DESIGN OF CYCLONE DUST COLLECTOR

A project report submitted in partial fulfilment of the requirement for

the award of the degree of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING
BY

P. DHARAN KUMAR (318126520L54)

K. MANOJ KUMAR (317126520204)

K. SAI DHEERAJ (317126520198)

Y. PRASHANTH (318126520L38)

P. UGANDHAR ANIL (317126520212)

Under the esteemed guidance of

K. GOWRI SHANKAR

B. TECH, M.E

Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

ANIL NEERUKONDA INSTITUTE OF TECHNOLOGY & SCIENCES (A)

(Affiliated to Andhra University, Accredited By NBA and NAAC with ‘A’ Grade )

SANGIVALASA, VISAKHAPATNAM (District) – 531162

 CONTENTS
ABSTRACT
INTRODUCTION
1. CYCLONE DUST COLLECTOR
1.1 WORKING PRINCIPLE
2. LITERATURE
2.1 BLOWER
2.2 CYCLONE SEPARATOR
2.3 WATER SPRINKLER
2.4 FRAME
2.5 CASTOR WHEELS
2.6 DC MOTORS
2.7 DC ADAPTORS
3. CIRCUIT DIAGRAM OF CYCLONE DUST COLLECTOR
4. DESIGN
5. CONCLUSION
6. FUTURE SCOPE
 ABSTRACT
To design a cyclone abatement system for particulate control, it
is necessary to accurately estimate cyclone performance. In this cyclone study,
new theoretical methods for computing travel distance, numbers of turns and
cyclone pressure drop have been developed. The flow pattern and cyclone
dimensions determine the travel distance in a cyclone. The number of turns
was calculated based on this travel distance. The new theoretical analysis of
cyclone pressure drop was tested against measured data at different inlet
velocities and gave excellent agreement. The results show that cyclone
pressure drop varies with the inlet velocity, but not with cyclone diameter.
Cyclone cut-points for different dusts were traced from measured cyclone
overall collection efficiencies and the theoretical model for calculating
cyclone overall efficiency. The cut-point correction models 2D2D cyclones
were developed through regression fit from traced and theoretical cut-points
Diameter.
Experimental results indicate that optimal cyclone design
velocities, which are for 2D2D cyclones, should be determined based on
standard air density. It is important to consider the air density effect on cyclone
performance in the design of cyclone abatement systems. The tangential inlet
generates the swirling motion of the gas stream, which forces particles toward
the outer wall where they spiral in the downward direction. Eventually the
particles are collected in the dustbin located at the bottom of the conical section
of the cyclone body. The cleaned gas leaves through the exit pipe at the top.

In Pakistan it has been installed in many industries its Main

modes of operation is similar to collect the particles but the collection of
particles and method of collection are Distinguish. Cement Sector is one of
advance sector application for Cyclone Separator. DG cement in one of those
Cement Manufacturing Plant where Cyclone working Efficiently .
 INTRODUCTION
Floor cleaning is achieved by different technique which
might be of different kinds. Different types of floor need different type of
treatment. The floor should be totally dry after the cleaning process. Otherwise
it may result in hazard. On some floors sawdust is used to absorb all kinds of
liquids. This ensures that there will no need of preventing them from spill of.
The sawdust has to be swept and replaced every day. This process is still used in
butchers but it was common in bars in the past. In some places tea leaves are
also used to collect dirt from carpets and also for odour removing purposes.
Different types of floor cleaning machines are available today such as floor
buffers, automatic floor scrubbers and extractors that can clean almost all types
of hard floors or carpeted flooring surfaces in very less time than it would have
taken using traditional cleaning methods. Again the cleaning would be different
for different floorings.
 1. CYCLONE DUST COLLECTOR

1.1 WORKING PRINCIPLE

Materials flow two locations. This phenomenon is the basic working

principle of an ideal vacuum from one location to another when a pressure
difference is created between cleaner. When a centrifugal fan rotates it makes
the air to flow by adding it external kinetic energy. Air is sucked from behind
and pushed forward with pressure and so negative pressure is creates behind the
fan. Ideal vacuum cleaners have such centrifugal fan in it connected to a motor.
This unit has suction and discharge connections, on the suction side filter bag is
fitted before the hose connection. The discharge has another air purifier filter
and opened to atmosphere. When the electric power is given the motor rotates
and so that the centrifugal fan. Air from the suction side is sucked into the unit
along with the air all air born particles, cat allergen, mist, dirt, and small solid
particles are carried to the auction filter. They are trapped in the filter and dirt
free air is pushed out from the discharge opening.
 2. LITERARTURE

