KWAME NKRUMAH UNIVERSITY OF SCIENCE AND

TECHNOLOGY (KNUST)
KUMASI (GHANA)

COLLEGE OF ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
BSC. PETROCHEMICAL ENGINEERING

LABORATORY REPORT

TITTLE: GAS CYCLONE

PRESENTED BY GROUP 1B
Names Index No. Signature
1. Serwonu Ebenezer 8371519

2. Ansu Sylvester 8366119

3. Adjeiwaa Sandra Ameyaw 8364319

4. Opoku Richard
5. Owusu Kwarteng Emmanuel
6. Nathaniel

Table of Content

s
GROUP 1B MEMBERS............................................................................................................1
1.0 AIMS.......................................................................................................................................2
2.0 OBJECTIVES............................................................................................................................3
3.0 INTRODUCTION......................................................................................................................3
4.0 CHEMICALS AND APPARATUS................................................................................................9
5.0 PROCEDURE............................................................................................................................9
6.0 TABLE OF RESULTS AND CALCULATION................................................................................10
8.0 DISCUSSION..........................................................................................................................15
9.0 PRECAUTIONS.......................................................................................................................16
10.0 ERROR ANALYSIS................................................................................................................16
11.0 CONCLUSION......................................................................................................................16
12.0 POST LAB............................................................................................................................17
13.0 REFERENCES.......................................................................................................................17
1.0 AIMS

7. To determine how the solid material content and the airflow volume affect
 Pressure loss at the gas cyclone
 Degree of separation
 Separation function and separation size

8. To compare pressure loss and degree of separation with theoretically calculated

values.

2.0 OBJECTIVES

1. To demonstrate the cyclone separation operation and measure the pressure drop
against input velocity.
2. To determine the cyclone separation efficiency on different air flow rate.
3. To evaluate the relationship between separation efficiency and flow rate.
4. To study the effect of cyclone body diameter upon collection efficiency.

3.0 INTRODUCTION

A gas cyclone is a stationary mechanical device that utilizes centrifugal force to

separate solid or liquid particles from a carrier gas. The gas cyclones belong to the type
of centrifugal separators. The flow enters near the top through the tangential inlet,
which gives rise to an axially descending spiral of gas and a centrifugal force field that
causes the incoming particles to concentrate along, and spiral down the inner walls of
the cyclone separator. The collected particulates are allowed to exit out an underflow
pipe while the gas phase reverses its axial direction of flow and exits out through the
vortex finder (gas outlet tube). The cyclone separator is one of the most efficient and
robust dust separators. Its robustness results from lack of moving parts and the ability to
withstand harsh operating environments. Moreover, cyclones are well suited for high
pressure and temperature applications. Centrifugal collectors use cyclonic action to
separate dust particles from the gas stream. In a typical cyclone, the dust gas stream
enters tangentially forcing the flow into a spiral movement. The centrifugal force
created by the circular flow throws the dust particles toward the wall of the cyclone.
This process is called Impartation. After the impartation, the particles fall into a hopper
located underneath. Interception also occurs when the particles collide with one another.
The most common types of centrifugal or inertial collectors in use today are single-
cyclone separators and multiple-cyclone separators. Single-cyclone separators create a
dual vortex to separate the dust from the gas. The main vortex, also called the primary
vortex, spirals downward and carries most of the heavier particles. The secondary
vortex, created near the bottom of the cyclone, spirals upward and carries finer dust
particles. Multiple-cyclone separators consist of a number of small-diameter cyclones,
operating in parallel and having a common gas inlet and outlet. Multicyclones operate
on the same principle as single cyclones, creating a main downward vortex and an
ascending inner vortex.

