by

CYCLONE DESIGN AND ANALYSIS

Esco Engineering
179 Lansdowne Avenue,
Kingsville, Ontario N9Y 3J2 Canada
ph
519 733 3122
fax
519 733 6094
Contact:
Neil Stone, Chief Engineer
e-mail
jnstone@mnsi.net
Website
www.mnsi.net/~pas/esco.htm

Revisions
26-Nov-98
18-Jan-99
3-Apr-99
2-Dec-99
13-Dec-99

Corrected error in cell D14 on efficiency sheets

Added diagram
Corrected cell O7, Efficiency 1 - thanks to Laercio Frare for pointing out this error
Added metric option, NV sketch
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.

5/26/2012

98245565.xls.ms_office

DEFINITION OF CYCLONE DIMENSIONS

De

S
h

NV =

5/26/2012

ELEVATION

Neutral vane
Extension of inner
side if inlet to centerline
of cyclone
PLAN

98245565.xls.ms_office

Cyclone size

CALCULATE DIMENSIONS FOR CYCLONE

NOTES

SPECIFY UNITS (U = US CUSTOMARY[IMPERIAL], M = METRIC)

Input
Flow rate
Q
cfm
2000
Design inlet vel
vi
fps
50
Gas density
rg
pcf
0.0740
Inlet area
PD parameter

U
Working
2000 cfm
50 fps
0.074 pcf
0.67 sf
0.56 in water

Dimensions

Dia
Inlet ht
Inlet width
Outlet length
Outlet dia
Cylinder ht
Overall ht
Dust outlet dia
# vel hds
Press drop, no NV
Press drop, with NV

D
a
b
S
De
h
H
B
Nh

ft
in
in
ft
in
ft
ft
in
in water
in water

Sheet 1 is for sizing

Sheets 2/3 are for efficiency (alte
Sheet 4 are charts of results of s

Stairmand
HE

Swift
HE

2.58
15.49
6.20
1.29
15.49
3.87
10.33
11.62
5.14
2.85
1.34

2.69
14.18
6.77
1.34
12.89
3.76
10.48
12.89
4.87
2.70
1.27

Type of cyclone
Lapple
Swift
LE
LE
2.31
13.86
6.93
1.44
13.86
4.62
9.24
6.93
4.49
2.49
1.17

2.31
13.86
6.93
1.39
13.86
4.04
8.66
11.09
4.69
2.60
1.22

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, Ch

Page 3

Cyclone size

heet 1 is for sizing

heets 2/3 are for efficiency (alternates)
heet 4 are charts of results of sheets 2/3
This setting applies to the whole spreadsheet

e
Peterson/Whitby
LE
2.34
16.40
5.85
1.37
14.07
3.13
7.43
14.07
4.77
2.65
1.24

Copy one col of outline

data (copy values only)
to efficiency sheet.

hem Eng Nov 7 1977, 80

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

Page 4

Efficiency 1

CALCULATE EFFICIENCY FOR CYCLONE (method 1)

CALCULATIONS ARE IN
US CUSTOMARY [IMPERIAL] UNITS
Geometry
Input
Working
Dia
D
ft
2.58
2.58
Inlet ht
a
in
15.49
15.49
Inlet width
b
in
6.20
6.20
Outlet length
S
ft
1.29
1.29
Oulet dia
De
in
15.49
15.49
Cylinder ht
h
ft
3.87
3.87
Overall ht
H
ft
10.33
10.33
Dust outlet dia
B
in
11.62
11.62
Natural length
L
ft
6.40
6.40
# vel hds
Nh
5.14
Press drop, no NV
in water
2.85
Press drop, with NV
in water
1.34
Gas data
Flow rate
Density
Viscosity
Temperature
Salt. temp fact
Salt dens. fact
Particle data
Log mean dia
Log SD
Use distribution? (Y/N)
Specific gravity

Q
rg
u
T
fT
fp

acfm
pcf
cP
F

dp
sd

m
m

2000
0.0740
0.010
60
1.00
1.00

2000.00
0.0740
0.010
60
1
1

Limits/warnings

Overall efficiency

33.3333333 cfs
0.076 air @ 1 atm, spec'd temp
0.00000672 lb/f-s

Value used
12 11.905565
3 3.1077764
y
0.8

If yes, run regression - adjust input ranges

49.92 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

Page 6

Efficiency 1

Calculated data

imits/warnings

Overall efficiency

Log SD
Inlet velocity
Ratio inlet/salt vel
Corrected L
Core dia
Eff vol
Inlet vol
Cycl const
G
Vortex exp

