Cyclonic separation

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A cyclone separator
Cyclonic separation is a method of removing particulates from an air, gas or water
stream, without the use of filters, through vortex separation. Rotational effects and
gravity are used to separate mixtures of solids and fluids.
A high speed rotating air!flow is esta"lished within a cylindrical or conical container
called a cyclone. Air flows in a spiral pattern, "eginning at the top wide end! of the
cyclone and ending at the "ottom narrow! end "efore exiting the cyclone in a straight
stream through the center of the cyclone and out the top. #arger denser! particles in the
rotating stream have too much inertia to follow the tight curve of the stream and strike the
outside wall, falling then to the "ottom of the cyclone where they can "e removed. $n a
conical system, as the rotating flow moves towards the narrow end of the cyclone the
rotational radius of the stream is reduced, separating smaller and smaller particles. %he
cyclone geometry, together with flow rate, defines the cut point of the cyclone. %his is the
si&e of particle that will "e removed from the stream with a '() efficiency. *articles
larger than the cut point will "e removed with a greater efficiency, and smaller particles
with a lower efficiency.
Airflow diagram for Aerodyne cyclone in hori&ontal position, an alternate design to
minimi&e a"rasion within the device
Airflow diagram for Aerodyne cyclone in standard vertical position
An alternative cyclone design uses a secondary air flow within the cyclone to keep the
collected particles from striking the walls to protect them from a"rasion. %he primary air
containing the particulate enters from the "ottom of the cyclone and is forced into spiral
rotation "y a stationary spinner. %he secondary air flow enters from the top of the cyclone
and moves downward toward the "ottom, intercepting the particulate from the primary
air. %he secondary air flow also allows the collector to "e mounted hori&ontally "ecause it
pushes the particulate toward the collection area.
#arge scale cyclones are used in sawmills to remove sawdust from extracted air.
+yclones are also used in oil refineries to separate oils and gases, and in the cement
industry as components of kiln preheaters. +yclones are increasingly used in the
household, as the core technology in "agless vacuum cleaners. +yclones are also used in
industrial and professional kitchens for separating the grease from the exhaust air in
extract hoods
,-.
. /maller cyclones are used to separate air"orne particles for analysis.
/ome are small enough to "e worn clipped to clothing and are used to separate respira"le
particles for later analysis.
Analogous devices for separating particles or solids from li0uids are called
hydrocyclones or hydroclones. %hese may "e used to separate solid waste from water in
wastewater and sewage treatment.
Contents
,hide.
- +yclone theory
o -.- /teady state
1 Alternative /teady /tate Analysis
2 Alternate models
3 /ee also
' References
[edit] Cyclone theory
[edit] Steady state
As the cyclone is essentially a two phase particle4fluid system, fluid mechanics and
particle transport e0uations can "e used to descri"e the "ehaviour of a cyclone. %he air in
a cyclone is initially introduced tangentially into the cyclone with an inlet velocity Vin.
Assuming that the particle is spherical, a simple analysis to calculate critical separation
particle si&es can "e esta"lished.
5iven that the fluid velocity is moving in a spiral the gas velocity can "e "roken into two
component velocities: a tangential component, Vt, and a radial velocity component Vr.
Assuming /tokes6 law, the drag force on any particle in this inlet stream is therefore
given "y the following e0uation:
Fd 7 89rp:Vr.
$f one considers an isolated particle circling in the upper cylindrical component of the
cyclone at a rotational radius of r from the cyclone6s central axis, the particle is therefore
su";ected to centrifugal, drag and "uoyant forces. %he centrifugal component is given "y:
%he "uoyant force component is o"tained "y the difference "etween the particle and fluid
densities, <p and <f respectively:
%he force "alance can "e created "y summing the forces together
%his rate is controlled "y the diameter of the particle6s or"it around the central axis of the
cyclone. A particle in the cyclonic flow will move towards either the wall of the cyclone,
or the central axis of the cyclone until the drag, "uoyant and centrifugal forces are
"alanced. Assuming that the system has reached steady state, the particles will assume a
characteristic radius dependent upon the force "alance. =eavier, denser particles will
assume a solid flow at some larger radius than light particles. %he steady state "alance
assumes that for all particles, the forces are e0uated, hence:
Fd > Fc > Fb 7 (
Which expands to:
%his can "e expressed "y rearranging the a"ove in terms of the particle radius. %he
particle radius as a function of cyclonic radius, fluid density and fluid tangential and
rotational velocities can then "e found to "e:
?xperimentally it is found that the velocity component of rotational flow is proportional
to r
1,1.
, therefore:
%his means that the esta"lished feed velocity controls the vortex rate inside the cyclone,
and the velocity at an ar"itrary radius is therefore:
/u"se0uently, given a value for Vt, possi"ly "ased upon the in;ection angle, and a cutoff
radius, a characteristic particle filtering radius can "e estimated, a"ove which particles
will "e removed from the gas stream.
[edit] Alternative Steady State Analysis
Assume we have a particle of radius rp and density <p moving with a parcel of fluid of
viscosity :f and density <f. %he particle and the fluid are moving along a curved tra;ectory
with tangential velocity Vt with a radius of curvature of rc.
$f we view the particle in a frame of reference moving with the fluid, we can descri"e the
"ehavior of the particle "y invoking the imaginary, inertial centrifugal force acting as a
form of gravity directed outward, away from the axis of rotation. %he magnitude of the
centrifugal force will "e give "y
.
where mp is the mass of the particle.
$f we ignore the universal downward force of gravity and viscous drag "etween the
particle and the fluid parallel to the velocity, there are two other forces acting on the
particle 4 radial viscous drag and "uoyancy.
