192 Ind. Eng. Chem. Res.

2008, 47, 192-200

Computational Fluid Dynamics (CFD) Analysis of Cyclone Separators Connected

in Series
Atilano Antônio Vegini and Henry França Meier
Department of Chemical Engineering, UniVersity of Blumenau (FURB), Blumenau,
Santa Catarina SC 89010-971, Brazil

João Jaime Iess

Votorantim Cement Industry, Curitiba, Paraná PR 82130-570, Brazil

Milton Mori*
Department of Chemical Processes, School of Chemical Engineering, State UniVersity of Campinas, Campinas,
São Paulo SP 13081-970, Brazil

Cyclone separators are very useful equipment for particle removal from gaseous streams. Their simple design
and low capital and maintenance costs have made cyclones one of the most widely used gas-solid separators.
Their dynamic behavior includes several phenomena, such as vortex breakdown, reversal of flow, and high
turbulence intensity. Prediction of pressure drop and collection efficiency over a temperature range of several
hundred degrees with a high solids loading flow and different cyclone dimensions is very difficult with
simplified models. In this work, a model that is based on computational fluid dynamics (CFD) techniques is
used to verify the performance of cyclone separators connected in series; this collection of separators is
called a cyclone tower. The model is based on the Eulerian-Eulerian approach, and it is composed of several
time differential equations in a two-dimensional (2-D) space domain with a three-dimensional (3-D) symmetric
cyclone inlet. The model is solved using the finite volume method with staggered grids. The results on collection
efficiency and pressure drop of an experimental study were used to validate the proposed model. After validation
of the model, it was possible to examine the performance of the cyclone separators through a comparison of
the numerical results and information obtained in the cement industry.

1. Introduction
Cyclones are extensively used in the cement industry for the
heating of raw material (raw meal), which is of basic importance
to the thermal performance of the entire system of cement
production. Figure 1 shows a typical design of a cyclone tower
(cyclone separators that have been connected in series), which
is composed of two streams, each having four cyclones
connected in series. The raw meal is heated in all the cyclones
with the raw meal fed into the system at cyclone C1. The hot
gas from the kiln enters cyclone C4 in a countercurrent flow
and goes through the other cyclone, heating the raw meal. It
can be observed that, in cyclone C4, the phenomena of chemical
reactions and combustion are predominant (calcination region).
The solid material collected in cyclone C4 goes to the kiln.
The exact mechanisms of gas-particle separation in cyclones
still are not completely understood, even though the equipment
has used for a long time. The dynamic behavior includes several
phenomena, such as vortex breakdown, reversal of flow, and
high turbulence intensity.1 In addition, different operating
conditions such as temperature, pressure, and flow rate create
even more difficulties in the already-complicated problem. The
typical models had been developed on the basis of experimental
data collected at room temperature to calculate the main design
parameters of cyclones (i.e., pressure drop and collection
efficiency).2-6 These models give acceptable results only under Figure 1. Cyclone tower.
certain limitations or for certain types of cyclones. The
prediction of results over a temperature range of several hundred degrees with a high solids loading flow and different cyclone
dimensions is very difficult with these simplified models.
* To whom correspondence should be addressed. Fax: +55 19 In this work, a model based on computational fluid dynamics
35213963. E-mail address: mori@feq.unicamp.br. (CFD) techniques was used to predict the design parameters
10.1021/ie061501h CCC: $40.75 © 2008 American Chemical Society
Published on Web 11/28/2007
 Ind. Eng. Chem. Res., Vol. 47, No. 1, 2008 193

