclone tests were
performed on the system as shown in Figure 2.
Definition and composition of the pressure drop
Generally, the pressure drop over a cyclone is the difference of
static pressure between the inlet and outlet, which can be written
as:
si so
P P P
∆ = −
The static pressure at the inlet cross-section is uniformly distributed
because there is no swirling motion. It can be easily measured with
a pressure tapping in the wall. But the static pressure at the outlet
wall is quite different from its cross- sectional average due to the
strong swirling flow. The dynamic pressure stored in the swirling
motion can be significant. The determination of the static pressure
downstream of a cyclone, hence the pressure drop, becomes more
complicated and difficult (Chen and Shi, 2006).
The total pressure drop consists of four partial pressure drops
(Equation 1) pressure drop due to gas expansion at the separators
entrance; (Equation 2) pressure drop due to wall friction within the
separator; (Equation 3) pressure drop due to swirling motion of the
gas (Equation 4); pressure drop due to gas flow through the outlet
pipe (Zhao,2004).
806 Int. J. Phys. Sci.
Figure 2. Schematic diagram of experimental set-up.
Pressure drop due to gas expansion at the separator entrance
Pressure drop due to gas expansion at the separator inlet was
determined as follows:
1
( )
2
in in g in
P v
ξ ρ
∆ = (1)
This pressure drop was calculated for the case of uniform flow from
the right pipe to the limited space, and was expressed as:
1
( )
Rw
ev
w e re
v v dr
R r
θ θ
=−
2
1( )
in
w e
ab
R r H
ξ
= − − (2)
Pressure drop due to wall friction within the separator
Pressure drop due to wall friction within the separator can be
described under static equilibrium in the cyclone separators:
2 2
1
1
( ) ( )
4eev
fr
P D d c DL
θ
π τ π
∆ − = (3)
1
c
is a swirling flow correction factor related to the uniform flow at
the wall in the cyclone separator. According to Stepherd and
Lapple’s method:
1
D
c
a
π
= (4)
ev
θ
τ
is the mean shear stress of the gas in the external vortex, and
can be calculated in terms of Fanning’s equation as:
1
( ).
2
g
ev ev
f v DL
θ θ
τ ρ π
= (5)
where
0.0055
f
=
.
w
v
θ
is the mean tangential velocity in the external vortex, and can
be obtained from:
1
( )
Rw
ev
w e re
v v dr
R r
θ θ
=−
(6)
Combining the above equations gives:
2
2
2 2
( / )( ) 1 1
( )
1/4 ( ) ( ) 2
Rw
g in
fr
e w e in re
D a DL f
P v dr v
D d R r v
θ
π π ρ
π
∆ = − − (7)
Pressure drop due to swirling motion of the gas
From the Navier-Stokes equation in cylindrical coordinates, the
relationship between pressure and 3D velocity can be simplified by
neglecting the axial effects:
2
g
v
dp
dr r
θ
ρ
= (8)
According to Mothes and Loffler (1988) the circumferential flow
pattern or velocity profile including the wall roughness is expressed
as follows:
( / ) 1 (1 / )
w
w w
v
vr R P r R
θ
θ
=+ − (9)
1 1
( . )
4 2
.
d w
w
d
vv
v h v
h
θ
θ
ξ
ξ
∗
∗
∗
= + −
(10)
2
0.204( / ) 0.889
w
wd
w
R
v v ab b R
θ
π
∗
=− + (11)
2
d
w
Q
v
R
π
= (12)
2
2 arccos( / 1)
2
w
w w
b R
a h
h
R R
π
π
∗
− −
= + (13)
( )
sin
w
d
v
Pv
θ
ζ
ζ
ε
= + (14)
( )
in
Q ab v
=
(15)
Where
0.0065 0.0075
ζ
= −
Although the expression for
v
θ
looks complicated, the result
agrees very well with the typical velocity profile based on the power-
law correlation of Alexander (1949). The advantage of this
expression is that it presents a quantitative value of the tangential
velocity at the edge of the core,
w
v
θ
∗
, which has sometimes been
assumed equal to the inlet velocity.
