Improve Particle Separation With an Advanced Hydrocyclone Separator
Sand, grit and other fine particles reduce equipment efficiency by plugging up heat exchangers, cooling water systems, valves and nozzles – thus decreasing productivity while increasing maintenance costs.
Utilizing a cyclone to separate particles can increase productivity and efficiency. Understanding the structural and operational parameters that influence particle distribution can ensure successful separation.
Increased Separation Efficiency
Hydrocyclone separation efficiency can be affected by multiple factors. Some of these include:
Feed particle size, volumetric flow rate and hydrocyclone design are key considerations. Another factor is material concentration; higher concentration levels tend to reduce separation efficiency.
The ratio between axial and tangential velocity has a direct bearing on separation efficiency. An increase in axial velocity allows fine particles to exit via overflow outlets while still maintaining high centrifugal forces for coarse-sized particles, providing better separation efficiency and expanding application scope of hydrocyclones.
Changes in orifice angle also have an effect on separation efficiency, when other parameters remain the same. When other variables remain unchanged, increasing orifice angle enhances separation efficiency but increases pressure drop; finding an optimum orifice angle balance between separation efficiency and pressure drop may optimize hydrocyclone performance while reducing its energy consumption. Furthermore, increasing underflow diameter improves separation efficiency through more symmetric pressure and velocity distributions, ultimately helping reduce internal pressure drop.
Reduced Maintenance Costs
Cyclone separators require minimal maintenance and operate unattended with little supervision, offering the added advantage of reduced waste disposal costs for industries while supporting environmental sustainability initiatives. They allow significant cost-cutting while supporting sustainability efforts.
Cyclones can be tailored specifically to individual applications by customizing inlet and outlet diameter, head-loss through the cyclone, volumetric solids concentration in the underflow volumetric concentration levels and volumetric solids concentration ratio to ensure peak performance. Cyclones made with high alumina ceramic, polyurethane or highly abrasion-resistant ceramic composite materials can address various working environments effectively.
Cyclones can handle large airflows and heavy dust loads with ease, but there are many design and operational variables that could interfere with their effectiveness and capacity. Our experts can assist in selecting the appropriate cyclone for your application based on factors like particle size, gas flow rate, desired efficiency level, budget constraints and more – also helping select an appropriately-sized unit to reduce energy usage and equipment wear and tear.
Increased Productivity
Hydrocyclone separation efficiency depends on many variables; understanding these can help optimize design and operation of your system. Some of these include:
A sharp separation requires consideration of multiple factors. Particle size distribution, geometry of cyclone inlet geometry and material concentration all play key roles. Furthermore, using an appropriate turbulence model to describe flow can have an impactful result.
As increasing cyclone inlet diameter increases separating size but decreases split ratio, decreasing cone angle increases tangential velocity but reduces separation efficiency.
Typically, separating size depends on the concentration of solids in a feed slurry. At higher concentrations, viscosity increases and causes separation efficiency to diminish; as such it’s essential that you select a separating size that meets both process requirements and guarantees no unwanted particles reach discharge valve. An essential parameter to keep an eye out for here is spigot inlet diameter.
Increased Safety
Hydrocyclone filters, commonly referred to as hydrocyclones, are among the most frequently employed industrial filtration devices. Cyclone filters separate solids from liquids using rotational forces generated within a conical vessel without moving parts – an innovative design which makes these reliable devices. In addition, they come equipped with various lining materials tailored for specific uses – polyurethane for low temperature applications or highly abrasion resistant ceramic for dealing with solid wastes such as erosive solids.
Liquids are fed tangentially into the desander, creating strong centrifugal force which causes its cone to rotate and create a vortex. Heavier particles are forced toward the vessel wall while lighter fluids move towards its center before exiting through an apex nozzle.
MC Series Desanding Hydrocyclone geometry has been carefully developed to offer maximum separation efficiency and capacity across a wide range of particle size distributions, fluid rates, pressures and temperatures – providing a tailored solution for oilfield produced water treatment, aquifer deballast water management operations as well as hydrocarbon desanding and sand cleaning operations.