for cyclones in a cement industry. The cyclones have different Mass ConserVation in the Gas Phase
shapes and are operated at high temperatures with a high solids
loading flow. The model used is based on the Eulerian-Eulerian ∂
(f F ) + ∇‚(fgFgvg) ) 0 (1)
approach, and it is composed of several time differential ∂t g g
equations in a two-dimensional (2-D) space domain with a three-
Mass ConserVation in the Solid Phase
dimensional (3-D) symmetric cyclone inlet. The transformation
of a 3-D asymmetric inlet to a 3-D symmetric inlet was validated ∂
in previous work,7,13 as suggested by several researchers.1,8-10 (f F ) + ∇‚(fsFsvs) ) 0 (2)
∂t s s
This transformation was also validated with the experimental
data from Patterson and Munz11 with the numerical simulation Momentum ConserVation in the Gas Phase
obtained with the CYCLO code that was developed by Meier7
and with the commercial code CFX 4.4 of ANSYS,12 which is ∂
(f F v ) + ∇‚(fgFgvgvg) ) -fg∇‚(Tef
g ) + fgFgg - ∇p + Fres
based on an anisotropic model of the Reynolds stress. Both ∂t g g g
(3)
models provided a successful representation of the behavior of
gas and gas-solid turbulent swirling flow in cyclones with Momentum ConserVation in the Solid Phase
industrial characteristics.12 The mathematical model is completed
using a hybrid turbulence model composed of a combination ∂
(f F v ) + ∇‚(fsFsvsvs) ) fsFsg - Fres (4)
of the k- standard model and Prandtl’s longitudinal mixing ∂t s s s
model to represent the turbulence of the gas phase. Our research
group has studied turbulence models for swirling gas-solid flow Energy ConserVation in the Gas Phase
in cyclones since 1994, and the main conclusion obtained shows
∂
that the anisotropy behavior of the Reynolds stress can be (f F C T ) + ∇‚(fgFgvgCpgTg) ) -fg∇.(qef
g ) - fgqgs (5)
∂t g g pg g
introduced very well using this hybrid turbulence model.
Comparisons between experimental and numerical profiles of Energy ConserVation in the Solid Phase
tangential velocity for several experimental cases have shown
good agreement.13 The model is solved using the finite volume ∂
(f F C T ) + ∇‚(fsFsvsCpsTs) ) fsqgs (6)
method with staggered grids. Experimental data on the collection ∂t s s ps s
efficiency and pressure drop obtained by Zhao et al.14 are
compared with the numerical results to validate the code. The 2.1.2. Constitutive Equations. The model adopted for the
numerical results allowed prediction of pressure drop and effective shear stress is based on the Boussinesq approximation,
collection efficiency, as well as the complete fluid dynamics where the relation of shear stress to deformation rate is similar
behavior of the gas-solid flow for the cyclones. By analyzing to that in the general Newtonian fluid model. In this case, the
and comparing the information from the cement industry with tensor is directly proportional to the deformation rate:
the results obtained by the model, we are able to verify the
g ) -2µ Dg
Tef ef
performance of the cyclone tower. (7)

2. Mathematical Modeling where the deformation rate is

Cyclones in the cement industry are operated at very high
1
temperatures (in the range of 450-900 °C) with an inlet dust Dg ) [∇vg + (∇vg)T] (8)
2
loading from 250 g/m3 to 500 g/m3. This type of problem can
be modeled using a multifluid concept where a phase interacts and the effective viscosity (µef) is a combination of molecular
with one or more other phases by means of drag forces and viscosity (µg) and turbulent viscosity (µ(t)):
mass and energy fluxes between phases. The main assumption
of this model is that the phases interpenetrate where all phases µef ) µg + µ(t) (9)
have fluid dynamics properties at the same point in the time-
space domain (i.e., continuous properties, such as density, In eq 9, the turbulent viscosity (µ(t)) can be obtained from an
viscosity, thermal conductivity, etc.). Only the molecular anisotropic model,7 from a combination of the k- standard
behavior of the material is neglected. More detailed information turbulence model and Prandtl’s mixing length theory.
on multifluid modeling can be obtained in the work of In the cylindrical coordinate system, for example, Prandtl’s
Gidaspow15 and Meier and Mori.13 model can be written as follows:
2.1. The Two-Phase Model. The development of a multifluid
model for gas-solid flow in cyclones requires some assump-
tions: (i) the solid phase can be represented by a mean diameter;
∂ug 2
(µ(t))θ,θ ) (µ(t))r,θ ) (µ(t))z,θ ) (µ(t))in + Fgr2l2
∂r
+ (( ) ( )
ug 2
r
+
(ii) the turbulence in the gas phase is anisotropic and can be
represented by means of a hybrid turbulence model that is
composed of a combination of the k- standard model and
( ) {[ ( )] (
∂wg
∂z
2
+
1
2
r
∂ Vg
∂r r
2
+
∂ug ∂wg 2
∂z
+
∂r
+
∂z ) ( ) })
∂Vg 2 1/2
(10)