Combining and transforming the above equations gives:
2 2
2
2 2
2( / ) ( / ) 1
( )
( / ) (1 / ) 2
Rw
w
wd
g in
Pvf
w r w
re
v v ab R
dr v
r r R P P R
θ
πρ
∆ = + −
(16)
Pressure drop due to gas flow through the outlet pipe
This pressure drop includes the local pressure drop and the friction
Ficici et al. 807
pressure drop within outlet pipe.
out
ol of
p p p
∆ = ∆ + ∆
(17)
The local pressure drop was handled as gas flow contraction loss
from the cyclone body to the outlet pipe:
2 2 2
2
1 1
( ) 1 ( ) ( )
2 2
e
g in
ol
e
r
ab
v
r Rw
ξ ρ
π
= − (18)
Because of the strong swirling flow in the outlet pipe, this pressure
drop was calculated in an analogous way to the pressure drop due
to wall frictions within the separator:
2
2
1
( ) . ( )
4
e e
iv
ol
p d c d s s
θ
π τ π
′
∆ = + ∆
(19)
'
2
e
e
d
c
d
π
= (20)
2
1
( )
2
g
iv iv
f v
θ θ
τ ρ
= (21)
Where
iv
θ
τ
is the mean shear stress of gas in the internal vortex,
and
iv
v
θ
is the mean tangential velocity in the internal vortex, and
can be obtained by assuming it to be equal to the tangential velocity
at
e
r r
=
:
( / )(1 Pr / )
w
iv
e w e w
v
v
r R P R
θ
θ
=+ − (22)
Combining and transforming the above equations yields:
2
2
2
/
( )
1/4 ( / )(1 Pr / )
wd
of
e e w e w w
v v
S S f ab
d r R P R R
θ
π
ξπ π
+∆
=+ − (23)
Total pressure drop
Su mming up, the equation for total pressure drop can be
expressed as:
in out
fr vf
p p p p p
∆ = ∆ + ∆ + ∆ + ∆
(24)
The pressure drop across a cyclone is co mmonly expressed as the
number of gas inlet velocity heads
ξ
, named the pressure drop
coefficient (PDC), which is just a function of the cyclone geometrical
dimensions. It is accordingly defined as:
2
1/ 2 g
in
p
v
ξρ
∆
= (25)
808 Int. J. Phys. Sci.
Figure 3. Cyclone vortex finder adjusting mechanism
Test procedure
In the experiment (Figure 2), chimney gas of 1100°C is produced
with a diesel oil burner (1). Cyclone inlet flow is measured with a
pitot tube. The necessary gas flow is adapted by tuning the cycle
number of the exiting ventilator. Desired amount of far is supplied
into the system by a loading unit (2) before the entrance of the
testing cyclone (6) and after regime is established, the measures
are recorded. These measuring results recorded as analog signals
are evaluated at Data collecting and Controlling System which is
conducted by a PC. In the experiment, the temperature is
measured at seven different places beginning from the entrance up
to the existence as TG, 1, 2, 3, 4, 5, C with the help of a
thermocouple. Moreover, pressures at the entrance and existence
of cyclones are measured and their difference is calculated as
pressure drop (Ari, 2000).
In the experiments, pressure decrease, change at vent depth of
cyclone vortex finder, cyclone entrance velocity, entrance
temperature and entrance concentration are chosen as varying
parameters and pressure drop are investigating according to these
parameters.
The mechanism designed for investigation of the powder
suppression efficiency and pressure drop according to cyclone
vortex finder insert depth are shown in Figure3. The depth of vortex
finder insert depth, here is denoted as h4 and varies from 10 up to
220 mm in length. Experimental program consists of 3 main groups.
First, cyclone, vortex finder diameter of which is changed, is
adapted to experiment set-up. For finding the pressure drop and
powder suppression efficiencies according to change in depth of
vent of the vortex finder, ventilator cycle is stabilized as the flow
velocity would be 12.44 m/s for each vent length and regime of the
system is waited for. Then, 0.566 kg/ m3 farin is loaded to system.
After loading, the decrease of the system entrance temperature to a
constant value is waited for. After that process, other test data,
cyclone entrance temperature, flow measure temperature, cyclone
temperature of conic section, cyclone temperature of cylindrical
section, storing temperature of farin, cyclone entrance and existing
temperatures are recorded by taking the correct values from Control
Unit. Stopping the test, farin, which is and preheated raw material of
cement (limestone kalker+clay) and taken from cyclone powder
reservoir, is carefully collected and weighed out.
At second group of tests, cyclone characteristics for changing
velocities are measured which is increased from 9.5 m/s up to
10.18 m/s. Here, the powder concentration is fixed.
