Separation and Purification Technology 179 (2017) 236247

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Separation and Purification Technology

journal homepage: www.elsevier.com/locate/seppur

Analysis of the effect of counter-cone location on cyclone separator

efficiency
Marek Wasilewski
Faculty of Production Engineering and Logistics, Opole University of Technology, 76 Proszkowska St., 45-758 Opole, Poland

a r t i c l e i n f o a b s t r a c t

Article history: This paper analyzes the possibility of optimizing the structure of cyclone separators through the applica-
Received 13 September 2016 tion of an additional compartment in the form of a counter-cone. Analysis of studies published so far indi-
Received in revised form 3 February 2017 cates that few of them concern such improvements for cyclone separators, and those that do focus solely
Accepted 5 February 2017
on determining the effect of a counter-cone on the efficiency of solid particle separation. This paper also
Available online 8 February 2017
assesses the effect of a counter-cone on pressure drop. Furthermore, the risk of excessive agglomeration
of particles in the lower area of the conical part of the cyclone due to the proposed structural modifica-
Keywords:
tions was assessed. Based on the obtained study results, was proposed a method for the determination of
Cyclone separator
Modeling flow phenomena
the optimum counter-cone location.
Counter-cone Fifteen variants of geometric configurations of the counter-cone were tested using two study methods -
Kiln gas bypass systems Computational Fluid Dynamics (CFD) and experimental research. The Reynolds-averaged NavierStokes
Clinker burning equations with the Reynolds stress turbulence model (RSM) were used in the analysis. Cyclone separators
CFD from a real industrial installation, i.e. a kiln gas bypass system for cement clinker burning, were used for
the research. This allowed for additional validation of the numerical models used and parametrization of
calculation and boundary conditions.
The application of a counter-cone was found to benefit the basic parameter characterizing cyclone sep-
arators, i.e. separation efficiency.
2017 Elsevier B.V. All rights reserved.

1. Introduction important, since it is directly reflected in the efficiency of cyclone

Number of studies have addressed the development and
improvement of cyclone separators. Initially, such studies involved
experimental and analytical research. Many methods for calculat-
ing pressure drop and the efficiency of solid particle separation
in cyclone separators (i.e. two parameters characterizing the effi-
ciency of these devices) have been developed. The most commonly
used models that allow determining the first of these parameters
include the models developed by Stairmand [1], Barth [2], Shep-
herd and Lapple [3] or Casal and Martinez [4]. On the other hand,
for example, Barth [2], Rietema [5], Mothes and Lffler [6] and
Muschelknautz [7,8] proposed the models that help to determine
the separation efficiency with a small share of the solid phase.
A separate set of data required to design cyclone separators are
relationships that describe the characteristic geometrical dimen-
sions (e.g., a, b, De, S, h, Hc, H or B). In this case, the results obtained
in studies by Lapple, Stairmand and Swift may prove useful. Wang
et al. [9] discuss the geometrical relationships described by these
research studies. The precise geometric dimensioning is very
E-mail address: m.wasilewski@po.opole.pl
often also in the operating costs. Chiefly, there should be a search
for a compromise between high efficiency of separation and low
pressure drop. Svarovsky [10] proposed the relationship between
these parameters, which allow designing a reasonable cyclone
designs.
With the rapid development of computer technology and
improved access to increasingly efficient computational hardware,
a new research method has emerged that helps solve the problem
of multiphase flows inside cyclones, termed computational fluid
dynamics (CFD). Boysan et al. [11] were the first to use CFD method
calculations for the analysis of flow in a cyclone and to calculate
separation efficiency. A review of studies on the subject allows
the conclusion that the researchers used different numerical mod-
els. Some authors used the k-e RNG model [1215]. The RSM model
is the most common model for the study of cyclone separators. An
example of this type of research are studies [1621]. Its main
advantage rests in the possibility to map turbulent stress with a
highly anisotropic character. The RSM model enables more precise
test results to be obtained in comparison to the k-e RNG model.
Azadi et al. [22] compared these two models. Their study results
show greater precision of the RSM model in comparison to

http://dx.doi.org/10.1016/j.seppur.2017.02.012
1383-5866/ 2017 Elsevier B.V. All rights reserved.
 M. Wasilewski / Separation and Purification Technology 179 (2017) 236247 237

