CYCLONE DESIGN AND ANALYSIS

by Esco Engineering
179 Lansdowne Avenue,
Kingsville, Ontario N9Y 3J2 Canada Revisions
ph 519 733 3122 ### Corrected error in cell D14 on efficiency sheets
fax 519 733 6094 ### Added diagram
Contact: Neil Stone, Chief Engineer 3-Apr-99 Corrected cell O7, Efficiency 1 - thanks to Laercio Frare for pointing out this error
e-mail [email protected] 2-Dec-99 Added metric option, NV sketch
Website www.mnsi.net/~pas/esco.htm ### Corrected error in density calc (size!E9, Efficiency 1! and 2!E19)

Copyright 1997 by John Neil Stone. All rights reserved.

May be redistributed free of charge, but may not be sold without the author's explicit permission.
Provided "as is" without warranty of any kind.

HOW TO USE THIS SPREADSHEET

NOTE: This spreadsheet is for the use of knowledgeable professionals, capable of evaluating the accuracy
of the results. The author is not responsible for the use to which these results are put.

1 The 'Cyclone size' sheet calculates dimensions for various standard cyclones.
Enter the flow rate, design inlet velocity and gas density in the colored squares
and the sheet will give dimensions for five standard cyclones - two high efficiency, and
three low efficiency. The table also gives the predicted pressure drop, but be aware that this is a
very uncertain calculation (see original references). See 'Diagram' sheet for nomenclature.
On the 'Cyclone size' sheet you specify the units you want to use - metric or US Customary (Imperial)
THIS UNITS SELECTION APPLIES TO ALL SHEETS

2 Two methods are provided for calculating cyclone efficiency. You can calculate both, and
compare the results on the chart. Both sheets are set up with the same layout, so data can be copied
between sheets easily.

3 The efficiency calculation requires particle size data, cyclone dimensions, and physical property
data for the gas and the solids. The calculation assumes that the size distribution of the particles
is log normally distributed. The sheet is set up so that you can enter either the mean and standard
deviation of the log normal distribution, or the particle size data, from which these data are then calculated.

4 Procedure for efficiency calculations:

a) Enter the cyclone dimensions in cells D4 to D11. If you have calculated these using this
spreadsheet, the values in cells 13 to 20 for the selected cyclone design can be directly copied
into D4 to D11. NOTE: Paste special the values - do not just copy the cells.
b) Enter the gas property data in cells D18 to D21.
c) Enter the particulate data in cells D26 to D29. If you enter the mean and standard deviation, and
select 'N' for cell D28, then the overall efficiency is immediately given in cell H15, and the inlet and
outlet size distributions are given in cells O21 to O41 and R21 to R41.
d) If you want to use the size distribution method, enter 'Y' in cell D28, and then the range limits starting in
cell N50 and the corresponding % in range starting in O50. If you want to use more than nine ranges, you
can extend these columns to as many rows as you want - just remember to copy the formulae
in columns M and P through T into any rows that you add.
After entering the size distribution data, You have to run the regression tool. Choose the 'Tools' menu
then 'Data Analysis' then 'Regression'. For the 'X' value pick all the values in column Q, starting in Q50;
for the 'Y' values, pick all the values in column T, starting in T50. For the 'Output range' enter V48. You will
get a message saying results will overwrite cells - pick OK.
Once the regression is done, the results are available, as described in c) above.

5 The chart sheet graphs the penetration (col P = 1 - fractional efficiency) against particle size for the two efficiency
calculation methods. CAUTION: The two efficiency sheets are not linked, so make sure they are both calculating
from the same data if you want to compare the two efficiency calculations!

6 The spreadsheet is protected in order to prevent accidental overwriting of the formulae.

However, there is no password needed to unprotect it, so you can freely adapt it to suit your purposes.