At third and final group of tests, tests are repeated for increasing
behavior of particle concentration.
At each experiments with particles and without particles,
measured values are recorded (Ficici, 2006).
RESULTS AND DISCUSSION
Dependencies at pressure drop according to length of
vortex finder, inlet velocity and concentration for three
different types of vortex finders with different vortex finder
diameters are investigated at the experiments. These
diameters are taken as 80,120 and 160 mm.
Effects of length of vortex finder
The cyclone pressure drops for the different vortex finder
are compared at different length of vortex finder in
Figure4 and Fig5. Figure 5 shows that pressure drop
increases as vortex finder length increases. This situation
is observed for all cyclones. Under these conditions there
is, however, poor separation of coarse particles. The
main reason is that large quantities of coarse particles
bypass the separation process via the short circuit flow
under the top cover and report to the overflow. Extension
of the vortex finder, however, shortens the natural vortex
in the cyclone body and reduces the opportunity of the
fine particles to separate from the vortex. This has been
confirmed for cyclones (Fuping et al., 2006; Martinez et
al., 2008).
In these experiments, pressure drop measured betw-
een entrance and exit points of cyclone are displayed
graphically. According to these results, an increase at
pressure drops is determined depending on the dia-
meters of vortex finder. When we increase the diameter
of vortex finder to 120 mm in the test cyclone with a
diameter of 80 mm, this pressure drop is increased while
a further decrease in diameter to 160 mm causes the
pressure drop to approach to the measured values of the
case with 80 mm diameter. This situation tells us that up
to a critical diameter of vortex finder, pressure drop shows
Ficici et al. 809
y = 7.726x + 11.60
R² = 0.988 y = 7.571x + 0.678
R² = 0.983
y = 6.595x - 3.678
R² = 0.975
0
10
20
30
40
50
60
70
80
10 50 90 96 130 170 210 220
Pressure Drop (Pa)
Length of Vortex Finder (mm)
80 mm
120 mm
160 mm
Figure 4. The effect of length of vortex finder on pressure drop.
Figure 5. Effect of length of vortex finder on pressure drop.
shows a climbing behavior and for further increasing
diameters after that absolute diameter value (120 mm), a
sinking behavior is observed. This finding is verified in
other studies of literature (lim et al., 2003; Cullivan et al.,
2004).
In addition, experimental results were also analyzed
with statistical regression method. As a result of
analyzing the experimental results with such a statistical
method, it was observed that there was a linear
relationship between length of vortex finder and pressure
loss. According to the analysis results, relevance values
were obtained as 98.87, 98.37 and 97.59% for lengths of
vortex finder considered as 80, 120 and 160 mm,
respectively. Table 2 shows the using regression
equations.
Effects of inlet velocity
Measurement of the cyclone pressure drop was carried
out for average inlet velocity ranging from 4.62 to 14.16
m/s by Bohnet (Bohnet, 1995) and from 5.1 to 25 m/s by
Griffiths and Boysan (1996). In this study, measurement
of the cyclone pressure drop was carried out for inlet
velocity ranging from 9.56 to 10.18 m/s. The cyclone
pressure drops for the different vortex finder are compar-
810 Int. J. Phys. Sci.
Table 2. Static analysis of length of vortex finder
Regression R2 F Sigf
0
1
80 mm 0.9887 1184.11 0.00 7.7262 11.607
120 mm 0.9837 1124.90 0.00 7.5714 0.6786
160 mm 0.9759 1555.20 0.00 6.5952 3.6786
y = 16.65x + 19.53
R² = 0.948
y = 16.31x + 36.4
R² = 0.959
y = 16.65x + 56.53
R² = 0.948
0
20
40
60
80
100
120
140
160
180
9.56 9.73 9.81 9.98 10.02 10.18
Pressure Drop (Pa)
Average of Inlet Velocity (m/s)
80 mm
120 mm
160 mm
Figure 6. Pressure drops of the cyclone separator with different vortex finder diameter.
Figure 7. Effect of average inlet velocity on pressure drop.
ed at different inlet velocities in Figures 6 and 7. These
Figures show that the cyclone pressure drop is increased
with the all vortex finder diameter. At a low inlet velocity,
the pressure drop increases slowly, and at a higher inlet
velocity, the pressure drop increases greatly (Gimbun et
al., 2005).
