24- Discussion on Improving the Gas Flow Pattern at the Inlet of Cyclone Separators for Gas-Solid Separation
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This post was last edited by luoli519 on 2020-1-4 at 11:12. OVER THE PAST YEARS, NOVEL has been committed to promoting high-efficiency dynamic separators for use in domestic projects and installations. For example, the G54 multi-factor cyclone separator is used to upgrade and replace traditional cyclone separators; for more detailed information, please visit the HaiChuan Forum at https://bbs.hcbbs.com/thread-1354813-1-1.html. In China, cyclone separators are widely used in gas-solid separation applications. For example, catalyst recovery and separation in the high-temperature medium-pressure fluidized bed syngas methanation process, catalyst recovery and separation in high-temperature low-pressure catalytic cracking units, capture and recovery of catalysts from flue gases generated during FCC/DCC regeneration, gas-phase dust and foam removal in high-temperature high-pressure gasification units, and high-temperature low-pressure gas flow drying and dust separation, among others. For certain existing conventional cyclone separators, it is very difficult and costly to retrofit them using the G54 multi-factor cyclone parent-child separation technology. However, for traditional cyclone separators that are already in use and cannot be upgraded using the G54 multi-factor swirl separator technology, NOVEL also has experience and recommendations for targeted local optimization improvements that offer low costs and high returns, which we would like to share with everyone.
The last edit to this post was made by luoli519 on 2016-9-8 at 19:40. First, guide vanes need to be installed inside the inlet device, and their edges must fit tightly against the inner wall of the inlet pipe. Traditional cyclone separator inlet devices originally required a structure with a gradually changing channel cross-sectional area, but for the sake of simplification and aesthetics in manufacturing, the equipment producers used inlet pipes with a constant cross-sectional area. In fact, the cross-sectional areas of the flow channels at both ends of the inlet device differ significantly, so guide vanes must be installed within the inlet device ； Otherwise, as the fluid enters the cyclone from the inlet device, significant turbulence is generated, which disrupts the fluid entering the cyclone body tangentially and thus **reduces the separation efficiency**. Looking at the conventional cyclone separators currently in use in China, many of them lack guide vanes in their inlet devices, which results in a significant gap between their actual operating efficiency and the efficiency designed for them. It should also be emphasized that the edges of the guide plates installed within the inlet device must fit tightly against the inner wall of the inlet pipe. Judging from the situation where guide vanes are already installed in the inlet devices of conventional cyclone separators in use domestically, many of these devices have guide vanes installed only as a formality, without ensuring that the edges of the vanes fit tightly against the inner wall of the inlet pipe. As a result, solid particulate matter or gelatinous substances will enter the dead corner areas behind the baffle through the large gaps around it, and continue to accumulate there until those areas are filled ； During normal operation of the cyclone separator, solid particles may collapse from the accumulation area from time to time, creating a pulse flow with a high solid content that disrupts the otherwise stable separation process, resulting in repeated significant drops in separation efficiency. Users experiencing this issue can seek technical assistance from NOVEL Company.
Secondly, in the case of traditional cyclone separators where the distance from the upper edge of the tangential inlet to the upper cover of the cyclone tube exceeds 50 mm, especially for cyclone tubes with small diameters, it is necessary to install a full-section flow rectifier plate at the extended end inside the inlet device of the cyclone tube. The goal is to minimize the formation of upward swirling turbulence as the fluid enters the cyclone, thereby preventing disruption of the flow field and reducing separation efficiency ； At the same time, it also prevents the upward swirling turbulence from carrying viscous substances, which could then accumulate and grow in the area of the top cover of the cyclone tower, potentially affecting the flow pattern at the inlet.
This post was last edited by luoli519 on 2023-10-3 at 15:01. Additionally, the following professional discussion posts published by NOVEL Nuowei Energy Technology Company on the HaiChuan Chemical Forum are listed here for everyone to use as links to join the discussions: 13. Discussion on improvements to the inlet devices of cyclone separators in gas-solid separation applications; please visit http://bbs.hcbbs.com/thread-1614524-1-1.html to participate in the discussion. 14. Regarding the issues arising from the use of swirl tube/swirl plate demisters in the wet flue gas desulfurization process for boilers, please visit http://bbs.hcbbs.com/thread-1599605-1-1.html to participate in the discussion.
This post was last edited by luoli519 on 2017-1-16 at 12:59. 35. Discussion on the removal of liquid sulfur foam from SO2 in the sulfur dioxide production unit of the sulfolane plant: http://bbs.hcbbs.com/thread-1616252-1-1.html.
37. Regarding the application of the C4 hydrocarbons/water coalescing separator in the MMA methyl methacrylate project, please visit http://bbs.hcbbs.com/thread-1617142-1-1.html to participate in the discussion. To be continued......
This post was last edited by luoli519 on 2017-1-16 at 13:00. For discussions on measures for removing liquid droplets from the flue gas resulting from the mixed combustion of waste gas from chlor-alkali plants and coke oven gas, as well as for heat recovery and cooling processes, please visit http://bbs.hcbbs.com/thread-1617257-1-1.html.
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41. For discussions on the recovery and capture of caprolactam droplets and mist entrained in the high-vacuum exhaust stream of the distillation unit in caprolactam plants, please visit http://bbs.hcbbs.com/thread-1621905-1-1.html to participate in the discussion.
Since the operating condition of a cyclone separator is typically two-phase or multi-phase separation, the heavier phase settles and accumulates in the inlet pipe. To prevent the accumulation of sediment in the inlet pipe due to phase recombination, the inlet pipe of the cyclone separator needs to be designed to slope downward and connect with the separator cylinder. Therefore, the shape of the flow rectifying plates installed in the inlet pipe of the cyclone separator, as well as the junction lines between them and the inlet pipe wall, are very complex. The shape of the rectifying plate that ensures high separation efficiency, along with an accurate representation of its junction line with the inlet tube wall, represents a specialized technical capability possessed by only a few separation technology companies.
42. For solutions to the liquid presence at the inlet of the cycle hydrogen compressor in the NO reduction unit of the caprolactam plant, please visit http://bbs.hcbbs.com/thread-1622897-1-1.html to participate in the discussion.