%he viscous drag Fd ! "etween the particle and the fluid resulting from radial movement
of the particle through the fluid is given "y
Fd 7 @ 89rp:fVr
where Vr is the radial drift velocity of the particle through the fluid and the sign reflects
the opposition of the force to the motion.
%he "uoyancy force Fb! exerted on the particle "y the fluid is given "y
where vp is the volume of the particle
$f we assign upward toward the center of rotation! as the positive radial direction >! in
our frame of reference, then Fc will "e pointed in the negative direction, Fb will "e
pointed in the positive direction and the direction of Fd will depend on the direction of vp.
$f we assume the system has reached dynamic e0uili"rium then the sum of the forces is
&ero
Fb > Fd > Fc 7 (.
After applying the appropriate signs and expanding mp and vp explicitly we have
/olving this e0uation for Vr we have
.
Aotice that if the density of the fluid is greater than the density of the particle, the motion
is >!, toward the center of rotation and if the particle is denser than the fluid, the motion
is 4!, away from the center.
?xpressing the motion in terms of angular velocity B we have
/u"stituting into the e0uation a"ove yields
.
$n this analysis, Vr is the drift velocity at which dynamic e0uili"rium is attained 4 the drag
friction generated "y the movement of the particle through the fluid "alances the
centrifugal force of the rotation and the particle has no radial acceleration, traveling at a
constant velocity. $n the extreme case where :f 7 ( a fluid with no viscosity! the
e0uili"rium drift velocity is undefined C the particle can accelerate without ever reaching
e0uili"rium. $n the opposite extreme, :f 7 D, the e0uili"rium drift velocity is (, there is no
outward radial movement and the particle is fro&en in the fluid
$n non4e0uili"rium conditions, the general case e0uation F7ma must "e solved
%he presence of "oth ar and vr makes this a differential e0uation and complicates the
solution. Aote that if the densities of the particle and fluid are e0ual, the solution is ar 7 vr
7 ( and cyclonic separation is not possi"le.
$n a cyclone particle separator, the design o";ective is to control the system geometry and
the operating parameters so that the drift velocity will move the particle out of the fluid
"efore it exits. $n most cases, the steady state solution is used as guidance in designing a
separator, "ut the actual performance must "e evaluated and modified empirically.
[edit] Alternate models
%he a"ove e0uations are relatively simple and provide a "asic approximation to the
"ehaviour of a cyclone separator. %hese e0uations are, however, limited in many regards.
For example, the geometry of the separator is not considered, the particles are assumed to
achieve a steady state and the effect of the vortex inversion at the "ase of the cyclone is
also ignored, all "ehaviours which are unlikely to "e achieved in a cyclone at real
operating conditions.
Eore complex differential e0uation "ased models exist, as many authors have studied the
"ehaviour of cyclone separators
,2.
. Aumerical modelling using computational fluid
dynamics has also "een used extensively in the study of cyclonic "ehaviour.
,3.,'.
Fesigned to handle heavy dust loads, a dust collector system consists of a "lower, dust
filter, a filter4cleaning system, and a dust receptacle or dust removal system. $t is
distinguished from air cleaners which use disposa"le filters to remove dust.
Contents
,hide.
- %ypes of dust collectors
o -.- $nertial separators
-.-.- /ettling cham"er
-.-.1 Gaffle cham"er
-.-.2 +entrifugal collectors
-.-.2.- /ingle4cyclone separators
-.-.2.1 Eultiple4cyclone separators
-.-.2.2 /econdary Air Flow /eparators
o -.1 Fa"ric filters
-.1.- %ypes of "aghouses
-.1.-.- Eechanical shaker
-.1.-.1 Reverse air
-.1.-.2 Reverse ;et
-.1.-.3 +artridge collectors
o -.2 Wet scru""ers
-.2.- %ypes of scru""ers
-.2.-.- #ow4energy scru""ers
-.2.-.1 #ow4 to medium4energy scru""ers
-.2.-.2 Eedium4 to high4energy scru""ers co4current4flow
scru""er
-.2.-.3 =igh4energy scru""ers
o -.3 ?lectrostatic precipitators ?/*!
-.3.- %ypes of precipitators
-.3.-.- *late precipitators
-.3.-.1 %u"ular precipitators
-.3.1 Hnit collectors
1 /electing a dust collector
2 Fan and motor
o 2.- %ypes of fans
2.-.- +entrifugal fans
2.-.1 Axial4flow fans
o 2.1 ?lectric motors
o 2.2 Hses
o 2.3 +onfigurations
o 2.' *arameters involved in specifying dust collectors
2.'.- Filter cleaning methods
3 ?xternal links
[edit] Types of dust collectors
Five principal types of industrial dust collectors are:
$nertial separators
Fa"ric filters
Wet scru""ers
?lectrostatic precipitators
Hnit collectors
[edit] Inertial separators
$nertial separators separate dust from gas streams using a com"ination of forces, such as
centrifugal, gravitational, and inertial. %hese forces move the dust to an area where the
forces exerted "y the gas stream are minimal. %he separated dust is moved "y gravity into
a hopper, where it is temporarily stored.
%he three primary types of inertial separators are:
/ettling cham"ers
Gaffle cham"ers
+entrifugal collectors
Aeither settling cham"ers nor "affle cham"ers are commonly used in the minerals
processing industry. =owever, their principles of operation are often incorporated into the
design of more efficient dust collectors.
[edit] Settling chamber
A settling cham"er consists of a large "ox installed in the ductwork. %he sudden
expansion of si&e at the cham"er reduces the speed of the dust4filled airstream and
heavier particles settle out.
/ettling cham"ers are simple in design and can "e manufactured from almost any
material. =owever, they are seldom used as primary dust collectors "ecause of their large
space re0uirements and low efficiency. A practical use is as precleaners for more efficient
collectors.
Gaffle cham"er diagram.