Nomenclature

a height of the gas inlet p0 dispersion pressure

b width of the gas inlet Qi inlet gas volumetric flow rate
B diameter of the cyclone lower (dust) outlet RANS Reynolds average NavierStokes
Bh distance from the base of the counter-cone to the lower RSM Reynolds stress model
outlet s the source term
CD drag coefficient sd distance between the counter-cone and the conical part
CFD computational fluid dynamics of the cyclone
dp diameter of a particle S height of the outlet duct in the interior of the cyclone
D cyclone body diameter SIMPLE semi-implicit method pressure-linked equations
De diameter of the cyclone gas outlet t time
Ds counter-cone diameter ui(j, k) gas velocity to direction i (j, k)
DPM discrete phase model up particle velocity
Dij the stress diffusion term u0 i(j, k) fluctuating velocity to direction i (j, k)
Fk momentum transport coefficient a apex angle of the counter-cone
g acceleration of gravity DP pressure drop in a cyclone separator
Gi inlet particle mass flow rate d Kronecker factor
h height of the cyclone cylindrical section eij the dissipation term
H total height of the cyclone m dynamic viscosity of gas
Hc cyclone cone part height Pij the pressure-strain correlation term
k turbulence kinetic energy q density of gas
P pressure qp density o a particle
Pij the shear production term sij the Reynolds stress tensor
PRESTO Pressure Staggering Option