04/27/2025 877946429.xlsx
 DEFINITION OF CYCLONE DIMENSIONS

DD

De
b De
De

a S
h

NV = Neutral vane
Extension of inner
side if inlet to centerline
of cyclone

B ELEVATION PLAN

04/27/2025 877946429.xlsx
 Cyclone size

CALCULATE DIMENSIONS FOR CYCLONE NOTES Sheet 1 is for sizing

Sheets 2/3 are for efficiency (alternates)
Sheet 4 are charts of results of sheets 2/3

SPECIFY UNITS (U = US CUSTOMARY[IMPERIAL], M = METRIC) M This setting applies to the whole spreadshe
Input Working
Flow rate Q m^3/h 23000 13532 cfm
Design inlet vel vi m/s 20 66 fps vertical vel. (m/s)2.545581
Gas density rg kg/m^3 1.2000 0.075 pcf
Inlet area m^2 0.319444 3.44 sf
PD parameter 2.46 cm water

Dimensions Type of cyclone

Stairmand Swift Lapple Swift Peterson/Whitby
HE HE LE LE LE

Dia D m 1.79 1.86 1.60 1.60 1.62

Inlet ht a m 0.89 0.82 0.80 0.80 0.95 Copy one col of outline
Inlet width b m 0.36 0.39 0.40 0.40 0.34 data (copy values only)
Outlet length S m 0.89 0.93 1.00 0.96 0.95 to efficiency sheet.
Outlet dia De m 0.89 0.74 0.80 0.80 0.81
Cylinder ht h m 2.68 2.60 3.20 2.80 2.16
Overall ht H m 7.15 7.25 6.40 6.00 5.15
Dust outlet dia B m 0.67 0.74 0.40 0.64 0.81
# vel hds Nh 5.14 4.87 4.49 4.69 4.77
Press drop, no NV cm water 12.62 11.97 11.02 11.53 11.71
Press drop, with NV cm water 5.92 5.61 5.17 5.40 5.49
Press drop, no NV Pa 1238.07 1174.36 1081.23 1130.69 1149.00 1485.68
Press drop, with NV Pa 580.34 550.48 506.83 530.01 538.59

Cyclone data from "New design approach boosts cyclone efficiency", W.H.Koch and W.Licht, Chem Eng Nov 7 1977, 80
Pressure drop vel head correlation from "A better way to calculate cyclone pressure drop" J.Casal and J.M. Martinez-Benet, C

Page 3
 Cyclone size

ncy (alternates)
ults of sheets 2/3

plies to the whole spreadsheet

33.92857 13261.22

Di?n tích c?a vào

Thi?t b? W L A (m2) v (m/s)
C1 1.4 3.4 4.76 22.17554
C2 1.7 3.1 5.27 20.02952
C3 1.9 3.25 6.175 17.09402
C4 1.95 3.3 6.435 16.40335
C5 1.94 3.4 6.596 16.00296

Copy one col of outline

data (copy values only)
to efficiency sheet.

7428.41 9828.41 81.54884

em Eng Nov 7 1977, 80

l and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99

Page 4
 Efficiency 1

CALCULATE EFFICIENCY FOR CYCLONE (method 1)

CALCULATIONS ARE IN METRIC UNITS
Geometry Input Working Limits/warnings
Dia D m 1.39 4.56
Inlet ht a m 0.70 27.37
Inlet width b m 0.28 10.95
Outlet length S m 0.70 2.28
Oulet dia De m 0.70 27.37
Cylinder ht h m 2.09 6.84
Overall ht H m 5.56 18.24
Dust outlet dia B m 0.52 20.53
Natural length L m 3.45 11.30
# vel hds Nh 5.14
Press drop, no NV cm water 13.62
Press drop, with NV cm water 6.39 Overall efficiency 89.7

Gas data
Flow rate Q m^3/h 16000 9413.33 156.8889 cfs
Density rg kg/m^3 0.9800 0.0612 0.062 air @ 1 atm, spec'd temp
Viscosity u cP 0.010 0.010 6.72E-06 lb/f-s
Temperature T °C 80 176
Salt. temp fact fT 1.00 1.00
Salt dens. fact fp 1.00 1.00

Particle data Value used

Log mean dia dp µm 150 11.905565
Log SD sd µm 3 3.1077764
Use distribution? (Y/N) y If yes, run regression - adjust input ranges (cols Q,T) to
Specific gravity 1.3 81.12 pcf

References
Efficiency from "New design approach boosts cyclone efficiency",
W.H.Koch and W.Licht, Chem Eng Nov 7 1977, 80
Pressure drop vel head correlation from "A better way to calculate cyclone pressure
drop" J.Casal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99