Figure 3.1: Typical cyclone separator

Some advantages of the separator cyclones are:

• The collected product remains dry and, normally useful.
• Low capital investment and maintenance costs in most applications.
• Very compact in most applications.
• Can be used under extreme processing conditions, in particular at high temperatures
and pressures and with chemically aggressive feeds.
• No moving parts.
• Very robust.
• Can be constructed from mostly any material suitable for the intended service
including plate steel, casting metals, alloys, aluminium, plastics, ceramics, etc.
• Can be equipped with erosion resistant or corrosion resistant or particle repelling type
liners, such as Teflon. Internal surfaces may be electro-polished to help combat fouling.
• Can be fabricated from plate metal or, in the case of smaller units, cast in moulds.
• Can, in some processes, handle sticky or tacky solids with proper liquid irrigation
• Can separate either solids or liquid particulates; sometimes both in combination with
proper design.
Some disadvantages of cyclones are:
• Low efficiency for particle sizes below their cut-off diameter when operated under low
solids-loading conditions.
• Usually higher-pressure loss than other separator types, including bag filters and low
pressure drop scrubbers.
• Subject to erosive wear and fouling if solids being processed are abrasive or ‘sticky’.
• Can operate below expectations if not designed and operated properly.
Although this problem, as well as the erosion and fouling problem mentioned above, is
not unique to cyclones.

Figure 3.2: Applications of cyclone separator

The CE 235 GAS CYCLONE

One area of application of gas cyclones is the pre-filtration of solids from gases. Gas
cyclones have no moving parts, and so are low-maintenance systems. Gas cyclones can
also be used in conjunction with high gas temperatures. For these reasons they are in
widespread use.
A disperser or brush is used to disperse the feed material (quartz powder recommended)
finely in an air flow. The air flow laden with solid material (raw gas) in this way is fed
tangentially into the cyclone at the top. In the cyclone, the air flow moves downwards as
a rotating primary vortex. At the bottom of the cyclone the vortex is reversed. In the
middle of the cyclone it moves as a secondary vortex back up towards the immersion
tube, where the cleaned gas emerges from the cyclone. The main separation process
takes place in the primary vortex. Owing to the centrifugal forces and the difference in
density between the air and the solid, the coarse solid particles move towards the wall.
They slide down the wall and are collected in a tank at the bottom of the cyclone. No
complete separation of the entire solid material takes place. The fine particles which are
smaller than the separation sizes are ideally discharged from the immersion tube at the
top with the secondary vortex. This fine material is separated out of the air flow by a
filter. The separation size defines the theoretical boundary between the fine and coarse
material. The solid content of the raw gas can be adjusted by means of the disperser and
a valve for the volumetric air flow rate. To prevent loading of the air flow with particles
upstream of the disperser, the drawn-in room air is filtered. A fan generates the air flow.
Pressure measurement points at the relevant positions in the trainer enable to determine
the pressure loss. Using a suitable analysis device (such as a diffraction spectrometer), a
separation function can be produced and the separation size determined.

Figure 3.3 Diagram of the CE 235 Gas Cyclone.

Figure 3.4 Shows the flowchart for the process

1. Air inlet with filter
2. Valve (air flow rate)
3. Feed material tank
 4. Transport unit
5. Disperser,
6. Coarse material tank
7. Gas cyclone
8. Fine material filter
9. Fan
Depends on volumetric flow rate, differential pressure, temperature

Figure 3.5 Flow condition in a gas cyclone.

1. Raw gas inlet
2. Separated solid
3. Collected solids
4. Secondary vortex
5. Primary vortex,
6. Immersion tube
7. Cleaned gas

4.0 CHEMICALS AND APPARATUS

 1 laboratory scale up to 1000g
 1 spatula
 Several sheets of paper
 Several cellulose cloths
 Electronic beam
 CE 235 Gas Cyclone

5.0 PROCEDURE
1. The feed cylinder was placed on a firm surface and the plunger was placed in the feed
cylinder with the Phillips screw facing upwards
2. The tamper was used to press down on the plunger until it touched the surface.
3. The empty feed cylinder was weighed with the plunger, a sheet of paper, the coarse
material cylinder with the empty tank for coarse material.
a. A spatula was used to pour approximately 2g of feed material into the feed
cylinder by weighing with the analytical balance.
b. Carefully and only by its own weight (i.e. no pressure) repeatedly, the tamper
was placed on top of the feed material in the feed cylinder material.
c. This step was repeated 10-12 times until the feed cylinder was completely
filled.
d. The feed cylinder filled with feed material was weighed. The mass of the
filled feed cylinder was compared with the mass of the empty feed cylinder from step 2.
There was about 24g of feed in the feed cylinder.
e. The main switch on the trainer was turned to "OFF".
f. The feed cylinder was placed into the brush housing from below and the feed
cylinder was screwed in place with 2 knurled screws.
g. The switch for the brush was set to "Auto".
h. The desired feed rate on the potentiometer was adjusted (3, 6 and 10 for each
reproducible volume flow).
i. The main switch on the trainer was turned to "ON".
j. One stage on the air suction fan was turned on.
k. The desired volume flow was set (10, 20, 30, 40, 50 and 60 m 3/h) with the
gate valve. Another stage on the air suction fan was turned on. Three values were
reproduced for each volume flow.