experimental research. Moreover, the authors of some studies [29] the location of the counter-cone (above the lower outlet) and a
combine these two models. The work of Houben and Pirker [23] method for determining its parameters (Fig. 1).
is an example here. At the initial stage of simulation, they used In contrast, Kabsch [30] suggests that the counter-cone be
the k-e RNG model to stabilize the flow, and then switched to located below the conical part of the separator. Krambrock [31]
the RSM model. proposes a similar location to Kabsch, adding that the diameter
In recent years, a third model Large Eddy Simulation (LES) is of the counter-cone should be marginally greater than the
gaining in popularity in the study of cyclones. There are two vari- diameter of the outlet tube (De), and the apex cone should be equal
ants of this model Finite Volume Large Eddy Simulation (FV-LES) to 90.
and Lattice-Boltzmann Large Eddy Simulation (LB-LES). Gronald Kepa conducted studies [32,33] in which he compared the two
and Derksen [24] made a comparison of these two variants with suggested locations of the counter-cone (below the cyclone outlet
RANS-RSM model. They pointed some limitations of RANS model. and in the conical part of the cyclone) using CFD. He concluded that
In turn, Pirker et al. [25] proposed a hybrid approach they used placing the counter-cone below the conical part is more beneficial,
a LB-LES and RANS-RSM model in their study. Other studies that as it helps increase separation efficiency.
used FV-LES model are [26,27]. In turn, Yoshida et al. [3436] studied the apex angle within the
One of the methods for optimizing the structure of cyclone sep- 4080 range. They found that the optimal value of the angle for
arators in cases where the objective function involves maximizing optimizing separation efficiency is 70. Furthermore, they observed
separation effectiveness is to equip the traditional structures with that increasing the gap between the counter-cone and the wall of
an additional element in the form of a counter-cone in the lower the conical part of the cyclone increased the amount of small par-
area of the separator. This solution can be applied in most types ticles that can be extracted into the particle tank.
of cyclones. The goal of the additional element (also called a Chi-
nese hat, a vortex stabilizer or an apex cone) is to limit secondary cir-
culation of the separated particles. Hoffmann & Stein [28]
concluded that secondary circulation results from the vortex tail
(the place where the axial direction of movement changes) moving
back from the lower particle tank and adhering to the wall of the
conical part of the separator. Due to rotational movement, the solid
particles that drop to the tank are moved by the rising gas. Analysis
of studies on the issue [2937] (presented below) enables the
observation that, while using such additional design solutions,
the counter-cone diameter, apex angle and correct location should
be precisely selected. Incorrect selection of these parameters may
hamper the drop of the material to the tank, reduce separation effi-
ciency, and increase the risk of blockage in the lower outlet of the
cyclone.
Analysis of studies on the subject leads to the conclusion that
few researchers have focused on methods for selecting counter-
cone dimensions or a scientific description of the effects of applica-
tion of the additional compartment. Muschelknautz, the author of Fig. 1. Location of the counter-cone and a method for determining its dimensions,
many research papers on the design of cyclone separators, defined according to Muschelknautz [28].
238 M. Wasilewski / Separation and Purification Technology 179 (2017) 236247
Obermair et al. [37] analyzed two structural variants of a
counter-cone. In the first variant, the apex angle was 90, and the
device itself was located under the lower outlet of the cyclone. In
the second variant, the apex angle was 120, and the counter-
cone was located over the outlet of the cyclone. The latter solution
led to an increase in separation efficiency (by 2%) and an increase
in pressure drop by about 200 Pa (the value of about 1200 Pa up to
1400 Pa).
The present study analyzed and described multiphase flow
inside a cyclone separator equipped with a counter-cone. Imple-
menting this sort of improvement is one of the simplest methods
of increasing separation efficiency - it may be used both with
new cyclone separators which are being designed and improving
existing. The cost of this improvement also is not high and it does
not require for a cyclone separator to be offline for a long period of
time in case of improving existing and operating installations. The
main goal of the study was the elaboration of a universal method
enabling determination of the optimum location of the counter-
cone. To this end, analysis of the effect of the geometric dimensions
and location of an additional barrier on the efficiency of cyclone
separators was necessary.
2. Materials and methods
Since exploitation data from real industrial installations fre-
quently show considerable discrepancies with research results, it
was decided that this study would be based on the actual opera-
tional conditions of a particular installation. In order to accomplish
this task, was selected the cyclone separator design used for the
kiln gas bypass system in one of the cement plants in Poland
(Fig. 2). The task of gas bypass systems used in the systems of
dry clinker burning is the extraction of a part of the process gasses
out of the rotary kiln. This allows a reduction in the formation of
Fig. 2. Flow sheet of the bypass system in the installation for cement clinker burning.
growths in cyclones of individual stages of the cyclone suspension
preheater. This negative phenomenon stems from the formation of
closed alkali circuits (condensed volatile compounds from the
exchange column are returned to the rotary kiln, where, due to
the high temperature, they become volatilized). Now, in most
installations around the world the amount of gasses removed to
bypass ranges from 5% to 10%. Particle-laden gasses enter the
bypass system, where they undergo intense cooling with cool air.
This allows the volatile components to condense on the surface
of the raw material grains present in the kiln off-gasses. Next,
the particles are separated in cyclone separators and directed out-
side the system. The extraction of gasses into the bypass system
involves heat loss. One percent of the extracted gasses corresponds
to a loss of about 1525 kJ/kg  cl. Therefore, the percentage share
of the bypassed gasses should be precisely adjusted to the condi-
tions inside the installation, and the individual devices that make
up the bypass system should be optimized.
Key elements of the bypass system are cyclone separators, the
task of which is to extract volatile components deposited on solid
particles and vent them outside the system. Analysis of the struc-
ture of these devices has showed that the system used cyclones
with a helical-roof inlet. Such cyclone designs are common in a
variety of industry branches. Moreover, this constitutes an advan-
tage of the tested design the usefulness of the obtained results
may not be restricted to the construction of cyclones used in
bypass systems. Fig. 3 shows the geometry of the tested cyclone
with particular emphasis on the key element of the analyzed
device. In the following stage, installation balance was performed
and the granulometric distribution of dust supplied with gasses
to the bypass system was determined. For the analyzed installa-
tion, the separation efficiency was 89% and the value of pressure
drop 1250 Pa. As the cyclones, which are operating in a dual sys-
tem, had an identical geometry, the study was conducted on only
 M. Wasilewski / Separation and Purification Technology 179 (2017) 236247 239