Prandtl’s longitudinal mixing model; and (iii) disturbances in where the first term on the right side of eq 10, (µ(t))in, physically
the flow near the inlet region due to asymmetry of the tangential represents an additional turbulence contribution due to inlet
or involute gas inlet to the cyclone quickly disappear, which effects11 and l is the mixing length, by analogy with the kinetic
makes it possible to use axial symmetry and apply the 3-D theory of gases.
symmetry model. The flow is incompressible and the pressure A correlation for (µ(t))in, as suggested by Pericleous,16 is given
force acts only on the gas phase, which is a hypothesis of the as
mathematical modeling used in this work.
2.1.1. Conservation Equations. The conservations equations Dh
(µ(t))in ) Fg(kg)1/2 (11)
involved in this study are given as follows. 10
194 Ind. Eng. Chem. Res., Vol. 47, No. 1, 2008

The other component of the anisotropic turbulent viscosity with The rate of heat transfer between the phases can be calculated
the application of the k- standard model is using the equation

(µ(t))r,z ) (µ(t))r,r ) (µ(t))z,z ) CµFg ()

kg2
g
(12) qgs ) hgs ( )
3
(T - Ts)
2dp g
(23)

where Cµ is a constant, kg the turbulent kinetic energy, and g where the convective heat-transfer coefficient can be predicted
the dissipation rate of turbulent kinetic energy. There are also by the following equation:18
two additional conservation equations:

( ) ( )( ) ( ) ( )
kg d p Fs Qs
0.93 0.82 0.64
∂ µef hgs ) 175 -1 Re00.14Pr1/3 (24)
(fgFgkg) + ∇‚(fgFgvgkg) ) fg∇‚ k ∇kg + fg(Gg - Fgg) (13) d p Dc Fg Qg
∂t σ
and with

∂
∂t
µef
σ ( )
(fgFgg) + ∇‚(fgFgvgg) ) fg∇‚  ∇g + Re0 )
FgVendp
µg
(25)
g
fg(C1Gg - C2Fgg) (14)
kg where Q is the volumetric flow rate and Ven is the inlet mean
velocity.
where σk, σ, C1, and C2 are constants of the model and Gg is 2.2. Boundary and Initial Conditions. The initial conditions
a source of turbulence that can be predicted using the following used for numerical simulation of the single-phase dynamic flow
equation: were start-up conditions, where all velocity components were
considered to be equal to zero and the pressure field was the
Gg ) -T(t)
g :∇vg (15)
atmospheric field. For the gas-solid flow, profiles for the gas
were obtained from the steady state of single-phase flow with
Now the resistive or drag forces between phases can be modeled
an abrupt entry of the solid phase.
by a standard expression:
The boundary conditions used were a uniform profile at the
Fres ) βg,s(vg - vs) (16) inlet, no-slip conditions on the wall, axial symmetry conditions
at the symmetry axis, and continuity conditions at the exits.
where βg,s is the interface coefficient and can be predicted for More details can be found in the work reported by Meier.7
concentrated flows (fg < 0.8) by means of the Ergun equation:8 2.3. Numerical Methods. The software used to solve the

( )
model was the CYCLO code using CFD techniques; this model
fs 2 Fgfs|vg - vs|
βg,s ) 150µg + 1.75 (17) was developed by Meier.7 This program is composed of three
fgdpφp dpφp moduli: the preprocessor modulus, the processor modulus, and
the postprocessor modulus.
where dp is the particle diameter, φp the spherical shape
The preprocessor modulus is responsible for generating the
coefficient, and |vg - vs| the relative velocity between phases.
grid, which was developed in a cylindrical coordinate system
For diluted flows where fg > 0.8, a model that has been
with a multiblock scheme and staggered grids.
proposed15 relates the interface coefficient with the drag
coefficient, CD, by the following equation: The numerical solutions were obtained through the processor
modulus, which uses the finite volume method to discretize the

βg,s ) () (
3
C
4 D
fgFg|vg - vs|fs
dpφp ) (18)
partial differential equations of the model. For the pressure-
velocity coupling, the program uses the SIMPLEC algorithm.
After discretization by the finite volume method, a traditional
In the literature, there is a large number of empirical line-by-line algorithm with TDMA is applied to solve the system
correlations for drag coefficient calculation, as a function of of nonlinear equations. The time solution is obtained from an
the Reynolds number for the particles. One that establishes implicit first-order procedure. Details about this solution strategy
equations for all flow regimes was published by Coelho and can be found in the work of Patankar,19 Maliska,20 and Meier.7
Massarani:17 Animation techniques generated with the postprocessor
modulus are applied to visualize the behavior of the flow in