Note down the volume flow, temperature and differential pressure on the worksheet.
The switch for the feed was turned to "Forward". The "feed" lamp turned white.
The values of the displays for volume flow, feed, temperature and differential pressure
were noted down.
 6.0 TABLE OF RESULTS AND CALCULATION

TABLE 1: Worksheet for conducting the experiment

Unit Measurement Measurement Measurement Average

no. no. no.

Preparation of the experiment (without feed

material)

Volume flow Vgas m3/h 10.0000 10.0000 10.0000

Temperature o
C 25.3000 25.3000 25.4000
Differential pressure ∆p mbar 2.1000 2.1000 2.3000

Conducting the experiment (with feed

material)

Feed (potentiometer) - 3.0000 6.0000 10.0000

Feed vfeed mm/s 1.3000 1.9000 3.2000

Volume flow Vgas m3/h 10.0000 10.0000 10.0000

Temperature oC 25.3000 25.4000 25.5000
Differential pressure ∆p mbar 1.7000 1.6000 1.4000
Calculation of the separation size xs
Mass of feed material mfeed g 23.4500 23.6100 22.9800 23.2
Mass of coarse material mcoarse g 19.9800 20.1100 20.2100 20.1
Mass flow of the feed material mfeed g/s 0.3387 0.4984 0.8171
Load µ - 0.1017 0.1497 0.2453 0.1656
Separation size xs mm 0.0003659 0.00037685 0.00039405 0.0003789
Calculating the total degree
of separation E

Limit load µlimit - 0.0199 0.0202 0.0207

Total degree of separation E measured - 0.8520 0.8518 0.8795
Total degree of separation E calculated - 110.4322 74.6695 45.4118
Calculating the pressure loss ∆p
Pressure loss ∆p calculated mbar 2.1433 2.0673 1.9482

TABLE 2: Worksheet for conducting the experiment

 Unit Measurement Measurement Measurement Average
no. no. no.

Preparation of the experiment

(without feed material)

Volume flow Vgas m3/h 20.0000 20.0000 20.0000

Temperature oC 25.7000 25.7000 25.7000
Differential pressure ∆p mbar 7.3000 7.3000 7.3000
Conducting the experiment (with feed
material)

Feed (potentiometer) - 3.0000 6.0000 10.0000

Feed vfeed mm/s 1.4000 2.0000 3.3000
Volume flow Vgas m3/h 20.0000 20.0000 20.0000
Temperature o
C 25.8000 25.8000 25.9000
Differential pressure ∆p mbar 4.4000 4.1000 3.7000
Calculation of the separation size xs
Mass of feed material mfeed g 23.8900 23.4500 24.0000 23.78
Mass of coarse material mcoarse g 20.1200 19.7600 20.4500 20.11
Mass flow of the feed material mfeed g/s 0.3716 0.5211 0.8800
Load µ - 0.0558 0.0782 0.1321 0.0887
Separation size xs mm 0.00024989 0.00025431 0.00026315 0.00025578
Calculating the total
degree of separation E

Limit load µlimit - 0.0196 0.0198 0.0201

Total degree of separation E - 0.8520 0.8518 0.8795
measured
Total degree of separation E - 269.8381 192.0058 112.5950
calculated
Calculating the pressure loss ∆p
Pressure loss ∆p calculated mbar 8.8751 8.6474 8.2389

TABLE 3: Worksheet for conducting the experiment

 Unit Measurement Measurement no. Measurement
no. no.