2.1. Experimental research

In order to conduct experimental research, an experimental

installation was designed and constructed (Fig. 4). The test stand
was equipped with two installations which supplied the test
media. The gas phase was supplied to the system via a fan
equipped with a frequency inverter, which allowed for regula-
tion of the fans rpm. On the other hand, the solid phase was
supplied using a feeder. In order to eliminate the phenomenon
of non-separated particles leaving the system, the installation
was equipped with a fabric filter. The main element of the test
stand was a cyclone separator constructed of acrylic glass, the
main component of which was PMMA. Its geometrical design
(relations of characteristic dimensions) corresponded to the real
structure used in a bypass system. The model used in the exper-
imental study was performed in the scale of 1:3. Like in the case
of model scale, a flow similarity (1:3) was applied and this
helped to maintain the ratio of gas phase and solid phase share
(Gi/Qi). The inlet velocity of cyclone in both cases was 15 m/s.
Additionally, equal ratio between density of solid phase and
the gas phase was used.
The measurements started, when the flow was established and
lasted 30 s. The value of the pressure drop was determined via
measurement of the pressure difference at the inlet and outlet of
the cyclone. The separation efficiency was defined via the determi-
nation of the difference between the solid phase mass supplied to
Fig. 3. Base variant of the cyclone (mm).
the system and the weight of separated solids. In addition, after
each measurement series, solid phase separated in the lower tank
was analyzed for particle size, which allowed determining the effi-
ciency of separation efficiency of particular solid fractions. In order
Table 1
to limit measurement errors, tests for each variant were conducted
Flow parameters included in the CFD study.
in three repetitions, and mean values were assumed for the
Gaseous phase Solid phase analysis.
Qi 5.23 m3/s Gi 0.18 kg/s Fifteen modifications to the structure of the separator were
q 1.225 kg/m3 qp 2800 kg/m3 designed and analyzed. The modifications involved the installation
of a counter-cone with different geometrical parameters inside the
one such device. The gaseous and solid phases were divided pro- cyclone and these were proposed based on an analysis of the
portionally. Based on collected data, flow parameters included in results of other studies on the subject. As other researchers suggest
the study were defined (Table 1). [2836] that the location of the additional element plays the key

Fig. 4. Schematic diagram of the experimental setup. 1. Inlet pipe; 2. Flow meter; 3. Feeding system; 4. Pressure sensors; 5. Cyclone separator 6. Dust hopper; 7. Outlet pipe;
8. Air exhaust fan; 9. Bag filter.
240 M. Wasilewski / Separation and Purification Technology 179 (2017) 236247

Table 2 enabled a testing of the effect of the cone apex on the efficiency of
Description of the proposed variants of the location and geometry of the counter- cyclone separators. A full summary of the performed changes is
cone.
presented in Table 2 and in Fig. 5.
Oznaczenie Bh Ds [mm] a []
a1 0.15B 368 85 2.2. CFD studies
a2 0.15B 436 95
a3 0.15B 520 105
b1 0.1B 368 85 The study was conducted based on CFD using the finite volume
b2 0.1B 436 95 method with the Ansys Fluent 14 software package. The pressure-
b3 0.1B 520 105 based segregated solver method was applied. Differential equa-
c1 0.1B 368 85
tions were solved using the Semi-Implicit Method for Pressure
c2 0.1B 436 95
c3 0.1B 520 105
Linked Equations (SIMPLE) algorithm to accurately determine the
d1 0.15B 368 85 coupling of the pressure and velocity fields, in order to satisfy
d2 0.15B 436 95 the continuity equation for momentum. The second-order upwind
d3 0.15B 520 105 interpolation method was used to determine the representative
e1 0.35B 368 85
samples of the constituent values on the surface of the control vol-
e2 0.35B 436 95
e3 0.35B 520 105 umes. Turbulent flow was modeled using the RANS model and
according to the closing hypothesis (detailed model) for the Rey-
nolds Stress Model (RSM). The unsteady solver was used with a
time step of 0.001 s. The standard wall function was used to solve
role, five counter-cone locations were proposed (denoted in the turbulent flow problems in the wall regions. The reflect boundary
paper as a,b,c,d,e). Its location was marked Bh. In order to apply a conditions were used for the walls. Collisions between particles
universal character to the conducted study, the value of the param- and the walls of the cyclone were assumed to be perfectly elastic
eter was made dependent on the diameter of the lower outlet of (coefficient of restitution is equal to 1) [16,38].
cyclone B. Depending on the location of the counter-cone, the Bh The presence of the solid phase was modeled using the Euler-
value was from 0.35 B (variant e) to 0.15 B (variant a). This Lagrange method, applied through Ansys Fluent 14 as the discrete
parameter constituted the basis for the proposal of the optimum phase model (DPM). The DPM with one-way coupling was used for
counter-cone location. Moreover, for each of the five counter- the description of the dispersed phase. Hoekstra method [39] was
cone locations three apex angles were proposed. They were adopted as a criterion, which allows determining the effectiveness
marked with the symbols 1 (85), 2 (95) and 3 (105). This further of separation of particles of various diameters. The particles, which