Statistical correlation constants

2.515517
0.802853
0.010328
1.432788
0.189269
0.001308

Page 5
 Efficiency 1

Calculated data

Log SD 1.133907
Inlet velocity fps 75.40168
Ratio inlet/salt vel 1.782077
Corrected L ft 11.30
Core dia ft 2.88
Eff vol cf 293.2211
Inlet vol cf 13.96024
Cycl const Kc 1.693093
G 1353.099
Vortex exp n+1 1.683096

Efficiency calcs
Dia, um
Min Max Inlet massPenetration Outlet amt
fraction
0 0.4 0.0020 0.8359 0.0017
0.4 0.6 0.0028 0.6374 0.0018
0.6 1.2 0.0168 0.5344 0.0090
1.2 1.8 0.0260 0.4221 0.0110
1.8 2.4 0.0309 0.3470 0.0107
2.4 3 0.0330 0.2918 0.0096
3 3.6 0.0336 0.2493 0.0084
ust input ranges (cols Q,T) to suit data 3.6 4.2 0.0333 0.2154 0.0072
4.2 4.8 0.0324 0.1878 0.0061
4.8 7 0.1080 0.1443 0.0156
7 10 0.1197 0.0905 0.0108
10 13 0.0926 0.0554 0.0051
13 16 0.0724 0.0357 0.0026
16 22 0.1052 0.0210 0.0022
22 28 0.0698 0.0103 0.0007
28 34 0.0486 0.0054 0.0003
34 40 0.0351 0.0030 0.0001
40 49 0.0372 0.0016 0.0001
49 64 0.0384 0.0006 0.0000
64 79 0.0220 0.0002 0.0000
79 94 0.0136 0.0001 0.0000
0.9736 0.1029
Overall efficiency 89.7

Page 6
 Efficiency 1

Distribution data
Size, um Cum % % in ln dia max
Min Max range
0 2 6 6 0.693147
2 3 11 5 1.098612
3 5 22 11 1.609438
5 10 44 22 2.302585
10 20 67 23 2.995732
20 30 80 13 3.401197
30 40 85 5 3.688879
40 50 90 5 3.912023
50 100 97 7 4.60517

Page 7
 Efficiency 1

Int calcs
Distribution Relax time Penetration
Outlet mass fl fh tl th pl ph
fraction
0.0162 0 0.009991 0 1.16E-06 1 0.67187
0.0175 0.009991 0.018218 1.16E-06 2.6E-06 0.67187 0.60289
0.0873 0.018218 0.037832 2.6E-06 1E-05 0.60289 0.465857
0.1066 0.037832 0.048784 1E-05 2.34E-05 0.465857 0.378343
0.1040 0.048784 0.054068 2.34E-05 4.16E-05 0.378343 0.315648
0.0936 0.054068 0.056018 4.16E-05 6.5E-05 0.315648 0.268043
0.0814 0.056018 0.05603 6.5E-05 9.36E-05 0.268043 0.230561
0.0697 0.05603 0.054921 9.36E-05 0.000127 0.230561 0.200294
0.0592 0.054921 0.053178 0.000127 0.000166 0.200294 0.175391
0.1515 0.053178 0.04504 0.000166 0.000354 0.175391 0.113251
0.1052 0.04504 0.034769 0.000354 0.000722 0.113251 0.067726
0.0498 0.034769 0.026983 0.000722 0.00122 0.067726 0.043005
0.0251 0.026983 0.021255 0.00122 0.001848 0.043005 0.028451
0.0215 0.021255 0.013811 0.001848 0.003494 0.028451 0.013555
0.0070 0.013811 0.009455 0.003494 0.00566 0.013555 0.006988
0.0025 0.009455 0.006743 0.00566 0.008346 0.006988 0.003809
0.0010 0.006743 0.004969 0.008346 0.011551 0.003809 0.002165
0.0006 0.004969 0.003297 0.011551 0.017334 0.002165 0.000986
0.0002 0.003297 0.00183 0.017334 0.029571 0.000986 0.0003
0.0000 0.00183 0.001106 0.029571 0.045056 0.0003 0.000102
0.0000 0.001106 0.000711 0.045056 0.06379 0.000102 3.74E-05
1.0000
%