Preparation of the experiment

(without feed material)

Volume flow Vgas m3/h 30.0000 30.0000 30.0000

Temperature oC 25.5000 25.6000 25.6000

Differential pressure ∆p mbar 11.5000 11.4000 11.4000

Conducting the experiment (with feed

material)

Feed (potentiometer) - 3.0000 6.0000 10.0000

Feed vfeed mm/s 2.0000 2.5000 4.5000

Volume flow Vgas m3/h 30.0000 30.0000 30.0000

Temperature 0
C 25.5000 25.7000 25.7000

Differential pressure ∆p mbar 8.2000 7.5000 6.7000

Calculation of the separation size xs

Mass of feed material mfeed g 24.4400 23.9800 24.2100

Mass of coarse material mcoarse g 21.2300 21.1600 20.7700

Mass flow of the feed material mfeed g/s 0.5431 0.6661 1.2105

Load µ - 0.0544 0.0667 0.1212

Separation size xs mm 0.00020313 0.00020584 0.00021396

Calculating the total degree

of separation E

Limit load µlimit - 0.0196 0.0197 0.0201

Total degree of separation E measured - 0.8687 0.8824 0.8579

Total degree of separation E - 328.2212 266.3173 145.2875

calculated

Calculating the pressure loss ∆p

Pressure loss ∆p calculated mbar 8.8915 8.7585 8.3112

TABLE 4: Worksheet for conducting the experiment

 Unit Measurement Measurement no. Measurement n
no.

Preparation of the experiment

(without feed material)

Volume flow Vgas m3/h 40.0000 40.0000 40.0000

Temperature 0
C 25.9000 25.8000 26.0000

Differential pressure ∆p mbar 16.4000 16.4000 16.5000

Conducting the experiment (with feed

material)

Feed (potentiometer) - 3.0000 6.0000 10.0000

Feed vfeed mm/s 1.3000 2.7000 4.9000

Volume flow Vgas m3/h 40.0000 40.0000 40.0000

Temperature 0
C 25.9000 26.0000 26.0000

Differential pressure ∆p mbar 11.3000 9.9000 8.9000

Calculation of the separation size xs

Mass of feed material mfeed g 22.1200 23.4100 23.6100

Mass of coarse material mcoarse g 20.4000 21.3400 21.0400

Mass flow of the feed material mfeed g/s 0.3195 0.7023 1.2854

Load µ - 0.0240 0.0527 0.0965

Separation size xs mm 0.00016966 0.00017591 0.00018217

Calculating the total degree

of separation E

Limit load µlimit - 0.0192 0.0196 0.0199

Total degree of separation E measured - 0.9222 0.9116 0.8911

Total degree of separation E - 844.3228 381.4842 205.9477

calculated

Calculating the pressure loss ∆p

Pressure loss ∆p calculated mbar 9.3325 8.9106 8.4922

TABLE 5: Worksheet for conducting the experiment

 Unit Measurement Measurement Measuremen
no. no. no.

Preparation of the experiment (without feed

material)

Volume flow Vgas m3/h 50.0000 50.0000 50.0000

Temperature 0
C 25.2000 25.4000 25.3000
Differential pressure ∆p mbar 20.1000 20.2000 20.1000
Conducting the experiment (with feed
material)

Feed (potentiometer) - 3.0000 6.0000 10.0000

Feed vfeed mm/s 1.9000 2.7000 4.0000
Volume flow Vgas m3/h 50.0000 50.0000 50.0000
Temperature 0
C 25.3000 25.3000 25.4000
Differential pressure ∆p mbar 15.8000 14.2000 13.6000
Calculation of the separation size xs
Mass of feed material mfeed g 22.8900 23.7800 24.1200
Mass of coarse material mcoarse g 19.7700 20.0300 21.4000
Mass flow of the feed material mfeed g/s 0.4832 0.7134 1.0720
Load µ - 0.0290 0.0428 0.0644
Separation size xs mm 0.00015315 0.00015594 0.0005874
Calculating the total degree of
separation E

Limit load µlimit - 0.0193 0.0195 0.0197

Total degree of separation E measured - 0.8637 0.8423 0.8872
Total degree of separation E calculated - 764.6814 516.0429 341.7423
Calculating the pressure loss ∆p
Pressure loss ∆p calculated mbar 9.2421 9.0345 8.7820

TABLE 6: Worksheet for conducting the experiment

 Unit Measurement Measurement Measurement Average
no. no. no.