84.2 %
Efficiency calcs
Dia, um
Min

ir @ 1 atm, spec'd temp

0
0.4
0.6
1.2
1.8
2.4
3
3.6
4.2
4.8
7
10
13
16
22
28
34
40
49
64
79

ession - adjust input ranges (cols Q,T) to suit data

Distribution data
Size, um
Min
0
2
3

Page 7

Efficiency 1

5
10
20
30
40
50

Page 8

Efficiency 1

1.13390749
50
2.15516647
6.39713542
1.62820227
26.4972831
2.53486167
0.91693868
733.550942
1.64839814

fps
ft
ft
cf
cf
Kc
n+1

Int calcs
Dia, um

Distribution
Max
0.4
0.6
1.2
1.8
2.4
3
3.6
4.2
4.8
7
10
13
16
22
28
34
40
49
64
79
94

Size, um

Inlet mass frn Penetration Outlet amt

Outlet mass
fraction
fraction
0.0020
0.8752
0.0017
0.0111
0.0028
0.7215
0.0020
0.0129
0.0168
0.6321
0.0106
0.0672
0.0260
0.5304
0.0138
0.0871
0.0309
0.4579
0.0141
0.0893
0.0330
0.4020
0.0133
0.0839
0.0336
0.3568
0.0120
0.0758
0.0333
0.3195
0.0106
0.0672
0.0324
0.2879
0.0093
0.0590
0.1080
0.2346
0.0254
0.1602
0.1197
0.1640
0.0196
0.1241
0.0926
0.1126
0.0104
0.0659
0.0724
0.0805
0.0058
0.0368
0.1052
0.0530
0.0056
0.0352
0.0698
0.0305
0.0021
0.0135
0.0486
0.0185
0.0009
0.0057
0.0351
0.0117
0.0004
0.0026
0.0372
0.0071
0.0003
0.0017
0.0384
0.0034
0.0001
0.0008
0.0220
0.0014
0.0000
0.0002
0.0136
0.0006
0.0000
0.0001
0.9736
0.1582
1.0000
Overall efficiency
84.2 %

Cum %

% in
range

Max
2
3
5

6
11
22

Rela

fl

fh

0
0.00999118
0.01821771
0.03783188
0.04878351
0.05406752
0.05601818
0.05602999
0.05492097
0.05317768
0.04503989
0.03476918
0.02698254
0.02125479
0.01381122
0.00945487
0.00674347
0.00496863
0.00329665
0.00182986
0.00110627

0.00999118
0.01821771
0.03783188
0.04878351
0.05406752
0.05601818
0.05602999
0.05492097
0.05317768
0.04503989
0.03476918
0.02698254
0.02125479
0.01381122
0.00945487
0.00674347
0.00496863
0.00329665
0.00182986
0.00110627
0.00071142

ln dia max
6
5
11

0.69314718
1.09861229
1.60943791

2.37209221
2.10108301
1.74018834

Page 9

1.55509667 -1.55509667
1.2266687 -1.2266687
0.77197049 -0.77197049

Regressio

Efficiency 1

10
20
30
40
50
100

44
67
80
85
90
97

22
23
13
5
5
7

2.30258509
2.99573227
3.40119738
3.68887945
3.91202301
4.60517019

1.2813903
1.48906858
1.79412258
1.94788089
2.14596603
2.6482288

0.15065203 -0.15065203
0.4394801
0.4394801
0.84145672 0.84145672
1.03643149 1.03643149
1.28172876 1.28172876
1.88121279 1.88121279

X Variable 1

Page 10

Efficiency 1

Relax time
tl
0
7.1083E-07
1.5994E-06
6.3975E-06
1.4394E-05
2.559E-05
3.9984E-05
5.7577E-05
7.8369E-05
0.00010236
0.00021769
0.00044427
0.00075082
0.00113733
0.00215027
0.00348308
0.00513576
0.00710832
0.01066692
0.01819729
0.02772688

Penetration
th

7.1083E-07
1.5994E-06
6.3975E-06
1.4394E-05
2.559E-05
3.9984E-05
5.7577E-05
7.8369E-05
0.00010236
0.00021769
0.00044427
0.00075082
0.00113733
0.00215027
0.00348308
0.00513576
0.00710832
0.01066692
0.01819729
0.02772688
0.03925568

pl

ph

1
0.75036692
0.69261439
0.57162791
0.48908028
0.42672888
0.37717142
0.33652189
0.30244582
0.27341703
0.19587466
0.13211175
0.09317044
0.06775047
0.03817372
0.02282072
0.01422714
0.00915695
0.00495123
0.00194656
0.0008316