Fig. 5. Variants of the applied modifications (internal dimensions, mm).

 M. Wasilewski / Separation and Purification Technology 179 (2017) 236247 241

Table 3 reached the lower tank, were considered as separated, and those
Details of CFD settings. which left the cyclone through vortex finder were counted as
Inlet Inlet velocity 15 m/s unseparated.
Turbulence intensity 5% Table 3 provides detailed information about the established
Hydraulic diameter 0.57 m conditions for the CFD modeling.
Outlet Outflow boundary condition has
been used for the outlet.
During initial research, three densities (cell numbers of about
The walls of the cyclone The standard walls function 330,000, about 570,000 and about 720,000) of the hexagonal
Discrete phase model One-way coupling meshes were analyzed for the base structure of the cyclone. A dif-
8 fractions distributed over the ferent variable mesh density was applied depending by the cyclone
inlet surface 15 lm200 lm
to take into account areas with the highest flow disturbances. It
Stochastic tracking
Max. number of steps 50,000 was found that the value of about 570,000 ensured high compli-
Step length factor 5 ance, compared to the results from an industrial installation and
Pressure-Velocity Coupling SIMPLE experimental studies, with the possible low load of the computing
Terms of convergence: Continuity 106 unit. A summary of the obtained values is presented in Table 4. In
Terms of convergence: Other 103
Spatial discretization: Pressure PRESTO
the next step of the research, hexagonal meshes were generated for
Spatial discretization: Momentum, Second order upwind all analyzed geometrical variants. The density of these meshes ran-
Turbulent kinetic energy, Turbulent ged from a cell number of about 558,000 to about 579,000. The dif-
dissipation rate, Reynolds stresses ferences resulted from the proposed structural modifications. Fig. 6
Turbulence model: RANS
shows the computational mesh and the cell number according to
@ui element quality for the base variant.
0 1
@xi



@ui @P @ @ui @uj @ sij 3. Results and discussion
qu j  l 2
@xj @xi @xj @xj @xi @xj
The first step involved validation of the obtained results using
sij qu0i u0j 3 CFD tests and experimental research was also conducted. The anal-
ysis concerned the value of pressure drop and separation effi-
[4042] ciency. A comparative procedure was carried out for all variants.
Detailed model: RSM, Adopted standard numerical coefficients rk, Cl, re, Ce1,
For the base variant, an additional comparison of the obtained
Ce2, k
results was possible with the use of two test methods, with the
@ @ data originating from the industrial installation. The conducted
qu0i u0j quk u0i u0j Dij Pij pij eij s 4 validation was aimed at quantitative estimation of the errors stem-
@t @xk
ming from the assumptions in the numerical model and
parametrization of the calculation and boundary conditions. The


@ @ 0 0 obtained values of pressure drop and separation efficiency for the
Dij  qu0i u0j u0k p0 u0j dik p0 u0i djk  l uu 5
@xk @xk i j base variant show a broad convergence. Mean error for the pres-
sure drop was 7%; maximum 10% and minimum 5%. On the other
 