Additionally, in this experiment when the velocity of gas
with particles is increased, pressure drops at each
cyclone with three vortex finder diameters differ from
each other. With this fact, it is observed that the diffe-
rence of this pressure drop is decreasing when diameter
of vortex finder value is changed from 80 to 120 mm. A
Ficici et al. 811
Table 3. Static analysis of inlet velocity
Regression R2 F Sigf
0
1
80 mm 0.9482 74.44 0.01 16.657 56.533
120 mm 0.9593 54.80 0.02 16.314 36.400
160 mm 0.9482 54.80 0.02 16.657 19.533
y = 22.5x + 12
R² = 0.810
y = 15.7x +
59
R² = 0.
983
y = 24.7x + 60.5
R² = 0.975
0
20
40
60
80
100
120
140
160
180
0.23
0.38
0
.
52
0
.
67
Pressure Drop (Pa)
Figure 8. The effect of inlet farin concentration on pressure drop.
Table 4. Static analysis of inlet farin concentration
Regression R
2
F Sigf
0
1
80 mm 0.8106 74.44 0,096 16.657 56.533
120 mm 0.9838 54.80 0,007 16.314 36.400
160 mm 0.975 54.80 0,011 16.657 19.533
further increase up to 160 mm, again these differences of
losses become lower. The increase of entrance velocity
is very much related with cycle number of swirl. Since the
swirl cycle number will be much for smaller diameters of
vortex finder, pressure drop is higher than losses at
greater diameters. The conclusion presented in this study
is consistent with the literature (Fuping and Yanpeng,
2009). In addition, According to the regression analysis
results, relevance values were obtained as 94.82, 95.93
and 94.82 % for length of vortex finder considered as 80,
120 and 160 mm, respectively. Table 3 shows the using
regression equations.
Effects of inlet farin concentration
The cyclone pressure drops for the different vortex finder
are compared at different inlet farin concentration in
Figures 8 and 9. In this study, experiments are carried on
with cyclone concentrations are varied between 0.19
kg/m3–0.55 kg/m3. As the farin concentration is increas-
ed, the pressure drop, as expected, also increases. This
finding has been observed by many researchers (Kim
and Lee, 1990; Saltzman and Hochstrasser, 1983; Dirgo
and Leith, 1985; Dirgo and Leith, 1985; Moore and
Mcfarland, 1993).
Furthermore, Pressure loss is highest at cyclone with
160 mm diameter. The reason is that, number of swirls is
less at this diameter. Thus, higher pressure loss is seen
at 160 mm. Table 4 shows that relevant values were
obtained as 81.06, 98.38, and 97.5% for length of vortex
finder considered as 80, 120 and 160 mm, respectively.
Conclusions
As a result of this experimental research and data from it,
a critical diameter of vortex finder is obtained. This is
812 Int. J. Phys. Sci.
Figure 9. Effect of inlet farin concentration on pressure drop.
determined as 120 mm. A desired result has not been
obtained according to cyclone collection efficiency
despite the fact that further increase in diameter lowered
the pressure drops. That means that pressure drop can
be lowered with increasing diameter, however efficiency
of collection is lost then. In this research, the theoretical
argument of critical vortex finder is experimentally
proved.
ACKNOWLEDGEMENT
The authors would like to thank the Nuh Cement A.S for
financial and technical supports.
NOMENCLATURE
a [m] inlet height
b [m] inlet width
B [m] particle outlet diameter
c [-] swirling flow correction factor
D [m] cyclone body diameter
de [m] gas outlet diameter
h [m] cyclone cylinder height
H [m] cyclone height
L [m] natural length of cyclone
p [Pa] pressure
P [-] parameter of momentum
exchange between gas at the
wall
Q [m3/s] volumetric gas flow rate
r [m] radial dimension
Rw [m] cyclone body radius
re [m] vortex finder radius
S [m] gas outlet duct deep length
S [m] gas outlet duct extend length
Greek symbols
e [rad] the cone slope
g [kg/m3] gas density
t [Pa] shear stress
[m/s] gas velocity
[-] the pressure drop coefficient
[-] the wall friction coefficient
Subscripts
d cyclone body
g gas
e near the exit or vortex finder
fr friction
in cyclone inlet
iv internal vortex
ol outlet local loss
of outlet friction loss
out cyclone outlet
vf vortex flow
tangential coordinate directions
r radial coordinate directions
w near the wall
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