Preparation of the experiment

(without feed material)

Volume flow Vgas m3/h 60.0000 60.0000 60.0000

Temperature 0
C 25.2000 25.4000 25.4000
Differential pressure ∆p mbar 22.4000 22.4000 22.5000
Conducting the experiment (with feed
material)

Feed (potentiometer) - 3.0000 6.0000 10.0000

Feed vfeed mm/s 2.2000 3.4000 5.0000
Volume flow Vgas m3/h 60.0000 60.0000 60.0000
Temperature 0
C 25.3000 25.4000 25.4000
Differential pressure ∆p mbar 18.7000 15.9000 13.3000
Calculation of the separation size Xs
Mass of feed material mfeed g 22.4600 23.0200 23.4400
Mass of coarse material mcoarse g 19.1200 20.1100 21.2200
Mass flow of the feed material mfeed g/s 0.5490 0.8696 1.3022
Load µ - 0.0275 0.0435 0.0652 0.0454
Separation size xs mm 0.00013980 0.00014236 0.00014555 0.00014257
Calculating the total degree
of separation E

Limit load µlimit - 0.0193 0.0195 0.0197

Total degree of separation E measured - 0.8513 0.8736 0.9053
Total degree of separation - 869.6237 547.5297 362.6623
E calculated

Calculating the pressure loss ∆p

Pressure loss ∆p calculated mbar 9.2687 9.0254 8.7738

CALCULATIONS
 m course
Degree of Separation (Ecalculated) =
mfeed

For table 1

19.9800
E1= = 0.8520
23.4500

20.1100
E2 = = 0.8518
23.4500

20.2100
E2 = = 0.8795
22.9800

For table 2

20.1200
E1 = = 0.8422
23.8900

19.7600
E2 = = 0.8426
23.4500

20.4500
E3 = = 0.8521
24.0000

For table 3

21.2700
E1 = = 0.8687
24.4400

21.1600
E2 = = 0.8824
23.9800

20.7700
E3 = = 0.8579
24.2100

For table 4

20.4000
E1 = =0.9222
22.1200

21.3400
E2 = = 0.9116
234100

21.0400
E3¿ = 0.8911
23.6100

For table 5
 19.7700
E1 = = 0.8637
22.8900

20.0300
E2 = = 0.8423
23.7800

21.4000
E3 = = 0.8872
24.1200

For table 6

19,1200
E1 = = 0.8513
22.8900

20.1100
E2 = = 0.8732
23.0200

21.2200
E3 = = 0.9053
23.4400

GRAPH

A GRAPH OF Xs AS A FUNCTION OF Vgas

Series2 Xs Linear (Xs)
0.0004

0.00035
f(x) = − 4.32304761904762E-06 x + 0.000370771111111111
0.0003

0.00025
Xs axis mm

0.0002

0.00015

0.0001

0.00005

0
0 10 20 30 40 50 60 70
Vgas axis m3/h
 A GRAPH OF Xs AS A FUNCTION OF LOAD µ
Xs Linear (Xs)
0.0004
f(x) = 0.00192303708477758 x + 6.44780611729535E-05
0.00035