0.75036692
0.69261439
0.57162791
0.48908028
0.42672888
0.37717142
0.33652189
0.30244582
0.27341703
0.19587466
0.13211175
0.09317044
0.06775047
0.03817372
0.02282072
0.01422714
0.00915695
0.00495123
0.00194656
0.0008316
0.00037786

SUMMARY OUTPUT
Regression Statistics
Multiple R
0.9998743
R Square
0.99974861

Page 11

Efficiency 1

Adjusted R Square
0.99971269
Standard Error 0.02289434
Observations
9
ANOVA
df
Regression
Residual
Total

Intercept
X Variable 1

1
7
8

SS
14.5911821
0.00366906
14.5948511

MS
14.5911821
0.00052415

Coefficients Standard Error

t Stat
2.47700595 0.00774838 319.680571
1.13390749 0.00679611 166.846509

F
Significance F
27837.7574 7.3319E-14

P-value
Lower 95% Upper 95%
7.7387E-16 2.45868396 2.49532794
7.3319E-14 1.11783725 1.14997772

Page 12

Efficiency 1

Page 13

Efficiency 1

Lower 95.000%
Upper 95.000%
2.45868396 2.49532794
1.11783725 1.14997772

Page 14

Efficiency 2

CALCULATE EFFICIENCY FOR CYCLONE (method 2)

CALCULATIONS ARE IN
US CUSTOMARY [IMPERIAL] UNITS
Geometry
Input
Working
Dia
D
ft
3.33
3.33
Inlet ht
a
in
20.00
20.00
Inlet width
b
in
8.00
8.00
Outlet length
S
ft
1.67
1.67
Oulet dia
De
in
20.00
20.00
Cylinder ht
h
ft
5.00
5.00
Overall ht
H
ft
13.33
13.33
Dust outlet dia
B
in
15.00
15.00
Natural length
L
ft
8.26
8.26
# vel hds
Nh
5.14
Press drop, no NV
in water
1.03
Press drop, with NV
in water
0.48
Gas data
Flow rate
Density
Viscosity
Temperature
Salt. temp fact
Salt dens. fact

Q
rg
u
T
fT
fp

Particle data
Log mean dia
dp
Log SD
sd
Use distribution? (Y/N)
Specific gravity
Re-entrainment coeff alpha

acfm
pcf
cP
F

2000
0.0740
0.010
60
1.00
1.00

2000.00
0.0740
0.010
60
1
1

Limits/warnings

Overall efficiency

33.3333333 cfs
0.076 air @ 1 atm, spec'd temp
0.00000672 lb/f-s

Value used
24 11.905565
3 3.1077764

um
um
y

If yes, run regression - adjust input ranges (c

5
312 pcf
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 15

Efficiency 2

Page 16

Efficiency 2

Calculated data

imits/warnings

Overall efficiency

Log SD
Inlet velocity
fps
Ratio inlet/salt vel
Vortex exp
1-n
theta
rw
rn
uw
Dr

91.4 %
Efficiency calcs
Dia, um
Min

ir @ 1 atm, spec'd temp

Max

0
0.4
0.6
1.2
1.8
2.4
3
3.6
4.2
4.8
7
10
13
16
22
28
34
40
49
64
79

ession - adjust input ranges (cols Q,T) to suit data

per for definition)

Distribution data
Size, um
Min
0
2
3

Page 17

0.4
0.6
1.2
1.8
2.4
3
3.6
4.2
4.8
7
10
13
16
22
28
34
40
49
64
79
94

Max
2
3
5

Efficiency 2

5
10
20
30
40
50

Page 18

10
20
30
40
50
100

Efficiency 2

1.13390749
30
0.96975611
0.20581206
37.4176238
1.66666667
0.83333333
46.4414091
0.10062305

Int calcs
Distribution
Inlet mass frn Penetration Outlet amt
Outlet mass
fraction
fraction
0.0020
0.9998
0.0020
0.0232
0.0028
0.9987
0.0028
0.0328
0.0168
0.9814
0.0165
0.1919
0.0260
0.9000
0.0234
0.2720
0.0309
0.7003
0.0216
0.2513
0.0330
0.4072
0.0134
0.1564
0.0336
0.1523
0.0051
0.0596
0.0333
0.0303
0.0010
0.0117
0.0324
0.0024
0.0001
0.0009
0.1080
0.0001
0.0000
0.0001
0.1197
0.0000
0.0000
0.0000
0.0926
0.0000
0.0000
0.0000
0.0724
0.0000
0.0000
0.0000
0.1052
0.0000
0.0000
0.0000
0.0698
0.0000
0.0000
0.0000
0.0486
0.0000
0.0000
0.0000
0.0351
0.0000
0.0000
0.0000
0.0372
0.0000
0.0000
0.0000
0.0384
0.0000
0.0000
0.0000
0.0220
0.0000
0.0000
0.0000
0.0136
0.0000
0.0000
0.0000
0.9736
0.0860
1.0000
Overall efficiency
91.4 %