2.1 BLOWER

Blowers are mechanical or electro-mechanical devices used

to induce gas flow through ducting, electronics chassis, process stacks, etc.--
wherever flow is needed for exhausting, aspirating, cooling, ventilating,
conveying, and so on. See also Fans. Key specifications include intended
application, blower type, port design, as well as the parameters of flow capacity,
electrical ratings, and dimensions. Blowers cool electronic enclosures, induce
drafts in boilers, increase airflow on engines, and are configured in a variety of
designs such as centrifugal flow or rotary lobe styles. Motors usually drive
blowers, though they can be powered by other means such as engines. Often
used interchangeably with “Fans,” blowers are defined by the ASME as having
a ratio of discharge pressure over suction pressure between 1.11 and 1.2, while
fans are defined as anything below this ratio and compressors are defined as
anything above it. Some makers of portable fans refer to their units as blowers
even if they do not necessarily conform to the ASME distinction, which applies
to permanently installed industrial process equipment. Another kind of blower
is the mobile or hand held device used for moving fallen leaves.

Centrifugal Blowers

The centrifugal blower use high speed impellers or blades to

impart velocity to air or other gases. They can be single or multi-stage units.
Like fans, centrifugal blowers offer a number of blade orientations, including
backward curved, forward curved, and radial. Blowers can be multi- or variable
speed units. They are usually driven by electric motors, often through a belt and
sheave arrangement, but some centrifugal blowers are directly coupled to drive
motors. Fan speed can be changed to vary flow rates by resizing sheaves, using
variable speed drives, etc., but dampers are even more common as a means of
adjusting flow. Fan affinity laws dictate that a percent reduction in speed will
produce a like reduction in flow.
Main terms

Blades:
Backward inclined and forward curved refer to centrifugal blowers and relate
to the blades also relate to centrifugal units, representing simple paddle type
construction with no backward or forward inclinations. They can be self-
orientation of the blades. Forward curving blades move larger quantities of air
than backward inclined blades do, albeit at lower pressures. Backward inclined
blades tend toward higher efficiencies. Radial cleaning, an important
consideration for blowers handling dirty media. Airfoil blades also apply to
centrifugal blowers.

Flow Capacity:
This attribute is important when selecting a blower. Blower capacity is
generally rated in cubic feet per minute.

Maximum Operating Pressure:

Along with flow capacity, this is another important attribute in blower
selection. Manufactures generally rate this item in inches of water column.
2.2 CYCLONE SEPARATOR
Cyclone separators provide a method of removing particulate matter
from air or other gas streams at low cost and low maintenance. Cyclones are
somewhat more complicated in design than simple gravity settling systems, and
their removal efficiency is much better than that of settling chamber. Cyclones
are basically centrifugal separators, consists of an upper cylindrical part referred
to as the barrel and a lower conical part referred to as cone. They simply
transform the inertia force of gas particle flows to a centrifugal force by means
of a vortex generated in the cyclone body. The particle laden air stream enters
tangentially at the top of the barrel and travels downward into the cone forming
an outer vortex. The increasing air velocity in the outer vortex results in a
centrifugal force on the particles separating them from the air stream. When the
air reaches the bottom of the cone, it begins to flow radially inwards and out the
top as clean air/gas while the particulates fall into the dust collection chamber
attached to the bottom of the cyclone.
DIFFERENT CYCLONE MODELS:
2.3 WATER SPRINKLER

A sprinkler system is integrated system of piping, connected to a

water supply, with listed sprinklers that automatically initiate water discharge
over a area where required. As water sprays from a sprinkler it breaks up into
small drops between 0.5 and 4.0 mm in size. The small drops fall close to the
sprinkler whereas the larger ones fall close to the edge of the wetted circle.
Drop size is also controlled by pressure and nozzle size. When the pressure is
low, drops tend to be much larger as the water jet does not break up easily. So
to avoid more wetting of soil use small diameter nozzles operating at or above
the normal recommended operating pressure.

2.3 FRAME
1. Materials required: G.I square pipe of 1 inch side of 40 feet, castor
wheels, AC/DC arc welding equipment with accessories.
2. We took the beams measured and marked up to the points
Length:65 cm
Breadth:50 cm
Height :90 cm
3. Now, cut the pieces at marked points with help of a circular saw.
4. Fix all the pieces as shown in the figure below.
5. Weld them permanently which will now form the basic structure.
6. Now, take the M.S Flats measure and mark them as required for the
base.
7. Cut the pieces at marked points.
8. Arrange the M.S Flats in checked formation to form a strong base.
9. Weld the base to the frame.
10.Take the castor wheels and fix them at bottom of frame with help of
an arc welding.
11.We have made the basic structure on which the all the components are
to be mounted.