Page 8
 Efficiency 1

ln dia max SUMMARY OUTPUT

2.372092 1.555097 -1.5551 Regression Statistics

2.101083 1.226669 -1.22667 Multiple R 0.999874
1.740188 0.77197 -0.77197 R Square 0.999749
1.28139 0.150652 -0.15065 Adjusted 0.999713
1.489069 0.43948 0.43948 Standard E0.022894
1.794123 0.841457 0.841457 Observati 9
1.947881 1.036431 1.036431
2.145966 1.281729 1.281729 ANOVA
2.648229 1.881213 1.881213 df SS MS F Significance F
Regressio 1 14.59118 14.59118 27837.76 7.33E-14
Residual 7 0.003669 0.000524
Total 8 14.59485

Coefficients
Standard Errort Stat P-value Lower 95%Upper 95%
Intercept 2.477006 0.007748 319.6806 7.74E-16 2.458684 2.495328
X Variable1.133907 0.006796 166.8465 7.33E-14 1.117837 1.149978

Page 9
 Efficiency 1

Lower 95.000%
Upper 95.000%
2.458684 2.495328
1.117837 1.149978

Page 10
 Efficiency 2

CALCULATE EFFICIENCY FOR CYCLONE (method 2)

CALCULATIONS ARE IN METRIC UNITS
Geometry Input Working Limits/warnings
Dia D m 1.39 4.56
Inlet ht a m 0.70 27.37
Inlet width b m 0.28 10.95
Outlet length S m 0.70 2.28
Oulet dia De m 0.70 27.37
Cylinder ht h m 2.09 6.84
Overall ht H m 5.56 18.24
Dust outlet dia B m 0.52 20.53
Natural length L m 3.45 11.30
# vel hds Nh 5.14
Press drop, no NV cm water 13.62
Press drop, with NV cm water 6.39 Overall efficiency 94.7

Gas data
Flow rate Q m^3/h 16000 9413.33 156.8889 cfs
Density rg kg/m^3 0.9800 0.0612 0.062 air @ 1 atm, spec'd temp
Viscosity u cP 0.010 0.010 6.72E-06 lb/f-s
Temperature T °C 80 176
Salt. temp fact fT 1.00 1.00
Salt dens. fact fp 1.00 1.00

Particle data Value used

Log mean dia dp um 24 11.905565
Log SD sd um 3 3.1077764
Use distribution? (Y/N) y If yes, run regression - adjust input ranges (cols Q,T) to sui
Specific gravity 5 312 pcf
Re-entrainment coefalpha 0 default = 0 (see original paper for definition)

References
Efficiency from "A new collection theory of cyclone separators",
L.Enliang & W Yingmin, AIChEJ Vol 35, #4 April 1989, 666
Pressure drop vel head correlation from "A better way to calculate cyclone pressure
drop" J.Casal and J.M. Martinez-Benet, Chem Eng, Jan 24, 1983, 99

Statistical correlation constants

2.515517
0.802853
0.010328
1.432788
0.189269
0.001308

Page 11
 Efficiency 2

Calculated data

Log SD 1.133907
Inlet velocity fps 75.40168
Ratio inlet/salt vel 1.137199
Vortex exp 1-n 0.181058
theta 37.41076
rw 2.28016
rn 1.140369
uw 115.8197
Dr 0.343226

Efficiency calcs
Dia, um
Min Max Inlet massPenetration Outlet amtOutlet mass
fraction fraction
0 0.4 0.0020 0.9993 0.0020 0.0377
0.4 0.6 0.0028 0.9956 0.0028 0.0531
0.6 1.2 0.0168 0.9405 0.0158 0.2989
1.2 1.8 0.0260 0.7188 0.0187 0.3530
1.8 2.4 0.0309 0.3499 0.0108 0.2041
2.4 3 0.0330 0.0802 0.0026 0.0500
3 3.6 0.0336 0.0049 0.0002 0.0031
ust input ranges (cols Q,T) to suit data 3.6 4.2 0.0333 0.0000 0.0000 0.0000
4.2 4.8 0.0324 0.0000 0.0000 0.0000
4.8 7 0.1080 0.0000 0.0000 0.0000
7 10 0.1197 0.0000 0.0000 0.0000
10 13 0.0926 0.0000 0.0000 0.0000
13 16 0.0724 0.0000 0.0000 0.0000
16 22 0.1052 0.0000 0.0000 0.0000
22 28 0.0698 0.0000 0.0000 0.0000
28 34 0.0486 0.0000 0.0000 0.0000
34 40 0.0351 0.0000 0.0000 0.0000
40 49 0.0372 0.0000 0.0000 0.0000
49 64 0.0384 0.0000 0.0000 0.0000
64 79 0.0220 0.0000 0.0000 0.0000
79 94 0.0136 0.0000 0.0000 0.0000
0.9736 0.0529 1.0000
Overall efficiency 94.7 %