[( )24
]
0.85 1.18
CD ) - K20.85 (19) the cyclone.
K1Rep

with 3. Results and Discussion

K1 ) 0.843 log10 ( )φp

0.065
(20)
3.1. Validation of the Model. This model was compared with
data obtained under the experimental conditions presented by
Zhao et al.14 Experiments were performed with air under
K2 ) 5.31 - 4.88φp (21) ambient conditions, as a function of flow rate and with a dust
load of 5.0 g/m3. The solid particles were talcum powder with
and a skeletal density of 2700 kg/m3 and a mass median particle
diameter of 5.97 µm. The cyclone with a conventional tangential
Fg|vg - vp|dp
Rep ) (22) inlet and a body diameter of 0.3 m was studied. Because of the
µg main purpose of the article, it is not necessary to give the full
 Ind. Eng. Chem. Res., Vol. 47, No. 1, 2008 195

Figure 2. Comparison of experimental grade efficiency with numerical results at different velocities.

geometries of the test cyclone here; however, complete informa-

tion can be found in the reported work of Zhao et al.14 and
Vegini et al.21 In our previous work, the global collection
efficiency of the high solids flux inlet in the cement industry
cyclone was validated with CYCLO code, which showed a
deviation of 20%, and for the pressure drop, a relative error of
∼13.3% was observed. This difference seems to be caused by
irregularly shaped particles and a particle size distribution, which
prevents an accurate modeling of the interaction between
particles of different diameters (see Meier et al.26,27).
Figure 2 compares the grade collection efficiency of the
numerical results obtained with the CYCLO code to that of the
experimental data for different inlet velocities. As expected, the
experimental and predicted efficiency of all cases increase as
the particle size and entrance velocity increase. Good agreement
is observed between the numerical calculation of the two-phase
model and the experimental data. As can be observed, generally,
the predicted results are lower than the experimental values,
probably because of the model adopted for interaction between Figure 3. Pressure drop, as a function of inlet velocity.
the phases, which considers only the gas-solid interaction. The
influence of the solid-solid interaction in the performance of drop) from a microscopic property (pressure field as a function
cyclones is being studied by the authors. of spatial domain)).
Figure 3 shows the comparison of pressure drop as a function The results are generally in good agreement, with the
of inlet velocity obtained by experiments to that obtained by prediction being within 13%-25% of the experimental value.
numerical prediction. The pressure drop is obtained with the As expected, the pressure drop increases as the inlet velocity
CYCLO code, by integrating the pressure field into the inlet increases.
and outlet sections, followed by subtraction of the integrated In conclusion, it can be said that the CYCLO code is able to
values (in this way, calculating a macroscopic property (pressure predict the performance parameters of cyclones.
196 Ind. Eng. Chem. Res., Vol. 47, No. 1, 2008
Figure 4. Definition of cyclone dimensions.
3.2. Application of the Cyclone Tower in the Cement
Industry. The cyclone dimensions used in this case study are
listed in Table 1. Cyclones C4A and C4B could not be used in
this study, because the CYCLO code is not prepared to predict
results in situations where reactions such as calcinations occur.
A schematic diagram that represents the definition of cyclone
dimensions is shown in Figure 4. The cyclone dimensions are
the same at each stage, for streams A and B (see Tables 2 and
3). It was assumed that all particles have the same average
diameter. The average diameter of the particle was calculated
using the values given in Table 4. The average diameter of the
particle is given as
average particle diameter ) ∑ (particle diameter) ×
(% under size)
As expected, we can see that the particle diameter becomes
smaller with increasing temperature (see Table 4); this is due
to the volatilization of some components.
The main purpose of the present study is to examine the
performance of a cyclone tower (cyclone separators connected
in series) in a cement industry. The performance variables of
greatest concern are usually pressure drop and solid collection
efficiency. The study here was conducted to present a methodol-
ogy for detection of process deviation, which can be done by
comparing the pressure drop obtained in the cement plant with
the results of prediction with the CYCLO code.
3.2.1. Fluid Dynamic Behavior of the Two-Phase Flow.
The prediction of two-phase flow with CFD techniques can be
used to identify the main phenomenological characteristics of
the swirling flow in cyclones. Using the numerical results