2.4 CASTOR WHEELS

A caster is a wheeled device typically mounted to a larger object
that enables relatively easy rolling movement of the object. Casters are
essentially special housings that include a wheel, facilitating the installation of
wheels on objects. Casters are found virtually everywhere, from office desk
chairs to shipyards, from hospital beds to automotive factories. They range in
size from the very small furniture casters to massive industrial casters, and
individual load capacities span 100 pounds (45 kg) or less to 100,000 pounds
(45 t). Wheel materials include cast iron, plastic, rubber, polyurethane, forged

Applications:
Casters are available in a large selection of various rigs and yokes, wheel
materials, swivel offsets, and wheel configurations. In many cases, it can
become extremely difficult to choose the right caster for the application. In
order to help the user to determine the right caster to use, it's important to take a
couple of factors into consideration, which include:
• Load capacity (the total load applied on the casters)
• The number of casters to be used on the equipment (usually four or six
casters)
• Floor type (concrete, steel, linoleum, carpet, etc.)
• Floor condition (are there cracks, bumps, unlevel floors?)
• Environment (is the equipment operating in high temperatures, wet or
humid conditions, etc.)
• Floor cleanliness (are the floors clean or contain debris such as metal
chips, grease, gravel, etc.)Steel, stainless steel, aluminium, and more.

2.5 DC MOTOR

A DC motor is any of a class of rotary electrical machines that

converts direct current electrical energy into mechanical energy. The most
common types rely on the forces produced by magnetic fields. Nearly all types
of DC motors have some internal mechanism, either electromechanical or
electronic; to periodically change the direction of current flow in part of the
motor.

DC motors were the first type widely used, since they could be
powered from existing direct-current lighting power distribution systems. A DC
motor's speed can be controlled over a wide range, using either a variable
supply voltage or by changing the strength of current in its field windings.
Small DC motors are used in tools, toys, and appliances. The universal
motor can operate on direct current but is a lightweight motor used for portable
power tools and appliances. Larger DC motors are used in propulsion of electric
vehicles, elevator and hoists, or in drives for steel rolling mills. The advent of
power electronics has made replacement of DC motors with AC
motors possible in many applications.

OPERATION OF DC MOTOR:

1. When the coil is powered a magnet field is produced around the armature
 the left side of the armature is pushed away from the left magnet and drawn
towards right, causing rotation.
2. The armature continues to rotate.
3. When the armature becomes horizontally aligned, the commutator reverses
the direction of Current through the coil, reversing the magnetic field.
4. The process then repeats.
• Magnetic force acts perpendicular to both wire and magnetic field.
F=ILB
I=Electric current
F=Magnetic force
B=Magnetic field
L=Length of wire

ADVANTAGES:

• Provide excellent speed control for acceleration and deceleration.

• Easy to understand design.
• Simple, cheap drive design.

DISADVANTAGES OF DC MOTOR:
Brush wear: Since they need brushes to connect the rotor winding. Brush wear occurs, and it
increases dramatically in low pressure environment. So they cannot be used in artificial
hearts. If used on air crafts, the brushes would need replacement after one hour of operation.
Sparks from the brushes may cause explosion if the environment contains explosive
materials. RF noise from the brushes may interfere with nearby t.v. sets, or electronic devices
etc..,

2.6 DC ADAPTORS

An AC adapter, AC/DC adapter, or AC/DC converter [1] is a

type of external power supply, often enclosed in a case similar to an AC plug.
Other common names include plug pack, plug-in adapter, adapter
block, domestic mains adapter, line power adapter, wall wart, power brick,
and power adapter. Adapters for battery-powered equipment may be described
as chargers or rechargers (see also battery charger). AC adapters are used with
electrical devices that require power but do not contain internal components to
derive the required voltage and power from mains power. The internal circuitry
of an external power supply is very similar to the design that would be used for
a built-in or internal supply.
External power supplies are used both with equipment with no
other source of power and with battery-powered equipment, where the supply,
when plugged in, can sometimes charge the battery in addition to powering the
equipment.
Use of an external power supply allows portability of
equipment powered either by mains or battery without the added bulk of
internal power components, and makes it unnecessary to produce equipment for
use only with a specified power source; the same device can be powered from
120 VAC or 230 VAC mains, vehicle or aircraft battery by using a different
adapter. Another advantage of these designs can be increased safety; as the
hazardous 120 or 240 volt mains power is transformed to a lower safer voltage
at the wall outlet, and the appliance which is handled by the user is powered by
this lower voltage.
 3.CIRCUIT DIAGRAM OF CYCLONE DUST COLLECTOR

