National Institute of Technology Calicut

Department of Chemical Engineering

NATIONAL INSTITUE OF TECHNOLOGY CALICUT

A Deemed University

NIT CAMPUS P.O. KOZHIKODE-673601

KERALA ,INDIA

CH2093 MECHANICAL OPERATIONS LABORATORY

DEPARTMENT OF CHEMICAL ENGINEERING

APRIL 2015

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

NATIONAL INSTITUTE OF TECHNOLOGY, CALICUT

Department of Chemical Engineering

MECHANICAL OPERATIONS LAB PROJECT

COMPARING THE EFFICIENCY OF CYCLONE SEPARATOR

ON DIFFERENT TYPES OF MATERIALS

Submitted By

Navaneeth Krishnan A R

Naven kalirana

Neethu Sreedhar

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

CYCLONE SEPARATOR

AIM:

To find out the inlet gas velocity, pressure drop and collection efficiency of coal powder and
brick powder for a given cyclone separator.

THEORY:

. Cyclone is the most widely used separation equipment for separating dust or mist from gas. It
consists of a vertical cylinder with a conical bottom, a tangential inlet near the top and an outlet
for dust at the bottom of cone. The centrifugal force developed in the vortex send to move the
particle radially towards the wall and particle that reach the wall, slide down.

As the cyclone is essentially a two phase particle-fluid system, fluid mechanics and particle
transport equations can be used to describe the behavior of a cyclone. The air in a cyclone is
initially introduced tangentially into the cyclone with an inlet velocity . Assuming that the
particle is spherical, a simple analysis to calculate critical separation particle sizes can be
established.

If one considers an isolated particle circling in the upper cylindrical component of the cyclone at
a rotational radius of from the cyclone's central axis, the particle is therefore subjected to drag,
centrifugal, and buoyant forces. Given that the fluid velocity is moving in a spiral the gas
velocity can be broken into two component velocities: a tangential component, , and an
outward radial velocity component . Assuming Stokes' law, the drag force in the outward
radial direction that is opposing the outward velocity on any particle in the inlet stream is:

Using as the particles density, the centrifugal component in the outward radial direction is:

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

Schematic Diagram:

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

The buoyant force component is in the inward radial direction. It is in the opposite direction to
the particle's centrifugal force because it is on a volume of fluid that is missing compared to the
surrounding fluid. Using for the density of the fluid, the buoyant force is:

In this case, is equal to the volume of the particle (as opposed to the velocity).
Determining the outward radial motion of each particle is found by setting Newton's second law
of motion equal to the sum of these forces:

To simplify this, we can assume the particle under consideration has reached "terminal velocity",

i.e., that its acceleration is zero. This occurs when the radial velocity has caused enough
drag force to counter the centrifugal and buoyancy forces. This simplification changes our
equation to:

Solving for we have

Notice 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 (+), away
from the center. In most cases, this solution is used as guidance in designing a separator, while
actual performance is evaluated and modified empirically.

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

OBSERVATIONS:

BRICK POWDER

Sl h1 h2 h 1 - h2 Pressur Flow Velocit Weight Efficien

No e Head, Rate, y Collect cy
. (cm) (cm) (cm) H ed,
Q V %
(m) (g)
(m3/s) (m/s)

1. 3.7 3.1 0.6 0.7268 1.6212 0.0117 49 98

2. 3.7 3.1 0.6 0.7268 1.6212 0.0117 47 94

3. 3.9 3.0 0.9 1.0903 1.9874 0.0143 47 94

4. 4.2 2.7 1.5 1.8170 2.5625 0.0185 46 92

5. 4.6 2.3 2.3 2.9070 3.1725 0.0229 44 90

COAL POWDER

Sl h1 h2 h 1 - h2 Pressur Flow Velocit Weight Efficien

No e Head, Rate, y Collect cy
. (cm) (cm) (cm) H ed,
Q V %
(m) (g)
(m3/s) (m/s)

1. 3.7 3.2 0.5 0.6057 1.4801 0.0106 44 88

2. 4.0 2.8 1.2 1.4537 2.2850 0.0165 37 74

3. 4.2 2.7 1.5 1.817 2.5629 0.0185 34 68

4. 4.5 2.4 2.1 2.540 3.0201 0.0218 32 64

5. 4.6 2.3 2.3 2.786 3.1725 0.0229 30 60

DATA GIVEN:

Diameter of inlet air pipe = 4.2 cm = 4.2 10-2 m

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

Density of manometric fluid, m = 1000kg/m3

Density of air, a = 1.21 kg/m3
Acceleration due to gravity, g = 9.81m/s2

PROCEDURE:

1. Prepare a feed stock of cement dust or fly ash with constant average particle size.
2. Run the cyclone with pure at fixed speed.
3. Now feed the dust particles of one particle size; at 100gms.
4. Collect the solid at the solid outlet.
5. Measure the weight of particles collected.
6. Calculate collection efficiency.
7. Repeat the experiment for different air velocity.