obtained with the cyclone C1A for an average particle diameter
of 30 µm, it is possible to visualize some microscopic informa-
tion. For example, by means of visualizing the pressure field
on the symmetrical r-z plane, as shown in Figure 5, it is
possible to identify a low-pressure center that is responsible
for the stability of the high swirling flows, which attracts the
fluid in its vicinity, preventing dispersion of the swirl.
Reversal of the axial flow of the gas phase in the cyclone,
for the same case, can be observed in Figure 6. It is possible to
Table 1. Cyclone Dimensions
cyclone
dimension C1A-C1B
length of the inlet, Le (mm) 1849.00
length of the vortex finder, Ls (mm) 5490.00
length of the cylinder, Lc (mm) 5469.00
length of the conical section, Lco (mm) 6180.00
diameter of the vortex finder, DS (mm) 3500.00
diameter of the cyclone, DC (mm) 5701.00
diameter of the underflow, DL (mm) 865.00
width of the inlet, b (mm) 3721.00
conclude that the reversal occurs within practically the entire
conical section of the cyclone. This means that the natural length
was respected, ensuring the flexibility and the good performance
of the cyclone.
In the same way, Figure 7 shows the tangential velocity field
for the same conditions. Velocities close to twice the inlet
tangential velocity can be found near the inlet of the vortex
finder, which produces stability of the swirling flow and a large
centrifugal field, hwhich is responsible for the high collection
efficiency of the cyclone.
Finally, all of the previously mentioned analyses were made
possible only through the use of the microscopic properties of
the two-phase flow predicted by CFD techniques developed in
this work.
3.2.2. Pressure Drop and Collection Efficiency in the
Pressure and Volumetric Fraction Fields. Figures 8-13 were
obtained by numerical simulation, using the CYCLO code, and
have the purpose of verifying the consistency of the results with
practical knowledge, whereas the case under study represents
an industrial situation with specific process conditions. For
example, Figures 8 and 9 show the collection efficiency curves
for cyclones for streams A and B. As expected, the collection
efficiency increases as the particle size increases, and particles
with a diameter of >50 µm have a collection efficiency of 100%.
It can be verified that the collection efficiency of cyclone C1 is
greater than those of cyclones C2 and C3, although the inlet
velocity is lower for this cyclone. This type of behavior is
expected in practice, because cyclone C1 is responsible for the
efficiency of the process (i.e., the solid material that is lost in
this cyclone will not return to the process, which causes a
reduction in the efficiency of the process). The results can be
explained, because other effects beyond inlet velocity (such as
solid loading, temperature, and cyclone shape) also influence
the efficiency of cyclones. Hoffmann et al.22 reported the effects
of shape, and solids loading on the performance of cyclones,
while the effect of high temperatures was studied by Patterson
and Munz23 and Shi et al.24 Analyzing this information, and
because the experimental results follow the same trend, it can
be said that the results are qualitatively consistent.
In Figures 10 and 11, the results of the effect of pressure
drop for various particle diameters are presented. A reduction
in pressure drop, as a function of particle size, can be observed,
and the same behavior can also be observed for particles larger
than ∼40 µm. The phenomenon could be due to a reduction in
tangential gas velocity in the axial position near the entrance
of the vortex finder, which can be seen in Figures 12 and 13.
The tangential velocity is mostly responsible for the pressure
drop in the cyclone, and its reduction, as a function of particle
size, is due to the larger consumption of energy in the drag of
larger particles. As a consequence, there is a decrease in the
centrifugal field and, therefore, a decrease in the pressure drop.
The primary purpose of the present study was to examine
the performance of a cyclone tower in a cement industry to
detect process deviation by comparing the pressure drop
cyclone cyclone
C2A-C2B C3A-C3B
1720.00 1720.00
2060.00 2060.00
3660.50 3660.50
5703.50 5703.50
3190.00 3190.00
5333.00 5333.00
952.00 952.00
4244.00 4244.00
 Ind. Eng. Chem. Res., Vol. 47, No. 1, 2008 197

Table 2. Operating Conditions: Stream A

operating conditions cyclone C1A cyclone C2A cyclone C3A
fluid gas with particles gas with particles gas with particles
volumetric flow rate (m3/s) 121.78 156.07 178.88
inlet mean velocity (m/s) 17.70 21.38 24.50
dust load (g/m3) 471.83 340.94 297.46
mean temperature (°C) 460.42 670.88 832.47
mean pressure (mbar) 873.96 877.54 896.74