Cum %

% in
range
6
11
22

fl

fh

0
0.00999118
0.01821771
0.03783188
0.04878351
0.05406752
0.05601818
0.05602999
0.05492097
0.05317768
0.04503989
0.03476918
0.02698254
0.02125479
0.01381122
0.00945487
0.00674347
0.00496863
0.00329665
0.00182986
0.00110627

0.00999118
0.01821771
0.03783188
0.04878351
0.05406752
0.05601818
0.05602999
0.05492097
0.05317768
0.04503989
0.03476918
0.02698254
0.02125479
0.01381122
0.00945487
0.00674347
0.00496863
0.00329665
0.00182986
0.00110627
0.00071142

ln dia max
6
5
11

0.69314718
1.09861229
1.60943791

kh
0.00030905
0.00069536
0.00278143
0.00625821
0.01112571
0.01738392
0.02503284
0.03407248
0.04450283
0.09464577
0.19315462
0.32643131
0.49447584
0.93486838
1.51433225
2.23286745
3.09047398
4.63764252
7.9116134
12.0547801
17.0671426

SUMMARY OUTPUT
2.37209221
2.10108301
1.74018834

1.55509667 -1.55509667
1.2266687 -1.2266687
0.77197049 -0.77197049

Page 19

Regression Statistics
Multiple R
R Square

Efficiency 2

44
67
80
85
90
97

22
23
13
5
5
7

2.30258509
2.99573227
3.40119738
3.68887945
3.91202301
4.60517019

1.2813903
1.48906858
1.79412258
1.94788089
2.14596603
2.6482288

0.15065203 -0.15065203
0.4394801
0.4394801
0.84145672 0.84145672
1.03643149 1.03643149
1.28172876 1.28172876
1.88121279 1.88121279

Adjusted R Square
Standard Error
Observations
ANOVA
Regression
Residual
Total

Intercept
X Variable 1

Page 20

Efficiency 2

Penetration
wh
0.00573974
0.01291441
0.05165765
0.11622971
0.2066306
0.32286031
0.46491884
0.6328062
0.82652239
1.757795
3.58733674
6.06259909
9.18358206
17.3627098
28.1247201
41.4696127
57.3973879
86.1319552
146.937313
223.885686
316.977074

lh

pl

ph

1.175E-05
5.9483E-05
0.00095173
0.00481815
0.01522773
0.03717707
0.07709038
0.14281944
0.24364366
1.10200185
4.58976197
13.1088192
30.079464
107.517928
282.112473
613.346415
1174.97906
2645.90644
7700.34279
17877.16
35834.5188

1
0.99956045
0.99777675
0.96501504
0.8350333
0.5656468
0.24880702
0.05588056
0.0047769
0.00010983
1.2364E-18
2.601E-75
9.51E-214
0
0
0
0
0
0
0
0

0.99956045
0.99777675
0.96501504
0.8350333
0.5656468
0.24880702
0.05588056
0.0047769
0.00010983
1.2364E-18
2.601E-75
9.51E-214
0
0
0
0
0
0
0
0
0

UMMARY OUTPUT
Regression Statistics
0.9998743
0.99974861

Page 21

Efficiency 2

0.99971269
0.02289434
9

df
1
7
8

SS
14.5911821
0.00366906
14.5948511

MS
14.5911821
0.00052415

Coefficients Standard Error

t Stat
2.47700595 0.00774838 319.680571
1.13390749 0.00679611 166.846509

F
Significance F
27837.7574 7.3319E-14

P-value
Lower 95% Upper 95% Lower 95.000%
7.7387E-16 2.45868396 2.49532794 2.45868396
7.3319E-14 1.11783725 1.14997772 1.11783725

Page 22

Efficiency 2

Page 23

Efficiency 2

Upper 95.000%
2.49532794
1.14997772

Page 24

charts

EFFICIENCY
Koch and Licht

Enliang

1.2000

1.0000

Penetration

0.8000

0.6000

0.4000

0.2000

0.0000
0

10

15

Particle dia um

Page 25

charts

20

25

30

Page 26