BLOWER: Blowers use high speed impellers or blades to impart velocity to air
or other gases. They can be single or multi-stage units. Like fans, centrifugal
blowers offer a number of blade orientations, including backward curved,
forward curved, and radial. Blowers can be multi- or variable speed units. They
are usually driven by electric motors, often through a belt and sheave
arrangement, but some centrifugal blowers are directly coupled to drive motors.
BLOWER OUTLET: The blower outlet let all the dust particles into the throw
out bin with which we can collect all the dust in a bin and make the required
work done.

CYCLONE CYLINDER: It is one kind of a passage of the system which helps

in flow of dust particles into the cone and then to the throw out bin.

DIRTY AIR INLET: It is the passage through which the waste which is being
collected is entering the system.

CONE: The conical shaped container where the cone shape creates a cyclone
with higher centrifugal air speed and helps in collecting all the dust particles
into the throw out bin.

THROWOUT BIN: It is the bin which collects all the dust particles in it and
can be opened when required for emptying the bin.

MOTOR: It converts electrical energy into hydraulic energy.

CONTROL VALVE: The control valve helps in the controlled passage for the
air/water and the required amount can be passed through the passage.

WATER CONTAINER: The water container is for the storage of the water for
sprinkling the water on the cleaned surface.

HOSE: The hose pipe is for carrying the collected air for the inlet to the outlet
and it acts as the passage for the dust collection.
T-JOINT: The t-joints are used for connecting purpose, in which two pipes can
be connected and make a passage for collecting the dust.

L-JOINT: The L-joint is also known as angle joint it is of 90° angle and used
for connecting pipes in the L shape and make the passage for collecting the
dust particles.
4. DESIGN
SPECIFICATIONS OF MOTOR:

Voltage: 12 V
Speed: 200 rpm
Current: 0.5- 1 A

DESIGN OF BLOWER:

Flow Discharge Q = 0.5 m3/s

Static Suction Pressure = -196.4 N/m2
Static Delivery Pressure = 784.8 N/m2
Static Pressure Gradient ΔPs = 981.2 Pa
Speed of impeller rotation N = 2800 rpm
Air Density = 1.165 kg/m3
Optimized number of blades z = 16 [135]
Outlet Blade Angle β2 = 90°
Suction Temperature Ts = 30 °C = 303 K
Atmospheric Pressure Patm = 1.01325 x 105 Pa
Atmospheric Temperature Tatm = 30° C = 303° K
These parameters are kept identical for each design methodology prescribed
here in.
DESIGN OF PIPE:

Diameter of pipe (d) =1 inch =2.54cm

Length of pipe (l) = 205cm
𝜋𝑑 2
𝑉= × 𝑙 = 1039cm3
4
DESIGN OF CYLINDER:

Length (L) = 36cm

Diameter (d) =15cm
Radius(R) = 𝑑⁄2 =7.5cm
Area (A) = 𝜋𝑟 2 =176.78cm2
DESIGN OF FRUSTUM OF CONE:

Volume of a frustum of cone:

V = 𝜋ℎ(𝑅2+r2+R*r)/3 =101.35*102cm3
Slant height of frustum of a cone:
s = √((𝑅1-R2) +h2) =42.074cm
Lateral surface area of a frustum cone:
L = 𝜋(r+R)√((𝑅 − 𝑟)2+h2) =986cm2
Base surface area of a frustum cone (a circle):
B = 𝜋𝐷2/4 =176.71cm2
Total surface area of a cone:
A = L + B =986+176.71=1162.71cm2
TOTAL VOLUME

Total Volume= Volume of cylinder +volume of frustum of cone

= 6364.8+1162.71=7527.51cm3

DESIGN PARAMETERS OF CYCLONE SEPERATOR:

Length of cylinder(𝐿1 ) = 2𝐷2

Length of cone (𝐿2 ) = 2𝐷2
Diameter of exit (𝐷𝑒 ) = 0.5𝐷2
Height of entrance (H) = 0.5𝐷2
Width of entrance (B) = 0.25𝐷2
Diameter of dust exit (𝐷𝑑 ) =0.25𝐷2
Length of exit duct (𝐿3 ) = 0.125𝐷2
Applications:

cyclone separator is widely used in industries to separate dust from

gas or for product recovery because of its geometrical simplicity,
relative economy in power and flexibility.