Table 3. Operating Conditions: Stream B

operating conditions cyclone C1B cyclone C2B cyclone C3B
fluid gas with particles gas with particles gas with particles
volumetric flow rate (m3/s) 128.88 163.33 178.88
inlet mean velocity (m/s) 18.73 22.37 24.50
dust load (g/m3) 445.84 327.92 299.42
mean temperature (°C) 477.46 686.31 802.57
mean pressure (mbar) 869.67 877.22 898.01

Table 4. Particle Size Distributions or more other phases by means of drag forces. The influence
% under size (mass) of solids loading on pressure drop has been presented in the
particle diameter (µm) cyclone C1 cyclone C2 cyclone C3
literature by various authors.2,22,25 They observed that the
pressure drop decreases when solid particles are introduced into
50.00 41.59 39.99 33.20
the flow. However, the results were obtained with low solids
40.00 6.28 6.56 7.60
30.00 7.92 8.81 10.40 loadings, with a maximum value of 130 g dust/m3 gas. The
20.00 12.36 13.14 16.10 case under study has values of >300 g dust/m3 gas.
10.00 31.85 31.50 32.70 One of the most important results obtained in this study was
the detection of a process deviation that can be observed by
obtained in the cement plant with the results predicted by the analyzing Figures 14 and 15. The cyclones simulated in this
CYCLO code. The average pressure drop was calculated using case study are connected in series, as shown in Figure 1. Because
the results obtained for each particle size, and its mass fraction of this geometric arrangement (see Figure 1), if one fault is
is shown in Table 4. The calculated pressure drop shown in detected in one of the outlet valves in the bottom of one of the
Figures 14 and 15 is the total pressure loss between the inlet cyclones, there will be a false air inlet into the system. This
and outlet sections of the cyclones studied. false air inlet will affect the fluid dynamics behavior of the
The comparison between the calculated and the measured cyclone and could change the conditions of the subsequent
pressure drops for the cyclones is presented in Figures 14 and cyclone. Figures 14 and 15 show the numerical results obtained
15. The results show that pressure drop for gas-solid flow with the CYCLO code. The operating conditions were obtained
(GasSolid-CYCLO) is higher than that for gas flow (Gas- from the industrial control unit system, and they represent the
CYCLO). This can be explained because the model used is historical average values of unit operation during several days.
based on a multifluid concept where a phase interacts with one

Figure 6. Axial velocity field of the gas phase on the r-z symmetrical
Figure 5. Pressure field on the r-z symmetrical plane of the C1A cyclone. plane of the C1A cyclone.
198 Ind. Eng. Chem. Res., Vol. 47, No. 1, 2008

Figure 9. Collection efficiency for stream B.

Figure 7. Tangential velocity field of the gas phase on the r-z symmetrical
plane of the C1A cyclone.

Figure 10. Pressure drop, as a function of particle size (stream A).

Figure 8. Collection efficiency for stream A.

The numerical results show a similar behavior for both towers.
In the numerical simulation, the mass flow rate of gas through
the cyclones connected in series is the same: only the conditions
of temperature (T) and pressure (P) are changed. However, when
the pressure decreases in both streams, which is as measured
when the system showed an operational deviation with no
known cause, one observes that cyclones C1 and C2 in stream
B (see Figure 15) exhibit behavior that is different from the
numerical results for cyclones C1 and C2 in stream A. A false
air inlet causes perturbations in the fluid dynamics behavior by
absorbing energy from the centrifugal field and, thus, reduces
the tangential velocity profile, which is responsible for most of Figure 11. Pressure drop as a function of particle size (stream B).
the pressure drop in cyclones. In addition, the measured pressure
drop in cyclone C2 in stream B is smaller than the numerical be affected, because it will receive all the gas from cyclone C2
value, which suggests that the false air inlet occurs in the valve (see Figure 1), and as a consequence, the increase in mass flow
located on the bottom of this cyclone. Thus, cyclone C1 will rate in cyclone C1 will cause an increase in pressure drop in
 Ind. Eng. Chem. Res., Vol. 47, No. 1, 2008 199

Figure 12. Radial profiles of tangential velocity for cyclone C1A.