@uj @ui hand, these values for separation efficiency were 3.5%, 3.9%, and
P ij q u0i u0k u0j u0k 6
@xk @xk 3.1%, respectively. The comparison of CFD test results and values
from industrial installations for the base variant revealed that error

 for the pressure drop was approximately 7% and for the separation
@ui @uj
pij p0 7 efficiency approximately 6%. Detailed values of the parameters dis-
@xj @xi
cussed in the validation process are presented in Tables 4 and 5.
The consistent values obtained for pressure drop and separation
efficiency for the base variant show the correct selection of the cal-
@u0i @u0i
eij 2l 8 culation process parameters. Slight differences may stem from
@xk @xk
imperfections in the calculation models, which require the intro-
duction of certain simplifications and empirical coefficients with
[4143]
Two-phase flow: Discrete phase model
high levels of uncertainty.
The basic indicators used to assess the proposed modifications
2
and their effect on the efficiency of cyclone separators were as
18l qp dp CD Rep follows:
Fk  9
qp d2p 24

 change in separation efficiency as a result of the introduced

modifications;
8 24  change in pressure drop as a result of the introduced
>
> for Rep 6 1
< Re modifications;
2410:15Re0:687 for 16Rep 61000
CD p
10
>
>
:
Rep  concentration of solid particles in the area of the counter-cone.
0:44 for Rep > 1000
The third of these parameters formed the basis for determining
to what extent the proposed modifications may have affected the
 risk of excessive agglomeration of particles in the lower area of
dp qup  uj
Rep 11 the conical part of the cyclone (due to the introduction of the
l
counter-cone).
[41,42,44,45] Table 5 shows the values obtained for separation efficiency and
pressure drop for the proposed variants.
242 M. Wasilewski / Separation and Purification Technology 179 (2017) 236247

Table 4
Analysis of computational mesh density sensitivity.

Mesh Cell numbers Total separation efficiency [%] Pressure drop [Pa]
CFD results Exp. results Industrial installation result CFD results Exp. results Industrial installation result
1 330,000 83.15 87 89 1055 1210 1250
2 570,000 83.65 1344
3 720,000 83.55 1377

Fig. 6. Discretization of the computational area for the base variant according to element quality.

Table 5
Values for separation efficiency and pressure drop for each variant.

Variant of modification Total separation efficiency [%] Pressure drop [Pa]

CFD results Exp. Results Results compatibility [%] CFD results Exp. Results Results compatibility [%]
Base 83.65 87 96.1 1344 1210 90.0
a1 86.63 89.9 96.4 1367 1257 92.0
a2 86.13 89.2 96.6 1372 1272 92.7
a3 85.87 89 96.5 1390 1295 93.2
b1 86.52 89.7 96.5 1374 1280 93.2
b2 86.04 89.2 96.5 1384 1284 92.8
b3 85.34 88.5 96.4 1389 1290 92.9
c1 85.21 88.3 96.5 1372 1275 92.9
c2 84.97 88 96.6 1375 1280 93.1
c3 84.53 87.5 96.6 1378 1282 93.0
d1 84.92 87,9 96.6 1377 1280 93.0
d2 84.75 87.8 96.5 1391 1302 93.6
d3 84.55 87.5 96.6 1400 1330 95.0
e1 84.66 87.6 96.6 1379 1285 93.2
e2 84.57 87.5 96.7 1397 1315 94.1
e3 84.93 87.8 96.7 1371 1271 92.7
 M. Wasilewski / Separation and Purification Technology 179 (2017) 236247 243

Analysis of results began with the key parameter, i.e. separation
efficiency. All proposed variants were found to provide higher sep-
aration efficiency than the base variant (in relation to the value
obtained through CFD). Variant a1 was most favorable, whereas
the lowest values were obtained for variant c3. Considering the
values (presented in Table 5) obtained for the proposed geometric
variants, it can be observed that the counter-cone location was the
most significant. The highest values were obtained for modification
(Bh = 0.15B). Separation efficiency decreased as the counter-cone
was lowered. Placing the entirety of the counter-cone below the
cyclone outlet (modification e) was found to be the least beneficial.
The apex angle of the counter-cone also had a significant effect.
Analyzing the proposed apex angle for particular positions of
counter-cone, it can be concluded that the angle of 85 (denoted
by 1) ensured the highest values of separation efficiency. For vari-
ants a and b (for which the highest values of separation efficiency
were obtained), this angle ensured more efficient solid particles
removal by about 0.5% (for the results of CFD) compared to an
angle of 95. Increasing the angle to 105 caused a further deterio-
ration in the value of this parameter (by 0.26% relative to the angle
95 for variant a, and 0.7% relative to angle 95 for variant b). The
deterioration of the values obtained with an increasing apex angle
is probably due to the reduction in the gap between the counter-
cone and the wall of the conical part of cyclone. This may adversely
affect the discharge of the fine particle to the lower tank. The
exception is the value obtained when the counter-cone was
located entirely in the lower tank (variant e). In this case, the high-
est value was obtained for the angle of 105.
An additional analysis of separation efficiency for the individual
diameters of solid particles was necessary to fully describe the
effect of geometrical modifications on separation efficiency. Fig. 7
shows values of the parameter for individual fractions of the solid
obtained using CFD modeling, whereas Fig. 8 demonstrates exper-
imental research results. The figure includes particle diameters of