[edit] Baffle chamber
Gaffle cham"ers use a fixed "affle plate that causes the conveying gas stream to make a
sudden change of direction. #arge4diameter particles do not follow the gas stream "ut
continue into a dead air space and settle. Gaffle cham"ers are used as precleaners
[edit] Centrifugal collectors
Eain article: +yclonic separation
+entrifugal collectors use cyclonic action to separate dust particles from the gas stream.
$n a typical cyclone, the dust gas stream enters at an angle and is spun rapidly. %he
centrifugal force created "y the circular flow throws the dust particles toward the wall of
the cyclone. After striking the wall, these particles fall into a hopper located underneath.
%he most common types of centrifugal, or inertial, collectors in use today are:
[edit] Single-cyclone separators
%hey create a dual vortex to separate coarse from fine dust. %he main vortex spirals
downward and carries most of the coarser dust particles. %he inner vortex, created near
the "ottom of the cyclone, spirals upward and carries finer dust particles.
[edit] Multiple-cyclone separators
Also known as multiclonesI, consist of a num"er of small4diameter cyclones, operating
in parallel and having a common gas inlet and outlet, as shown in the figure.
EulticlonesI operate on the same principle as cyclonesJcreating a main downward
vortex and an ascending inner vortex.
EulticlonesI are more efficient than single cyclones "ecause they are longer and smaller
in diameter. %he longer length provides longer residence time while the smaller diameter
creates greater centrifugal force. %hese two factors result in "etter separation of dust
particulates. %he pressure drop of multicloneI collectors is higher than that of single4
cyclone separators.
Ga"cock K Wilcox is the original manufacturer and trademark holder of EulticloneI
dust collectors and replacement parts formerly offered "y Western *recipitation.
EulticloneI dust collectors are found in all types of power and industrial applications,
including pulp and paper plants, cement plants, steel mills, petroleum coke plants,
metallurgical plants, saw mills and other kinds of facilities that process dust.
[edit] Secondary Air Flow Separators
%his type of cyclone uses a secondary air flow, in;ected into the cyclone to accomplish
several things. %he secondary air flow increases the speed of the cyclonic action making
the separator more efficientL it intercepts the particulate "efore it reaches the interior
walls of the unitL and it forces the separated particulate toward the collection area. %he
secondary air flow protects the separator from particulate a"rasion and allows the
separator to "e installed hori&ontally "ecause gravity is not depended upon to move the
separated particulate downward.
[edit] Fabric filters
+ommonly known as "aghouses, fa"ric collectors use filtration to separate dust
particulates from dusty gases. %hey are one of the most efficient and cost effective types
of dust collectors availa"le and can achieve a collection efficiency of more than MM) for
very fine particulates.
Fust4laden gases enter the "aghouse and pass through fa"ric "ags that act as filters. %he
"ags can "e of woven or felted cotton, synthetic, or glass4fi"er material in either a tu"e or
envelope shape.
%he high efficiency of these collectors is due to the dust cake formed on the surfaces of
the "ags. %he fa"ric primarily provides a surface on which dust particulates collect
through the following four mechanisms:
$nertial collection 4 Fust particles strike the fi"ers placed perpendicular to the gas4
flow direction instead of changing direction with the gas stream.
$nterception 4 *articles that do not cross the fluid streamlines come in contact with
fi"ers "ecause of the fi"er si&e.
Grownian movement 4 /u"micrometre particles are diffused, increasing the
pro"a"ility of contact "etween the particles and collecting surfaces.
?lectrostatic forces 4 %he presence of an electrostatic charge on the particles and
the filter can increase dust capture.
A com"ination of these mechanisms results in formation of the dust cake on the filter,
which eventually increases the resistance to gas flow. %he filter must "e cleaned
periodically.
[edit] Types of baghouses
As classified "y cleaning method, three common types of "aghouses are:
[edit] Mechanical shaker
$n mechanical4shaker "aghouses, tu"ular filter "ags are fastened onto a cell plate at the
"ottom of the "aghouse and suspended from hori&ontal "eams at the top. Firty gas enters
the "ottom of the "aghouse and passes through the filter, and the dust collects on the
inside surface of the "ags.
+leaning a mechanical4shaker "aghouse is accomplished "y shaking the top hori&ontal
"ar from which the "ags are suspended. Ni"ration produced "y a motor4driven shaft and
cam creates waves in the "ags to shake off the dust cake.
/haker "aghouses range in si&e from small, handshaker devices to large,
compartmentali&ed units. %hey can operate intermittently or continuously. $ntermittent
units can "e used when processes operate on a "atch "asis4when a "atch is completed, the
"aghouse can "e cleaned. +ontinuous processes use compartmentali&ed "aghousesL when
one compartment is "eing cleaned, the airflow can "e diverted to other compartments.
$n shaker "aghouses, there must "e no positive pressure inside the "ags during the shake
cycle. *ressures as low as (.(1 in. wg can interfere with cleaning.
%he air to cloth ratio for shaker "aghouses is relatively low, hence the space re0uirements
are 0uite high. =owever, "ecause of the simplicity of design, they are popular in the
minerals processing industry.
[edit] Reverse air
$n reverse4air "aghouses, the "ags are fastened onto a cell plate at the "ottom of the
"aghouse and suspended from an ad;usta"le hanger frame at the top. Firty gas flow
normally enters the "aghouse and passes through the "ag from the inside, and the dust
collects on the inside of the "ags.
Reverse4air "aghouses are compartmentali&ed to allow continuous operation. Gefore a
cleaning cycle "egins, filtration is stopped in the compartment to "e cleaned. Gags are
cleaned "y in;ecting clean air into the dust collector in a reverse direction, which
pressuri&es the compartment. %he pressure makes the "ags collapse partially, causing the
dust cake to crack and fall into the hopper "elow. At the end of the cleaning cycle, reverse
airflow is discontinued, and the compartment is returned to the main stream.