Figure 15. Pressure drop (average) for stream B.

This probable process deviation in the system was discovered

in the maintenance of the cyclones for the company. During
the inspection, a defect was detected in the valves of the
cyclones for stream B.

4. Conclusions
In the present paper, a model that is based on computational
fluid dynamics (CFD) techniques was used to predict the design
parameters for cyclones in a cement industry to verify the
performance of a cyclone tower (cyclone separators connected
in series). The cyclones have different shapes and are operated
at high temperatures and with a high solids loading flow.
The model was validated with experimental data on pressure
drop and collection efficiency. The results obtained in this work
have demonstrated the sensitivity of the model to particle size,
thereby showing that the CYCLO code has considerable
potential for prediction of the collection efficiency.
Figure 13. Radial profiles of tangential velocity for cyclone C1B. In conclusion, it can be said that the multifluid concept
adopted in this study was demonstrated to be a reliable and
relatively inexpensive method of detecting process deviation.

Nomenclature
b ) width of the inlet
CD ) drag coefficient
C1, C2, C, µ ) constants of the k- model
D ) deformation rate tensor
d ) diameter
Dc ) cyclone diameter
Dh ) hydraulic diameter of the inlet
Dl ) “underflow” diameter
Ds ) “vortex finder” diameter
Fres ) resistive force
f ) volumetric fraction
g ) gravitational acceleration
G ) source of turbulence generation
h ) convective heat-transfer coefficient
k ) turbulent kinetic energy
Figure 14. Pressure drop (average) for stream A.
l ) mixing length
this cyclone. This can be observed in Figure 15, which shows Lc ) cylinder length
that the measured pressure drop in cyclone C1 is larger than Lco ) conical length
the simulated value. Through this investigation, one can Le ) inlet length
conclude that the cyclones in stream B are operating with a Ls ) “vortex finder” length
false air inlet into the system. p ) pressure
200 Ind. Eng. Chem. Res., Vol. 47, No. 1, 2008