Page 12
 Efficiency 2

Distribution data
Size, um Cum % % in ln dia max
Min Max range
0 2 6 6 0.693147 2.372092 1.555097
2 3 11 5 1.098612 2.101083 1.226669
3 5 22 11 1.609438 1.740188 0.77197
5 10 44 22 2.302585 1.28139 0.150652
10 20 67 23 2.995732 1.489069 0.43948
20 30 80 13 3.401197 1.794123 0.841457
30 40 85 5 3.688879 1.947881 1.036431
40 50 90 5 3.912023 2.145966 1.281729
50 100 97 7 4.60517 2.648229 1.881213

Page 13
 Efficiency 2

Int calcs
Distribution Penetration
fl fh kh wh lh pl ph

0 0.009991 0.001009 0.026094 3.91E-05 1 0.99854

0.009991 0.018218 0.00227 0.058712 0.000198 0.99854 0.99263
0.018218 0.037832 0.009081 0.23485 0.003164 0.99263 0.888383
0.037832 0.048784 0.020432 0.528411 0.016016 0.888383 0.549272
0.048784 0.054068 0.036323 0.939398 0.050618 0.549272 0.150522
0.054068 0.056018 0.056755 1.46781 0.123578 0.150522 0.009822
0.056018 0.05603 0.081727 2.113646 0.256252 0.009822 6.86E-05
0.05603 0.054921 0.11124 2.876907 0.474738 6.86E-05 1.94E-08
0.054921 0.053178 0.145293 3.757593 0.809882 1.94E-08 6.94E-14
0.053178 0.04504 0.309 7.991408 3.663103 6.94E-14 3.05E-60
0.04504 0.034769 0.630613 16.309 15.25657 3.05E-60 1E-248
0.034769 0.026983 1.065736 27.5622 43.57429 1E-248 0
0.026983 0.021255 1.61437 41.75103 99.98547 0 0
0.021255 0.013811 3.052168 78.93554 357.3943 0 0
0.013811 0.009455 4.944008 127.8625 937.7543 0 0
0.009455 0.006743 7.289889 188.532 2038.791 0 0
0.006743 0.004969 10.08981 260.9439 3905.682 0 0
0.004969 0.003297 15.14102 391.579 8795.11 0 0
0.003297 0.00183 25.82992 668.0165 25596.28 0 0
0.00183 0.001106 39.35657 1017.844 59424.47 0 0
0.001106 0.000711 55.72098 1441.063 119116 0 0

Page 14
 Efficiency 2

SUMMARY OUTPUT

-1.5551 Regression Statistics

-1.22667 Multiple R 0.999874
-0.77197 R Square 0.999749
-0.15065 Adjusted 0.999713
0.43948 Standard E0.022894
0.841457 Observati 9
1.036431
1.281729 ANOVA
1.881213 df SS MS F Significance F
Regressio 1 14.59118 14.59118 27837.76 7.33E-14
Residual 7 0.003669 0.000524
Total 8 14.59485

Coefficients
Standard Errort Stat P-value Lower 95%Upper 95%
Lower 95.000%
Upper 95.000%
Intercept 2.477006 0.007748 319.6806 7.74E-16 2.458684 2.495328 2.458684 2.495328
X Variable1.133907 0.006796 166.8465 7.33E-14 1.117837 1.149978 1.117837 1.149978

Page 15
 Efficiency 2

Upper 95.000%

Page 16
 charts

EFFICIENCY

Koch and Licht

0.9

0.8

0.7

0.6
Penetration

0.5

0.4

0.3

0.2

0.1

0
0 5 10 15 20 25 30

Particle dia um

Page 17
 charts

25 30

Page 18