%he flow of the dirty gas helps maintain the shape of the "ag. =owever, to prevent total
collapse and fa"ric chafing during the cleaning cycle, rigid rings are sewn into the "ags at
intervals.
/pace re0uirements for a reverse4air "aghouse are compara"le to those of a shaker
"aghouseL however, maintenance needs are somewhat greater.
[edit] Reverse jet
$n reverse4pulse4;et "aghouses, individual "ags are
supported "y a metal cage, which is fastened onto a cell plate at the top of the "aghouse.
Firty gas enters from the "ottom of the "aghouse and flows from outside to inside the
"ags. %he metal cage prevents collapse of the "ag.
Gags are cleaned "y a short "urst of compressed air in;ected through a common manifold
over a row of "ags. %he compressed air is accelerated "y a venturi no&&le mounted at the
reverse4;et "aghouse top of the "ag. /ince the duration of the compressed4air "urst is
short (.-s!, it acts as a rapidly moving air "u""le, traveling through the entire length of
the "ag and causing the "ag surfaces to flex. %his flexing of the "ags "reaks the dust cake,
and the dislodged dust falls into a storage hopper "elow.
Reverse4pulse4;et dust collectors can "e operated continuously and cleaned without
interruption of flow "ecause the "urst of compressed air is very small compared with the
total volume of dusty air through the collector. Gecause of this continuous4cleaning
feature, reverse4;et dust collectors are usually not compartmentali&ed.
%he short cleaning cycle of reverse4;et collectors reduces recirculation and redeposit of
dust. %hese collectors provide more complete cleaning and reconditioning of "ags than
shaker or reverse4air cleaning methods. Also, the continuous4cleaning feature allows
them to operate at higher air4to4cloth ratios, so the space re0uirements are lower.
%his cleaning system works with the help of digital se0uential timer attached to the fa"ric
filter. this timer indicates the solenoid valve to in;ect the air to the "low pipe.
Fa"ric filters generally have the following parts:
-. +lean plenum
1. Fusty pleanum
2. Gag, cage, ventury assem"ly
3. %u"eplate
'. RANO/+R?W
8. +ompressed air header
P. Glow pipe
Q. =ousing and hopper
[edit] Cartridge collectors
+artridge collectors are another commonly used type of dust collector. Hnlike "aghouse
collectors, in which the filtering media is woven or felt "ags, this type of collector
employs perforated metal cartridges that contain a pleated, nonwoven filtering media.
Fue to its pleated design, the total filtering surface area is greater than in a conventional
"ag of the same diameter, resulting in reduced air to media ratio, pressure drop, and
overall collector si&e.
+artridge collectors are availa"le in single use or continuous duty designs. $n single4use
collectors, the dirty cartridges are changed while the collector is off. $n the continuous
duty design, the cartridges are cleaned "y the conventional pulse4;et cleaning system.
Almost always includes a steel enclosure containing porous filter media that separate fine
dust particles from a flowing stream of dirty air. %he most common filter media used in
collectors are filter "ags and cartridges. Fust particles "uild up on the outside of the
media and form a coating called Rdust cake.R $t is this layer that does the actual ;o" of
filtering fine particles. As the cake "uilds up, the pressure drop across the filter "ag rises.
[edit] Wet scrubbers
Fust collectors that use li0uid are commonly known as wet scru""ers. $n these systems,
the scru""ing li0uid usually water! comes into contact with a gas stream containing dust
particles. %he greater the contact of the gas and li0uid streams, the higher the dust
removal efficiency.
%here are a large variety of wet scru""ersL however, all have one of three "asic
operations:
5as4humidification 4 %he gas4humidification process conditions fine particles to
increase their si&e so they can "e collected more easily.
5as4li0uid contact 4 %his is one of the most important factors affecting collection
efficiency. %he particle and droplet come into contact "y four primary
mechanisms:
o $nertial impaction 4 When water droplets placed in the path of a dust4laden
gas stream, the stream separates and flows around them. Fue to inertia, the
larger dust particles will continue on in a straight path, hit the droplets,
and "ecome encapsulated.
o $nterception 4 Finer particles moving within a gas stream do not hit
droplets directly "ut "rush against them and adhere to them.
o Fiffusion 4 When li0uid droplets are scattered among dust particles, the
particles are deposited on the droplet surfaces "y Grownian movement, or
diffusion. %his is the principal mechanism in the collection of
su"micrometre dust particles.
o +ondensation nucleation 4 $f a gas passing through a scru""er is cooled
"elow the dewpoint, condensation of moisture occurs on the dust particles.
%his increase in particle si&e makes collection easier.
5as4li0uid separation 4 Regardless of the contact mechanism used, as much li0uid
and dust as possi"le must "e removed. Snce contact is made, dust particulates and
water droplets com"ine to form agglomerates. As the agglomerates grow larger,
they settle into a collector.
%he RcleanedR gases are normally passed through a mist eliminator demister pads! to
remove water droplets from the gas stream. %he dirty water from the scru""er system is
either cleaned and discharged or recycled to the scru""er. Fust is removed from the
scru""er in a clarification unit or a drag chain tank. $n "oth systems solid material settles
on the "ottom of the tank. A drag chain system removes the sludge and deposits in into a
dumpster or stockpile.
/ee also *article collection in wet scru""ers.
[edit] Types of scrubbers
/pray4tower scru""er wet scru""ers may "e categori&ed "y pressure drop as follows:
#ow4energy scru""ers (.' to 1.' inches water gauge 4 -13.3 to 81-.M *a!
#ow4 to medium4energy scru""ers 1.' to 8 inches water gauge 4 (.811 to -.3M2
k*a!