FORMULAE:

H=

Where, (h1-h2) is head difference of air in cm.

m is density of manometric fluid
a is density of air.
H is difference in head for pressure drop

Velocity of air

V= in m/s

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

MODEL CALCULATIONS

Brick Powder

For Serial no: 1

h1 = 3.7 cm

h2 = 3.1 cm

Where h1 and h2 are heights of liquids o two monometers limits.

Pressure Head; H = [(h1 h2)/100]*[(m/ a -1 )]

= [(3.7-3.1)/100]*[(1000/1.21-1)]

-5
= 0.7268*10 m of water

where m = Density of water (kg/m3)

a = Density of Air

Velocity (V)= Cv

=0.98(2*9.81*0.6258*10-5 )0.5

=0.011702 m/s

Where Cv is co-efficient of velocity

Cv = Vactual/Vtheoretical

=0.98

g = Acceleration due to gravity

Area of Suction of Air = D2/4

=*(0.042)2/4

10

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

=1.385*10-3 m2

Flow Rate Q= A*V

=1.385*10-3*0.011702

=1.6212*10-5 m3/s

Coal powder

For Serial no: 1

h1 = 3.7 cm

h2 = 3.2 cm

Where h1 and h2 are heights of liquids o two monometers limits.

Pressure Head; H = [(h1 h2)/100]*[(m/ a -1 )]

=[(3.7-3.2)/100]*[(1000/1.21-1)]

-6
=6.057*10 m of water

where m = Density of water (kg/m3)

a = Density of Air

Velocity (V)= Cv

=0.98(2*9.81*6.057*10-6 ).5

=0.0106m/s

Where Cv is co-efficient of velocity

Cv =Vactual/Vtheoretical

=0.98

g = Acceleration due to gravity

Area of Suction of Air = D2/4

11

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

=*(0.042)2/4

=1.385*10-3 m2

Flow Rate Q= A*V

=1.385*10-3*0.0106

=1.4801*10-5 m3/s

CALCULATIONS:

BRICK POWDER
1.
Collection of efficiency of cyclone separator, E = (98+94+94+92+90)/5

=93.6%
2.
Average Inlet Gas Velocity Vaverage = (0.011702+0.011702+0.01435+0.0185+0.0229) /5
= 0.01583 m/s
3.
Average Pressure Drop; Haverage = (0.7268+0.7268+1.0903+1.817+2.786)*10-5
= 1.4293* 10-5 m of water

COAL POWDER
4.
Collection of efficiency of cyclone separator, E = (88+74+68+64+60)/5

=70.8%
5.
Average Inlet Gas Velocity Vaverage = (0.0106+0.0165+0.0185+0.0218+0.0229)/5
= 0.01914m/s
6.
Average Pressure Drop; Haverage = (0.6057+1.4537+1.817+2.54+2.786)*10-5/5

= 1.8404* 10-5 m of water

12

CH2093 Mechanical Operations Laboratory

National Institute of Technology Calicut
Department of Chemical Engineering

RESULT:

1. Collection efficiency of given cyclone separator for coal = 70.80%.

Collection efficiency of given cyclone separator for brick powder =93.6%

2. The inlet gas velocity for coal = 0.01914 m/s.

The inlet gas velocity for brick powder = 0.01583 m/s
3. The pressure head for coal is = 1.675*10-5 m of water
4. The pressure head for brick powder is = 1.4293*10-5 m of water

INFERENCE :

With an increase in density of the sample, collection efficiency increases. Higher

efficiencies were observed with brick powder compared to coal powder .This is due to the
fact that higher density particles have greater tendency to settle down compared to the
lower ones. For the same velocity, highly dense particles are removed with higher
collection efficiency compare to low dense particles. At high velocities, the efficiency
decreases instead of increasing due to carry over solid particles along with the exit gas.

13

CH2093 Mechanical Operations Laboratory