Fig. 7. Separation efficiency of each variant according to particle diameter (CFD results).

Fig. 8. Separation efficiency of each variant according to particle diameter (Exp. results).
244 M. Wasilewski / Separation and Purification Technology 179 (2017) 236247

60 lm for better clarity (above this value, separation efficiency
equalled 100% for all variants).
The obtained values show that the separation efficiency of the
smallest particles (dp = 15 mm) was of key importance, as these
particles led to the highest differences resulting from the intro-
duced modifications. The highest separation efficiency values were
recorded for the a1 variant (59% of the CFD tests and 71% of exper-
imental research) and lowest for the c3 variant (51% for CFD and
62% for experimental). These values are considerably higher than
in the base variant (50% for CFD tests and 60% for experimental
research). Fig. 9 presents partial separation efficiency for variant
a1 and base variant. Larger fractions of solid particles caused minor
changes as a result of the introduced modifications. Changes in the
separation efficiency values for both test methods (CFD and exper-
imental) have similar trends. However, values obtained with the
experimental method are higher. This may stem from the effect
of the formation of fine particle agglomerations of the solid body
and collisions between the particles. Especially the phenomenon
of fine particles agglomeration on wall surface can play a large role
in the case. Analyzing the studies [4648], one might encounter
the term of fishhook describing the phenomenon of fine solid
particles agglomeration on cyclone walls explaining the cause
of the differences in the results of the two research methods. Gro-
nald [48] detailed in his study the three types of particles agglom-
eration: one large cluster to which the small particles adhere to, a
chain of small particles, and the many small particles that adhere
to each other. The mapping of these phenomena in the case of
CFD study is difficult. It requires the use of additional models,
which contributes to a significant increase in the load of calcula-
tion units. Some researchers undertook the study in this area. An

Fig. 9. Partial separation efficiency for variant a1 and base variant.

Fig. 10. Pressure drop values for each variant.

 M. Wasilewski / Separation and Purification Technology 179 (2017) 236247 245

example can be the study [47] in which Houben focused on the last
of the abovementioned types of particles agglomeration. It is worth
to note that this phenomenon can be very important, especially for
a large share of solid phase in a diphase mixture. Therefore, it is
reasonable to undertake further studies on the phenomenon of
particles agglomeration using CFD method.
All variants were found to have a negative effect on pressure
drop. This was a natural result of introducing an additional com-
partment along the upward vortex flow of the gas. Fig. 10 presents
pressure drop values obtained for two test methods for all ana-
lyzed geometries. Changes in the location and dimensions of the
counter-cone have a minimal effect on the obtained values for
the analysis of results obtained using the CFD method (values
remain in the range from 1367 to 1400 Pa). On the other hand,
for experimental research the obtained range was larger from
1257 Pa to 1330 Pa. Independent of the research method, similar
effects were observed in individual variants as a result of the intro-
duction of structure changes. In both cases, the lowest value was
obtained for variant a1 and the highest for variant d3. The distribu-
tion of pressure fields for these variants is presented in Fig. 11. The
conducted observations suggest that the low pressure zone is
located on the axis of the cyclone separator. The closer to the walls
of the device, the higher the pressure. The lowest pressure values
were recorded just behind the top outlet from the cyclone. When
the cone is located at a lower position (variant d3) it causes the
gas vortex to lengthen. This may translate into a lower pressure
drop value.
Fig. 12 shows vectors of the gas phase velocity near the counter-
cone. This allows the representation of the phenomenon of flow
disturbance in the region. An analysis of the figure allows an
observation of the effect of the vortex end clinging to the upper
fragment of the counter-cone. This enables a limitation of the
abduction of solid particles settling on the cyclone walls near the
Fig. 11. Distribution of static pressure for variants a1 and d3.
bottom outlet. For conventional designs, the end of the gas phase
vortex may, to a greater extent, approach the walls of the device,