0.0003

0.00025
Xs axis mm

0.0002

0.00015

0.0001

0.00005

0
0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
load axis mm

8.0 DISCUSSION

From the results obtained, the separation size was found to be 0.001738mm, indicating
that the particle size between the separated coarse material and fine material not
separated is minimal. The total degree of separation was then found to be 0.99986
percent indicating a high efficiency of the gas cyclone device since the total degree of
separation indicates the percentage of the feed material that is separated. The higher
percentage indicates higher feed material being separated. It is also observed that
whenever there is an increase in mass percent, screen mesh size increases as well
indicating that the mass is directly proportional to screen mesh size. This is because the
amount of particles that go through also increases when the size of a sieve increases
from the polynomial graph. It was observed that the separation size increases as the load
increases. As the load of the gas increased the limit load was reached which meant that
for a load above the load limit, separation also took place in the cyclone vortex. The
remaining part of the feed material is then accelerated in the inlet towards the cyclone
wall and transported into the tank for coarse material. A graph of separation size
against volume flow gave a negative slope. Due to the fact that volume and pressure are
inversely proportional, increase in feed rate results in a corresponding pressure drop and
increase in volume will result in a pressure drop. It was also observed for smaller
changes in feed rate the pressure difference is not affected. A graph of load against the
volume flow rate indicated the higher the load, that is the higher mass flow of the feed
material relieve to the mass flow of the gas feed relative to the material the less the
volume flow rate.
9.0 PRECAUTIONS
1. We ensured that we repeatedly placed small amounts of our mass feed in the
feed cylinder till we got the amount of feed we wanted so as to prevent
overfilling of the feed in the mass cylinder.
2. It was ensured that the mass balance was tarred before any measurement was
taken to ensure accuracy of values.
3. We carefully placed the hamper in the feed cylinder any time a mass feed was
added.
4. We turned off the switch of the trainer before the start of the experiment.

10.0 ERROR ANALYSIS

1. Due to some pressure loss that occurred during the separation process, the
separation was not 100% effective.
2. There was some loss in mass when the mass feed was being transferred into the
feed cylinder

11.0 CONCLUSION
The higher the pressure dropped resulted in an increase in the degree of
separation of the fine material from the coarse material. With a very high percentage of
the coarse material obtained from the mass feed it is evident that the gas cyclone was
highly efficient.
There was a negative correlation between the separation size (Xs) and the
volume flow of the gas (Vgas). That is as the particle size between the separated coarse
material and the fine material that is not separate increases the volume flow of the gas
decreases.
There was also a negative between separation size and the load. Therefore, a
higher separation size corresponds to a lower mass of feed relative to the mass of the
gas.
.

12.0 POST LAB

1. For the graph of separation size, Xs as a function of the volume flow of gas Vgas,
it was seen that, the separation size was inversely proportion to the volume flow
of gas. That is as the separation size decreases the volume of gas increases
 which means that, the separation process is more effective when the volume
flow of gas increases.
2. The smaller separation size makes the separation process more effective.
3. For the graph of separation size as the function of the load, it was observed that
the separation size was directly proportional to the load that is, separation size
increases as the load increases. As the load of the gas increased, the limit load
was reached which meant that for a load above the load limit, the separation
took place both in the cyclone vortex and at the wall of the cyclone.
4. a). Ensure good electrical connections to avoid power interruption.
b) Wear nose marks to prevent inhalation of feed material (poisonous).
c) Use tamper's weight only (no pressure), during the compressing of feed
material in feed cylinder.

13.0 REFERENCES
1. Jolius Gimbun Thomas, Choong S Y, Fakhru’l-razi A and Chuah T G (2004),
“Prediction of the Effect of Dimension, Particle Density, Temperature, and Inlet
Velocity on the Cyclone Collection Efficiency”, Chemical Engineering and
Processing
2. Faulkner W B and Shaw B W (2006) “Efficiency and Pressure Drop of Cyclones
Across a Range of Inlet Velocities”. American Society of Agriculture and Biological
Engineers. ISSN: 0883_8542
3. Martignoni, Bernardo, P.W.; S.; Quintani, C. L. (2007). "Evaluation of cyclone
geometry and its influence on performance parameters by computational fluid
dynamics (CFD)". Brazilian Journal of Chemical Engineering. 24.
doi:10.1590/S0104-66322007000100008
4. M. Rhodes (1998). Introduction to particle technology. John Wiley and Sons. ISBN
978-0-471-98483-2.
5. "Solid Gas separation methods - Industrial dust collectors - cyclone - scrubbers -
filtration - PowderProcess.net". Pg1-3
6. Common waste water and waste gas treatment and management systems in the
chemical sector. BREF document, European IPPC Bureau, http://eippcb.jrc.es, pg1
7. Koch W H and Licht W (1977) “New Design Approach Boosts Cyclone Efficiency”
Chemical Engineering Vol.17, p.80.