Pr ) Prandtl number performance for various operating conditions using a general software.
Q ) volumetric flow rate Chem. Eng. Process. 2004, 43, 511.
(7) Meier, H. F. Modelagem Fenomenológica e Simulação Bidimensional
q ) heat-transfer rate de Ciclones por Técnicas da Fluidodinâmica Computacional. Ph.D. Dis-
Re ) Reynolds number sertation, Universidade Estadual de Campinas, Campinas-SP, Brazil, 1998.
r ) radial direction (8) Boysan, F.; Ayers, W. H.; Swithenbank, J. A fundamental math-
t ) time ematical modeling approach to cyclone design. Trans. Inst. Chem. Eng.
T ) temperature 1982, 60, 222.
(9) Zhou, L. X.; Soo, S. L. Gas-solid flow and collection of solids in a
Tef ) effective shear stress cyclone separator. Powder Technol. 1990, 63, 45.
u ) radial velocity component (10) Madsen, H. J.; Thorstensen, J. H.; Salimi, P.; Hassing, N. H.;
V ) tangential velocity component Rusaas, J. Prediction of the performance of gas cyclones. In Proceedings
v ) velocity vector of the Second CFDS International User Conference, 1994; p 211.
Ven ) inlet mean velocity (11) Patterson, P. A.; Munz, R. J. Gas and particle flow patterns in
cyclones at room and elevated temperatures. Can. J. Chem. Eng. 1996, 74,
z ) axial coordinate 213.
w ) velocity in the z-direction (12) Noriler, D.; Vegini, A. A.; Meier, H. F., Mori, M. Verificação e
validação em CFD do escoamento giratório em ciclones a gás. In XXV
Greek Letters Iberian Latin-American Congress on Computational Methods in Engineer-
β ) interface coefficient ing, 2004.
(13) Meier, H. F.; Mori, M. Anisotropic behavior of the Reynolds stress
 ) dissipation rate of turbulent kinetic energy
in gas and gas-solid flows in cyclones. Powder Technol. 1999, 101, 108.
φ ) spherical shape coefficient (14) Zhao, B.; Shen, H.; Kang, Y. Development of a symmetrical spiral
µ ) viscosity inlet to improve cyclone separator performance. Powder Technol. 2004,
F ) density 145, 47.
σ ) constant of the k- model (15) Gidaspow, D. Multiphase Flow and Fluidization-Continuum and
Kinetic Theory Descriptions; Academic Press: London, 1994.
θ ) tangential coordinate
(16) Pericleous, K. A. Mathematical simulation of hydrocyclones. Appl.
Superscripts Math. Modell. 1987, 11, 242.
(17) Massarani, G. Fluidodinâmica em Sistemas Particulados; Editora
ef ) effective property UFRJ: Rio de Janeiro, Brazil, 1997.
 ) dissipation rate of turbulent kinetic energy (18) Peres, A. P.; Cremasco, M. A. Proposta de uma correlação para o
k ) turbulent kinetic energy coeficiente de transferência de calor gás-partı́cula em um cyclone. XXIV
ENEMP Ann. 1997, 2, 512.
t ) turbulent property (19) Patankar, S. V. Numerical Heat Transfer and Fluid Flow; Hemi-
T ) shear stress tensor sphere Publishing Co.: New York, 1980.
(20) Maliska, C. R. Transferência de Calor e Mecânica dos Fluidos
Subscripts Computacional: Fundamentos e Coordenadas Generalizadas; LTC: Rio
g ) gas phase de Janeiro, Brazil, 1995.
p ) particle (21) Vegini, A. A.; Meier, H. F.; Mori, M. Four phase Eulerian-Eulerian
model for prediction of multiphase flow in cyclones, In XXVI Iberian Latin-
r ) radial direction American Congress on Computational Methods in Engineering, 2005.
ref ) reference (22) Hoffmann, A. C.; van Santen, A.; Allen, R. W. K. Effects of
s ) solid phase geometry and solid loading on the performance of gas cyclones. Powder
z ) axial coordinate Technol. 1992, 70, 83.
(23) Patterson, P. A.; Munz, R. J. Cyclone collection efficiencies at very
high temperatures. Can. J. Chem. Eng. 1989, 67, 321.
Acknowledgment (24) Shi, L.; Bayless, D. J.; Kremer, G.; Stuart, B. CFD simulation of
the influence of temperature and pressure on the flow pattern in cyclones.
The authors are very grateful to Universidade Estadual de Ind. Eng. Chem. Res. 2006, 45, 7667.
Campinas, Universidade Regional de Blumenau, CAPES and (25) Bernardo, S.; Mori, M.; Peres, A. P.; Dionı́sio, P. D. 3-D
to Votorantim Cimentos S. A., which made this work possible. computational fluid dynamics for gas and gas-particle flows in a cyclone
with different inlet section angles. Powder Technol. 2006, 162, 190.
Literature Cited (26) Meier, H. F.; Ropelato, K.; Forster, H.; Iess, J. J.; Mori, M.
Computational fluid Dynamics (CFD) zur Berechnung und Auslegung von
(1) Dyakowski, T.; Williams, R. A. Modelling turbulent flow within a Zyklonen, Teil 1 (Computational Fluid Dynamics (CFD) for cyclone
small-diameter hydrocyclone. Chem. Eng. Sci. 1993, 48, 1143. evaluation and design, Part 1). ZKG Int. 2002, 55 (4), 64.
(2) Shepherd, C. B.; Lapple, C. E. Flow pattern and pressure drop. Ind. (27) Meier, H. F.; Ropelato, K.; Forster, H.; Iess, J. J.; Mori, M.
Eng. Chem. 1939, 31, 972. Computational fluid Dynamics (CFD) zur Berechnung und Auslegung von
(3) Lapple, C. E. Processes use many collector types. Chem. Eng. 1951, Zyklonen, Teil 2 (Computational fluid Dynamics (CFD) for cyclone
58, 144. evaluation and design, Part 2). ZKG Int. 2002, 55 (6), 64.
(4) Barth, W. Berechnung und Auslegung von Zyklonabscheidern auf
Grund neuerer Untersuchungen. Brennst. Waerme-Kraft 1956, 8, 1. ReceiVed for reView November 24, 2006
(5) Leith, D.; Licht, W. The collection efficiency of cyclone type particle ReVised manuscript receiVed September 21, 2007
collectors: A new theoretical approach. AIChE Symp. 1972, 68, 196. Accepted October 2, 2007
(6) Altmeyer, S; Mathieu, V.; Jullemier, S.; Contal, P.; Midoux, N.;
Rode, S.; Leclerc, J. P. Comparison of different models of cyclone prediction IE061501H