Eedium4 to high4energy scru""ers 8 to -' inches water gauge 4 -.3M2 to 2.P2-
k*a!
=igh4energy scru""ers greater than -' inches water gauge 4 greater than 2.P2-
k*a!
Fue to the large num"er of commercial scru""ers availa"le, it is not possi"le to descri"e
each individual type here. =owever, the following sections provide examples of typical
scru""ers in each category.
[edit] Low-energy scruers
$n the simple, gravity4spray4tower scru""er, li0uid droplets formed "y li0uid atomi&ed in
spray no&&les fall through rising exhaust gases. Firty water is drained at the "ottom.
%hese scru""ers operated at pressure drops of - to 1 in. water gauge T to U k*a! and are
approximately P() efficient on -( Vm particles. %heir efficiency is poor "elow -( Vm.
=owever, they are capa"le of treating relatively high dust concentrations without
"ecoming plugged.
[edit] Low- to !ediu!-energy scruers
Wet cyclones use centrifugal force to spin the dust particles similar to a cyclone!, and
throw the particulates upon the collector6s wetted walls. Water introduced from the top to
wet the cyclone walls carries these particles away. %he wetted walls also prevent dust
reentrainment.
*ressure drops for these collectors range from 1 to Q in. water U to 1 k*a!, and the
collection efficiency is good for ' :m particles and a"ove.
[edit] Mediu!- to high-energy scruers co-current-"low scruer
*acked4"ed scru""ers consist of "eds of packing elements, such as coke, "roken rock,
rings, saddles, or other manufactured elements. %he packing "reaks down the li0uid flow
into a high4surface4area film so that the dusty gas streams passing through the "ed
achieve maximum contact with the li0uid film and "ecome deposited on the surfaces of
the packing elements. %hese scru""ers have a good collection efficiency for respira"le
dust.
%hree types of packed4"ed scru""ers are4
+ross4flow scru""ers
+o4current flow scru""ers
+ounter4current flow scru""ers
?fficiency can "e greatly increased "y minimi&ing target si&e, i.e., using (.((2 in.
P.81 mm! diameter stainless steel wire and increasing gas velocity to more than
-,Q(( ftOmin M.-3 mOs!.
[edit] #igh-energy scruers
Nenturi scru""ers consist of a venturi4shaped inlet and separator. %he dust4laden gases
venturi scru""er enter through the venturi and are accelerated to speeds "etween -1,(((
and 28,((( ftOmin 8(.MP4-Q1.Q2 mOs!. %hese high4gas velocities immediately atomi&e the
coarse water spray, which is in;ected radially into the venturi throat, into fine droplets.
=igh energy and extreme tur"ulence promote collision "etween water droplets and dust
particulates in the throat. %he agglomeration process "etween particle and droplet
continues in the diverging section of the venturi. %he large agglomerates formed in the
venturi are then removed "y an inertial separator.
Nenturi scru""ers achieve very high collection efficiencies for respira"le dust. /ince
efficiency of a venturi scru""er depends on pressure drop, some manufacturers supply a
varia"le4throat venturi to maintain pressure drop with varying gas flows.
[edit] lectrostatic precipitators !S"#
Eain article: ?lectrostatic precipitator
?lectrostatic precipitators use electrostatic forces to separate dust particles from exhaust
gases. A num"er of high4voltage, direct4current discharge electrodes are placed "etween
grounded collecting electrodes. %he contaminated gases flow through the passage formed
"y the discharge and collecting electrodes. ?lectrostatic precipitators operate on the same
principle as home R$onicR air purifiers.
%he air"orne particles receive a negative charge as they pass through the ioni&ed field
"etween the electrodes. %hese charged particles are then attracted to a grounded or
positively charged electrode and adhere to it.
%he collected material on the electrodes is removed "y rapping or vi"rating the collecting
electrodes either continuously or at a predetermined interval. +leaning a precipitator can
usually "e done without interrupting the airflow.
%he four main components of all electrostatic precipitators are4
*ower supply unit, to provide high4voltage F+ power
$oni&ing section, to impart a charge to particulates in the gas stream
A means of removing the collected particulates
A housing to enclose the precipitator &one
%he following factors affect the efficiency of electrostatic precipitators:
#arger collection4surface areas and lower gas4flow rates increase efficiency
"ecause of the increased time availa"le for electrical activity to treat the dust
particles.
An increase in the dust4particle migration velocity to the collecting electrodes
increases efficiency. %he migration velocity can "e increased "y4
o Fecreasing the gas viscosity
o $ncreasing the gas temperature
o $ncreasing the voltage field
[edit] Types of precipitators
%here are two main types of precipitators:
=igh4voltage, single4stage 4 /ingle4stage precipitators com"ine an ioni&ation and
a collection step. %hey are commonly referred to as +ottrell precipitators.
#ow4voltage, two4stage 4 %wo4stage precipitators use a similar principleL however,
the ioni&ing section is followed "y collection plates.
Fescri"ed "elow is the high4voltage, single4stage precipitator, which is widely used in
minerals processing operations. %he low4voltage, two4stage precipitator is generally used
for filtration in air4conditioning systems.
[edit] $late precipitators
%he ma;ority of electrostatic precipitators installed are the plate type. *articles are
collected on flat, parallel surfaces that are Q to -1 in. 1( to 2( cm! apart, with a series of
discharge electrodes spaced along the centerline of two ad;acent plates. %he contaminated
gases pass through the passage "etween the plates, and the particles "ecome charged and
adhere to the collection plates. +ollected particles are usually removed "y rapping the
plates and deposited in "ins or hoppers at the "ase of the precipitator.