Major applications include:

oil refineries to separate oils and gases

cement industry
ginning mills

CHEMICAL AND PETROCHEMICAL PROCESSES

Dust collector for dryer and cooler processes hot gas cleaning and
product recovery separation in spray dryers cyclone dust collector for dust
recovery of 5 microns [and below] recovery of particulate in maleic anhydride
process reactors ultra fine gas cleaning of fluid catalytic cracking (FCCU)
regenerator gases

INDUSTRIAL, METALLURGICAL AND POWER GENERATION

Cyclone dust collector for metallurgical process mills, smelters and kilns fine
particulate recovery cyclone in fluidised bed combustors hot gas cleaning in
coal gasifier and activated carbon plants particulate recovery in abrasive and hot
gas Streams cyclone separator for npk & lan fertilizer dust in coolers & dryers
dust collector cyclone for reducing emissions in fluidised bed boilers zinc dust
recovery and extraction in galvanizing plants.

FOOD & PHARMACEUTICAL

Powder recovery cyclone filter in pharmaceutical sterile processes

cyclone separator for product recovery in milk powder, coffee and cereal plants

Cement Industry

In cement manufacturing industries, large-sized cyclone separators are

used as main process equipments in significant numbers for handling high
volumetric flow rates of dust-laden gases. The cyclone is a simple mechanical
device commonly used in the grinding circuits to remove relatively large
particles from gas streams. Cyclones are often used as pre-cleaners to remove
more than 80% of the particles greater than 20µm in diameter. Smaller particles
that escape the cyclones can then be collected by more efficient control
equipment like bag filters and electro precipitators Cyclones are relatively
inexpensive since they have no moving parts and they are easy to operate The
most common type of cyclone is known as reverse flow cyclone separator

Others: Cyclones are used in sawmills to remove sawdust from extracted air
 5. CONCLUSION
A prominent problem in calculating the efficiency of
cyclone is the effect of flow characters in cyclone. In big cyclones the flow is
turbulent and friction factors assumed give good results. This is not true for
small cyclones. The flow in small cyclones can be laminar or even transitional.
In such case the operational conditions, like velocity, temperature, pressure,
viscosity and cyclone diameter, may be of significant importance and their
effect changes from cyclone to cyclone. In laminar flow, operating parameters
influence cyclone efficiency more than turbulent case. This makes the
prediction of efficiency and pressure drop very difficult especially in small
cyclone. Most of the models depend on empirical or semi-empirical equations.
The models calculate efficiency and predict the
cutoff size which corresponds to 50% efficiency. According to Wang et al.
cyclone performance is function of geometry and operating parameters of
cyclone, as well as particle size distribution of the entrained particulate matter.
Several models have been proposed to predict the efficiency of cyclone. It is
widely agreed amongst the scientists that cyclone performance is definitely
affected by operating parameters and hence they should be included in the
modeling. Many theories account for density, gas velocity, viscosity and
particle diameter. As far as effect of geometry is considered there is difference
in approach for various scientists. Some consider all the geometric parameters
where as some consider only few important parameters like inlet and outlet
diameter and height in their models.
As mentioned, most of the theories consider cut size
“d50”, which corresponds to diameter of particle where 50% of particles smaller
and 50% of particles greater that that size will be collected. Two most common
approaches for calculating efficiency are Force Balance Theory [Lapple] which
assumes that terminal velocity is achieved when drag fore and centrifugal force
equal each other and the Static Particle Approach [Barth] which considers
simple force balance where forces acting on particle are balanced. Various other
complicated theories have been proposed but the essentially have their base in
one of the two theories.
 6. FUTURE SCOPE

In the future, state implementation plans and local

environmental regulations will need to consider the energy consumption of
control devices and not just stack total emissions, as producing electricity to
operate control devices results in pollution where that electricity is generated
.Future cyclone research will continue to focus on collection effectiveness,
especially for finer particulates, but will also focus on minimizing energy costs.
As computing resources become less expensive and CFD modeling becomes
more sophisticated, increasingly complex models will continue to contribute to
our still imperfect understanding. Yet numerical simulation will always require
validation trials that test cyclones under conditions and loads as near to the real
world application as feasible. As methods for quantification of particulate
emission particle size distributions become more affordable, the quality of the
data collected in these future trials should further improve.