Performance evaluation of industrial large-scale cyclone separator with novel vortex finder

Fu, Shuangcheng; Zhou, Faqi; Sun, Guogang; Yuan, Huixin; Zhu, Jie

doi:10.1016/j.apt.2021.01.033

Cited by 51 publications

(14 citation statements)

References 33 publications

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“…In addition, Hoekstra et al 48 used three turbulence models to simulate the flow pattern inside a cyclone separator and discovered that RSM provided the most accurate results for the strong swirling flow. Since then, RSM and DPM have been widely applied and validated in the numerical studies of different cyclones and working conditions, 5,7,10,15,18,19 which means the numerical approaches in this study are not confined to a specific cyclone separator but are applicable to cyclones of various structures working conditions. 2 can be estimated and are summarized in Table 3.…”

Section: Validation Of the Numericalmentioning

confidence: 99%

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Double-Eccentric Design for the Vortex Finder of a Cyclone Separator

Yao

Huang

Zhou

et al. 2022

Ind. Eng. Chem. Res.

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In the present study, a double-eccentric design for the vortex finder of a cyclone separator was proposed to enhance the cyclone performance. Using the numerical approaches, the flow field inside the cyclone was simulated and the cyclone performance was evaluated. The orthogonal method was adopted to obtain the optimal structure of the double-eccentric vortex finder. The range analysis of the five key geometric factors in the double-eccentric design was also conducted. It was found that cyclone performance is more sensitive to the eccentricity of the vortex finder than the other factors. The best eccentric angle of the inlet of the vortex finder is 270°, which markedly improves the separation efficiency and slightly increases the pressure drop. The simulated flow field depicted that the double-eccentric vortex finder results in the strongest swirling flow in the middle and lower parts of the cyclone compared with the vortex finders of the original, non-eccentric, and single-eccentric designs. The results also reflected that off-centering the vortex finder has the most significant impact on the flow patterns. Moreover, an industrial test was carried out in a circulating fluidized bed boiler for this novel vortex finder. The fly ash of the double-eccentric vortex finder becomes finer and contains less carbon content than that of the original one, which indicates that the double-eccentric vortex finder successfully enhances the separation performance.

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Section: Validation Of the Numericalmentioning

confidence: 99%

“…Some researchers tried to optimize the vortex finder by changing the wall structure. Fu et al 18 adopted the slotted vortex finder to increase the separation efficiency. Pei et al 19 inserted blades at the bottom of the vortex finder, which significantly decrease the pressure drop and slightly increase the separation efficiency.…”

Section: Introductionmentioning

confidence: 99%

Double-Eccentric Design for the Vortex Finder of a Cyclone Separator

Yao

Huang

Zhou

et al. 2022

Ind. Eng. Chem. Res.

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“…However, it is difficult for cyclone separators to separate fine particulate matter with strong penetration and diffusivity. To improve its performance, various optimization investigations of the structures of cyclones have been conducted, such as entrance structure designs, − cylinder-to-cone ratios, dipleg , and vortex finder shapes, − and additional components. , Nevertheless, relying on structural development alone, the separation efficiency is improved at the expense of an increase in energy consumption, or the reduction in energy consumption is accompanied by a sacrifice in efficiency.…”

Section: Introductionmentioning

confidence: 99%

Pilot-Scale Investigation on a Spraying Pretreatment Process Integrated with an Axial Flow Cyclone to Separate Fine Particles with Low Energy Consumption

Wang,

Song,

Liu

et al. 2023

Ind. Eng. Chem. Res.

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This study was designed to explore the synergistic enhancement of the spraying pretreatment section and axial flow cyclone on the separation of particles from gases. First, in the spraying pretreatment section, the effects of the gas flow rate, droplet flow rate, droplet diameter, and gas or droplet temperature on the collection efficiency of the particles and the supersaturation degree were analyzed. Then, the nucleation and growth process of fine insoluble particles were discussed. At last, combined with an axial flow cyclone, the influences of operating parameters on the separation efficiency and energy consumption were presented. Our results show that the spraying pretreatment can capture 80% of particles larger than 5 μm and can maintain a supersaturated environment. Fine particles (PM1.0) will be aggregated to above 6 μm quickly and removed in the axial flow cyclone with a separation efficiency of above 98%. In addition, the energy consumption of the integrated purification process in this study is reduced by 20.65%, on average, compared to that of an electrostatic precipitator. These findings provide new insights into the separation of fine particles in industrial applications.

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“…In an experimental-numerical study, the equipping of a large-scale industrial tangential inlet cyclone with a new vortex finder (including slots in the side walls to improve cyclone performance) has been investigated. According to the results, the pressure drop has decreased to 27.9% compared to the conventional separator and a 5.45% increase in collection efficiency has been reported (Fu et al, 2021). The six geometric dimensions of the cyclone separator were optimized using 10 meta-heuristic algorithms, multi-gene genetic programming (MGGP), experimental design, and computational fluid dynamics.…”

Section: Introductionmentioning

confidence: 99%

A novel idea to increase the performance of a wheat flour cyclone separator: Controlling the reverse flow

Aghaei

Rostampour

Fanaei

et al. 2022

J Food Process Engineering

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In this study, as a novelty, the reverse flow effect on a wheat flour cyclone performance was evaluated. A computational fluid dynamics (CFD) simulation was realized using a Reynolds stress turbulence model. Also, particle-air interactions were modeled applying a discrete phase model. Besides the experimental measurement, the numerical simulation was conducted in a main (without reverse flow) and six various reverse flow levels (I = 0.0385 m 3 s À1 , II = 0.0396 m 3 s À1 , III = 0.0484 m 3 s À1 , IV = 0.0583 m 3 s À1 , V = 0.0704 m 3 s À1 , and VI = 0.0836 m 3 s À1 ) by CFD. The validation between pressure drop in experimental data and numerical results revealed a good agreement with a maximum deviation of 8.2%. Cyclone performance including pressure drop and separation efficiency was assessed in the mentioned reverse flow levels. Moreover, velocity field, centrifugal force, and turbulence parameter were evaluated, comprehensively. It was found that the flour separation efficiency increased with enhancing the reverse flow level to IV = 0.0583 m 3 s À1 , but decreased with a sharp slope in the reverse levels of V = 0.0704 m 3 s À1 and VI = 0.0836 m 3 s À1 . Practical ApplicationsCyclone separators are widely used in various industries such as flour and cement.The various parameters of cyclones in a food processing unit effectively affect cyclone efficiency. Therefore, an innovative method for increasing cyclone performance is presented in this study. Computational fluid dynamics (CFD) is a powerful tool for simulation of the food processing phenomenon. Validation could be guaranteed by the usage of numerical results that are obtained from CFD simulations. The innovative methods can play a key role in decreasing energy usage by reducing the pressure drop and enhancing separation efficiency.

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Performance evaluation of industrial large-scale cyclone separator with novel vortex finder

Cited by 51 publications

References 33 publications

Double-Eccentric Design for the Vortex Finder of a Cyclone Separator

Double-Eccentric Design for the Vortex Finder of a Cyclone Separator

Pilot-Scale Investigation on a Spraying Pretreatment Process Integrated with an Axial Flow Cyclone to Separate Fine Particles with Low Energy Consumption

A novel idea to increase the performance of a wheat flour cyclone separator: Controlling the reverse flow

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