[edit] %uular precipitators
%u"ular precipitators consist of cylindrical collection electrodes with discharge electrodes
located on the axis of the cylinder. %he contaminated gases flow around the discharge
electrode and up through the inside of the cylinders. %he charged particles are collected
on the grounded walls of the cylinder. %he collected dust is removed from the "ottom of
the cylinder.
%u"ular precipitators are often used for mist or fog collection or for adhesive, sticky,
radioactive, or extremely toxic materials.
[edit] $nit collectors
Hnlike central collectors, unit collectors control contamination at its source. %hey are
small and self4contained, consisting of a fan and some form of dust collector. %hey are
suita"le for isolated, porta"le, or fre0uently moved dust4producing operations, such as
"ins and silos or remote "elt4conveyor transfer points. Advantages of unit collectors
include small space re0uirements, the return of collected dust to main material flow, and
low initial cost. =owever, their dust4holding and storage capacities, servicing facilities,
and maintenance periods have "een sacrificed.
A num"er of designs are availa"le, with capacities ranging from 1(( to 1,((( ftWOmin M(
to M(( #Os!. %here are two main types of unit collectors:
Fa"ric collectors, with manual shaking or pulse4;et cleaning 4 normally used for
fine dust
+yclone collectors 4 normally used for coarse dust
Fa"ric collectors are fre0uently used in minerals processing operations "ecause they
provide high collection efficiency and uninterrupted exhaust airflow "etween cleaning
cycles. +yclone collectors are used when coarser dust is generated, as in woodworking,
metal grinding, or machining.
%he following points should "e considered when selecting a unit collector:
+leaning efficiency must comply with all applica"le regulations.
%he unit should maintain its rated capacity while accumulating large amounts of
dust "etween cleanings.
%he cleaning operations should "e simple and should not increase the surrounding
dust concentration.
%he unit should "e capa"le of operating unattended for extended periods of time
for example, Q hours!.
%he unit should have an automatic discharge or sufficient dust storage space to
hold at least one week6s accumulation.
$f renewa"le filters are used, they should not have to "e replaced more than once a
month.
%he unit should "e dura"le.
%he unit should "e 0uiet.
Hse of unit collectors may not "e appropriate if the dust4producing operations are located
in an area where central exhaust systems would "e practical. Fust removal and servicing
re0uirements are expensive for many unit collectors and are more likely to "e neglected
than those for a single, large collector.
[edit] Selecting a dust collector
Fust collectors vary widely in design, operation, effectiveness, space re0uirements,
construction, and capital, operating, and maintenance costs. ?ach type has advantages
and disadvantages. =owever, the selection of a dust collector should "e "ased on the
following general factors:
Fust concentration and particle si&e 4 For minerals processing operations, the dust
concentration can range from (.- to '.( grains (.21 g! of dust per cu"ic feet of air
(.12 to --.33 grams per standard cu"ic meter!, and the particle si&e can vary
from (.' to -(( Vm.
Fegree of dust collection re0uired 4 %he degree of dust collection re0uired
depends on its potential as a health ha&ard or pu"lic nuisance, the plant location,
the allowa"le emission rate, the nature of the dust, its salvage value, and so forth.
%he selection of a collector should "e "ased on the efficiency re0uired and should
consider the need for high4efficiency, high4cost e0uipment, such as electrostatic
precipitatorsL high4efficiency, moderate4cost e0uipment, such as "aghouses or wet
scru""ersL or lower cost, primary units, such as dry centrifugal collectors.
+haracteristics of airstream 4 %he characteristics of the airstream can have a
significant impact on collector selection. For example, cotton fa"ric filters cannot
"e used where air temperatures exceed -Q(XF Q1X+!. Also, condensation of steam
or water vapor can "lind "ags. Narious chemicals can attach fa"ric or metal and
cause corrosion in wet scru""ers.
+haracteristics of dust 4 Eoderate to heavy concentrations of many dusts such as
dust from silica sand or metal ores! can "e a"rasive to dry centrifugal collectors.
=ygroscopic material can "lind "ag collectors. /ticky material can adhere to
collector elements and plug passages. /ome particle si&es and shapes may rule out
certain types of fa"ric collectors. %he com"usti"le nature of many fine materials
rules out the use of electrostatic precipitators.
Eethods of disposal 4 Eethods of dust removal and disposal vary with the
material, plant process, volume, and type of collector used. +ollectors can unload
continuously or in "atches. Fry materials can create secondary dust pro"lems
during unloading and disposal that do not occur with wet collectors. Fisposal of
wet slurry or sludge can "e an additional material4handling pro"lemL sewer or
water pollution pro"lems can result if wastewater is not treated properly.
[edit] Fan and motor
%he fan and motor system supplies mechanical energy to move contaminated air from the
dust4producing source to a dust collector.
[edit] Types of fans
%here are two main kinds of industrial fans:
+entrifugal fans
Axial4flow fans
[edit] Centrifugal fans
+entrifugal fans consist of a wheel or a rotor mounted on a shaft that rotates in a scroll4
shaped housing. Air enters at the eye of the rotor, makes a right4angle turn, and is forced
through the "lades of the rotor "y centrifugal force into the scroll4shaped housing. %he
centrifugal force imparts static pressure to the air. %he diverging shape of the scroll also
converts a portion of the velocity pressure into static pressure.
%here are three main types of centrifugal fans:
Radial4"lade fans 4 Radial4"lade fans are used for heavy dust loads. %heir straight,
radial "lades do not get clogged with material, and they withstand considera"le
a"rasion. %hese fans have medium tip speeds and medium noise factors.
Gackward4"lade fans 4 Gackward4"lade fans operate at higher tip speeds and thus
are more efficient. /ince material may "uild up on the "lades, these fans should "e
used after a dust collector. Although they are noisier than radial4"lade fans,
"ackward4"lade fans are commonly used for large4volume dust collection systems
"ecause of their higher efficiency.