Fig. 12. Velocity vectors in the lower area of the cyclone (variants a1 and d3).
246 M. Wasilewski / Separation and Purification Technology 179 (2017) 236247
Fig. 13. Concentration of solid particles in the area of the cyclone outlet (variants a1, a2 and a3).
which contributes to a decrease in separation efficiency. A similar
tendency can be observed when comparing the two design variants
presented in Fig. 12. When the counter-cone is located at a lower
position (variant d3), the end of the vortex is placed at a lower
position than for variant a1. Therefore, the vortex area, to a greater
extent, approached the walls of the cyclone separator in the area of
the bottom outlet.
The conducted research was complemented with an assess-
ment of the risk of excessive agglomeration of particles in the
lower conical part of the cyclone due to the proposed structural
modifications. As already mentioned in the study, agglomeration
phenomenon usually leads to an improved efficiency of dust
removal. However, in special cases, an excessive agglomeration
may hinder free sliding down of a set of particles that adhere
to each other. Such a situation may occur when the distance
between the surface of the counter-cone and the wall of the
cyclone is too small. In this case, analysis of particle concentration
in the area of counter-cones conducted using CFD tests proved
necessary. The point of reference were the maximum values of
the parameter for all design variants. The obtained values
remained in the range from 0.43 kg/m3 to 1.50 kg/m3. The lowest
risk (lowest values of the analyzed parameter) occur when the
counter-cone is entirely in the lower tank (e) independent of
the apex angle. On the other hand, the highest risk (highest values
of the analyzed parameter) occurs for the variants in which the
apex angle is 105 (with the exception for the above-mentioned
variant e). This particularly applies to the counter-cone located
at the highest position. This may lead to impeded sliding of the
separated particles to the lower tank. Fig. 13 presents example
concentrations of particles for cases when the counter-cone is
located at the highest level (variants a1, a2 and a3) to show the
effect of the apex angle on particle concentration. To maintain fig-
ure clarity, only the lower region of the cyclone is presented, i.e.
the region which underwent design changes. The highest concen-
tration of the solid phase for the a3 variant occurs in the bottom
area of the counter-cone. For these variants, the analyzed param-
eter values - maximum particle concentration, varied in the range
from 0.64 kg/m3 to 1.50 kg/m3.
4. Conclusions
The following conclusions can be drawn from this study into the
analysis of flow inside cyclone separators equipped with an addi-
tional structural element in the form of a counter-cone:
 The application of a counter-cone in each of the studied geo-
metrical variants led to an increase in solid particle separation.
 The location of the counter-cone was found to be the key geo-
metrical parameter. The results show that the counter-cone
should be located above the lower outlet of the cyclone. The
optimum location of the counter-cone (assuming maximization
of the separation efficiency) can be obtained when the distance
of the counter-cone base from the bottom outlet (Bh) is 0.15 B
(Bh = 0.15 B).
 The apex angle of the counter-cone also plays a significant role.
From the obtained results, it was determined that the value of
the parameter should be 85.
 Improvement in the separation efficiency was observed for par-
ticles smaller than 60 mm. This results from the fact that the
phenomenon of re-entrainment of the particles particularly
relates to fine particles and in particular particles with diameter
up to 15 mm.
 The application of an additional structural element with a high
apex angle (>100) may entail the risk of excessive agglomera-
tion of solid particles in the area of the counter-cone. In extreme
cases, this may negatively affect separation efficiency.
 A negative effect of the introduction of an additional compart-
ment is an increased pressure drop inside the cyclone separator.
Therefore, the application of a counter-cone is especially viable
if the optimization of separation efficiency is desired and as
long as the installation can withstand an increased pressure
drop.
 Validation of the results (based on the values of separation effi-
ciency and pressure drop) obtained via CFD tests and experi-
mental research allowed us to determine that numerical
models were correctly selected and the calculation and bound-
ary conditions were correctly parametrized.
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