Forward4curved4"lade fans 4 %hese fans have curved "lades that are tipped in the
direction of rotation. %hey have low space re0uirements, low tip speeds, and a low
noise factor. %hey are usually used against low to moderate static pressures.
[edit] A%ial&flo' fans
Axial4flow fans are used in systems that have low resistance levels. %hese fans move the
air parallel to the fan6s axis of rotation. %he screw4like action of the propellers moves the
air in a straight4through parallel path, causing a helical flow pattern.
%he three main kinds of axial fans are4
*ropeller fans 4 %hese fans are used to move large 0uantities of air against very
low static pressures. %hey are usually used for general ventilation or dilution
ventilation and are good in developing up to (.' in. wg -13.3 *a!.
%u"e4axial fans 4 %u"e4axial fans are similar to propeller fans except they are
mounted in a tu"e or cylinder. %herefore, they are more efficient than propeller
fans and can develop up to 2 to 3 in. wg P32.2 to MM' *a!. %hey are "est suited
for moving air containing su"stances such as condensi"le fumes or pigments.
Nane4axial fans 4 Nane4axial fans are similar to tu"e4axial fans except air4
straightening vanes are installed on the suction or discharge side of the rotor. %hey
are easily adapted to multistaging and can develop static pressures as high as -3 to
-8 in. wg 2.3Q2 to 2.MQ k*a!. %hey are normally used for clean air only.
Fan selection
When selecting a fan, the following points should "e considered:
Nolume re0uired
Fan static pressure
%ype of material to "e handled through the fan For example, a radial4"lade fan
should "e used with fi"rous material or heavy dust loads, and nonsparking
construction must "e used with explosive or inflamma"le materials.!
%ype of drive arrangement, such as direct drive or "elt drive
/pace re0uirements
Aoise levels
Sperating temperature For example, sleeve "earings are suita"le to
1'(XFO-1-.-X+L "all "earings to ''(XFO1QP.QX+!
/ufficient si&e to handle the re0uired volume and pressure with minimum
horsepower
Aeed for special coatings or construction when operating in corrosive
atmospheres
A"ility of fan to accommodate small changes in total pressure while maintaining
the necessary air volume
Aeed for an outlet damper to control airflow during cold starts $f necessary, the
damper may "e interlocked with the fan for a gradual start until steady4state
conditions are reached.!
Fan Rating %a"les
After the a"ove information is collected, the actual selection of fan si&e and speed is
usually made from a rating ta"le pu"lished "y the fan manufacturer. %his ta"le is known
as a multirating ta"le, and it shows the complete range of capacities for a particular si&e
of fan.
*oints to note:
%he multirating ta"le shows the range of pressures and speeds possi"le within the
limits of the fan6s construction.
A particular fan may "e availa"le in different construction classes identified as
class $ through $N! relating to its capa"ilities and limits.
For a given pressure, the highest mechanical efficiency is usually found in the
middle third of the volume column.
A fan operating at a given speed can have an infinite num"er of ratings pressure
and volume! along the length of its characteristic curve. =owever, when the fan is
installed in a dust collection system, the point of rating can only "e at the point at
which the system resistance curve intersects the fan characteristic curve.
$n a given system, a fan at a fixed speed or at a fixed "lade setting can have a
single rating only. %his rating can "e changed only "e changing the fan speed,
"lade setting, or the system resistance.
For a given system, an increase in exhaust volume will result in increases in static
and total pressures. For example, for a 1() increase in exhaust volume in a
system with ' in. pressure loss, the new pressure loss will "e ' Y -.1(!Z 7 P.1 in.
[ For rapid estimates of pro"a"le exhaust volumes availa"le for a given motor
si&e, the e0uation for "rake horsepower, as illustrated, can "e useful.
Fan installation %ypical fan discharge conditions Fan ratings for volume and static
pressure, as descri"ed in the multirating ta"les, are "ased on the tests conducted under
ideal conditions. Sften, field installation creates airflow pro"lems that reduce the fan6s air
delivery. %he following points should "e considered when installing the fan:
Avoid installation of el"ows or "ends at the fan discharge, which will lower fan
performance "y increasing the system6s resistance.
Avoid installing fittings that may cause non4uniform flow, such as an el"ow,
mitred el"ow, or s0uare duct.
+heck that the fan impeller is rotating in the proper direction4clockwise or
counterclockwise.
For "elt4driven fans4

o +heck that the motor sheave and fan sheave are aligned properly.

o +heck for proper "elt tension.

+heck the passages "etween inlets, impeller "lades, and inside of housing for
"uildup of dirt, o"structions, or trapped foreign matter.
[edit] lectric motors
Eain article: ?lectric motor
?lectric motors are used to supply the necessary energy to drive the fan.
$ntegral4horsepower electric motors are normally three4phase, alternating4current motors.
Fractional4horsepower electric motors are normally single4phase, alternating4current
motors and are used when less than - hp (.P' kW! is re0uired. /ince most dust
collection systems re0uire motors with more than - hp (.P' kW!, only integral4
horsepower motors are discussed here.
%he two most common types of integral4horsepower motors used in dust collection
systems are4
/0uirrel4cage motors 4 %hese motors have a constant speed and are of a
nonsynchronous, induction type.
Wound4rotor motors 4 %hese motors are also known as slip4ring motors. %hey are
general4purpose or continuous4rated motors and are chiefly used when an
ad;usta"le4speed motor is desired.
/0uirrel4cage and wound4rotor motors are further classified according to the type of
enclosure they use to protect their interior windings. %hese enclosures fall into two "road
categories:
Spen
%otally enclosed
Frip4proof and splash4proof motors are open motors. %hey provide varying degrees of
protectionL however, they should not "e used where the air contains su"stances that might
"e harmful to the interior of the motor.
%otally enclosed motors are weather4protected with the windings enclosed. %hese
enclosures prevent free exchange of air "etween the inside and the outside, "ut they are
not airtight.
%otally enclosed, fan4cooled %?F+! motors are another kind of totally enclosed motor.
%hese motors are the most commonly used motors in dust collection systems. %hey have
an integral4cooling fan outside the enclosure, "ut within the protective shield, that directs
air over the enclosure.
Goth open and totally4enclosed motors are availa"le in explosion4proof and dust4ignition4
proof models to protect against explosion and fire in ha&ardous environments.
Eotors are selected to provide sufficient power to operate fans over the full range of
process conditions temperature and flow rate!.
Figure -. Fust +ollection /ystem ?xample
[edit] $ses
Fust collectors are used in many processes to either recover valua"le granular solid or
powder from process streams, or to remove granular solid pollutants from exhaust gases
prior to venting to the atmosphere. Fust collection is an online process for collecting any
process4generated dust from the source point on a continuous "asis. Fust collectors may
"e of single unit construction, or a collection of devices used to separate particulate
matter from the process air. %hey are often used as an air pollution control device to
maintain or improve air 0uality.
Eist collectors remove particulate matter in the form of fine li0uid droplets from the air.
%hey are often used for the collection of metal working fluids, and coolant or oil mists.
Eist collectors are often used to improve or maintain the 0uality of air in the workplace
environment.
Fume and smoke collectors are used to remove su" micrometre si&e particulate from the
air. %hey effectively reduce or eliminate particulate matter and gas streams from many
industrial processes such as welding, ru""er and plastic processing, high speed machining
with coolants, tempering, and 0uenching.
[edit] Configurations
Fust collectors can "e configured into one of five common types.
-. Am"ient units 4 Am"ient units are free4hanging systems for use when applications
limit the use of source4capture arms or ductwork.
1. +ollection "ooths 4 +ollector "ooths re0uire no ductwork, and allow the worker
greater freedom of movement. %hey are often porta"le.
2. Fowndraft ta"les 4 A downdraft ta"le is a self4contained porta"le filtration system
that removes harmful particulates and returns filtered air "ack into the facility
with no external ventilation re0uired.
3. /ource collector or *orta"le units 4 *orta"le units are for collecting dust, mist,
fumes, or smoke at the source.
'. /tationary units 4 An example of a stationary collector is a "aghouse.
[edit] "arameters involved in specifying dust collectors
$mportant parameters in specifying dust collectors include airflow the velocity of the air
stream created "y the vacuum producerL system power, the power of the system motor,
usually specified in horsepowerL storage capacity for dust and particles, and minimum
particle si&e filtered "y the unit. Sther considerations when choosing a dust collection
system include the temperature, moisture content, and the possi"ility of com"ustion of
the dust "eing collected.
/ystems for fine removal may only contain a single filtration system such as a filter "ag
or cartridge!. =owever, most units utili&e a primary and secondary separationOfiltration
system. $n many cases the heat or moisture content of dust can negatively affect the filter
media of a "aghouse or cartridge dust collector. A cyclone separator or dryer may "e
placed "efore these units to reduce heat or moisture content "efore reaching the filters.
Furthermore, some units may have third and fourth stage filtration. All separation and
filtration systems used within the unit should "e specified.
A "aghouse is an air pollution a"atement device used to trap particulate "y filtering gas
streams through large fa"ric "ags. %hey are typically made of glass fi"ers or fa"ric.
A cyclone separator is an apparatus for the separation, "y centrifugal means, of fine
particles suspended in air or gas.
?lectrostatic precipitators are a type of air cleaner, which charges particles of dust "y
passing dust4laden air through a strong '(4-(( kN! electrostatic field. %his causes the
particles to "e attracted to oppositely charged plates so that they can "e removed from the
air stream.
An impinger system is a device in which particles are removed "y impacting the aerosol
particles into a li0uid. Eodular media type units com"ine a variety of specific filter
modules in one unit. %hese systems can provide solutions to many air contaminant
pro"lems. A typical system incorporates a series of disposa"le or cleana"le pre4filters, a
disposa"le vee4"ag or cartridge filter. =?*A or car"on final filter modules can also "e
added. Narious models are availa"le, including free4hanging or ducted installations,
vertical or hori&ontal mounting, and fixed or porta"le configurations. Filter cartridges are
made out of a variety of synthetic fi"ers and are capa"le of collecting su"4micrometre
particles without creating an excessive pressure drop in the system. Filter cartridges
re0uire periodic cleaning.
A wet scru""er, or venturi scru""er, is similar to a cyclone "ut it has an orifice unit that
sprays water into the vortex in the cyclone section, collecting all of the dust in a slurry
system. %he water media can "e recirculated and reused to continue to filter the air.
?ventually the solids must "e removed from the water stream and disposed of.
[edit] Filter cleaning methods
(nline cleaning C automatically timed filter cleaning which allows for continuous,
uninterrupted dust collector operation for heavy dust operations.
(ffline cleaning C filter cleaning accomplished during dust collector shut down.
*ractical whenever the dust loading in each dust collector cycle does not exceed the filter
capacity. Allows for maximum effectiveness in dislodging and disposing of dust.
(n&demand cleaning C filter cleaning initiated automatically when the filter is fully
loaded, as determined "y a specified drop in pressure across the media surface.
)everse&pulse*)everse&+et cleaning C Filter cleaning method which delivers "lasts of
compressed air from the clean side of the filter to dislodge the accumulated dust cake.
Impact*)apper cleaning C Filter cleaning method in which high4velocity compressed air
forced through a flexi"le tu"e results in a random rapping of the filter to dislodge the dust
cake. ?specially effective when the dust is extremely fine or sticky.