Hurricane - Numerically Optimized Cyclone Collector
Cyclones have been mostly designed and improved by empirical means. Computerized Flow Dynamics (CFD) can be used for partial cyclone optimization but it is still incomplete for full cyclone optimization. Notably low collection efficiency results from the fact that particle agglomeration for cyclone modelling has been disregarded until present days. ACS developed a complete line of very different Hurricane cyclone families for each different need, considering how inter-particle agglomeration / clustering affects collection efficiency. From coarse particle pre-separation proportioned by compact and low pressure drop cyclones, such as the SD and DX lines, to fine particulate capture with high-end geometries such as the EX and MK, ACS provides solutions for a wide range of industrial cases, being able to reach emissions comparable to ESPs (down to less than 30mg/Nm3).
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Product Overview
- Very high efficiencies: around 50 % of the emissions of other high efficiency cyclones
- Custom designs (single or parallel arrangement)
- Low pressure drop: < 100 mm w. g.
- Direct product discharge avoiding product degradation and cross contamination
- Break-apart construction for easy cleaning
- Very smooth surface finishing to meet pharma requirements
- Materials of construction in 316L stainless steel
- Absence of condensation with heat tracing systems
- Clean in Place (CIP) cleaning systems
- Dimensions: from lab scale to 2000 kg/h N2 or air
Particle Agglomeration in Cyclones
ACS has been investigating particle agglomeration in cyclones for several years. Understanding agglomeration in cyclones has helped ACS build more accurate models of collection efficiency estimation, capable of explaining why sub-micrometer particles are often captured with much higher efficiency than predicted by standard models. Indeed, fine particles tend to form agglomerates (clusters) with much higher collection efficiency than those of the primary particles. Agglomeration increases in the presence of wide particle size distributions, long residence times in the cyclone and high inlet particle concentrations. This knowledge has been incorporated into ACS numerical simulation tool - the PACyc (Particle Agglomeration in Cyclones, Chemical Engineering Journal 162 (2010) 861-876) algorithm. This has been crucial in improving the design of ACS technologies, which have demonstrated to achieve significant reduction in emissions when compared with other high efficiency cyclones.
Optimizing Cyclone's Efficiency
Supported by the PACyc Model, and considering several economical and operation constraints (such as size and pressure loss), with numerical optimization it is possible to generate millions of virtual prototypes within an affordable time period, and to observe the impact of each dimension ratio on the cyclone performance.
Considering this approach as the best path to obtain truly optimized cyclones, sound theories of cyclone collection and pressure loss were chosen for each application, and afterwards improved for predicting collection efficiencies for new geometries. These numerical optimization problems have resulted in many different new lines of cyclones and several patents.
Different Objectives - Different Cyclones
Indeed, different industrial cases have different needs resulting in very different cyclones, for which the optimization functions may be minimizing cost, minimizing space, among others. When high efficiency is required and particles are prone to agglomerate, which includes most of the handled dusts; recent developed Hurricane MK line of cyclones (patent pending) can be a solution to achieve emissions as low as 30mg/Nm3.
The Hurricane MK - The Agglomerator Cyclone
In 2014, a better understanding of agglomeration has allowed ACS to develop a completely new line of cyclone geometries, different from any other in the world: the Hurricane MK. It was obtained by combining stochastic numerical optimization with the PACyc model. This represents a giant leap in terms of efficiency for all ACS products, as these collectors can be used in ReCyclone configurations too, as presented ahead.
Hurricane MK cyclones, once adjusted for a particular process, maximize particle agglomeration. For PSDs that favor clustering, as biomass and coal fly ash, emissions can be as low as 30mg/Nm3 (patent pending).
Application/Industries Served
Emission Control
- Biomass and Coal Combustion
- Steel and Ferroalloys
- Pyrolisis, Incineration and Gasification
- Air Caption and Dedusting
- Biomass Dryers
- Fuel Oil Combustion
- Clinker Cooler and Pre-Heater Dedusting
- Calcination Processes
- High Temperature Separation Processes for Energy Recovery
Product Recovery
- Pharmaceutical Ingredients
- Chemicals
- Food Ingredients
- Nanoparticles
- Mineral Processing
- Fertilizers
- Catalysts
- Milling and Drying processes
Applications
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Emission control solutions for biomass and coal combustion sector - Energy - Bioenergy
For particulate matter (PM) emission control in high temperature exhaust streams, such as those from biomass or coal boilers and heaters, common dedusters such as cyclones and multicyclones are not able to comply with current emission limits. This is mainly due to their low efficiency, particularly for small particles (less than 10µm). In order to meet emission limits this usually requires an additional investment in a final stage deduster. Bag filters (BF) are very efficient dedusters. They can also be very ...
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Emission control solutions for steel and ferroalloys sector - Metal - Steel
Steel and ferroalloysmanufacturing processes involve high temperature exhaust streams, often at more than 900ºC. Typically, the gas flows from the furnace (usually electric arch type) and goes into a gas conditioning tower to cool down below 200ºC so that it can be treated by a Bag Filter. It`s also common to have ESP´s as end dedusters that can be preceded by a multicyclone serving as pre-separators.
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Emission control solutions for clinker cooler and pre-heater dedusting sector - Air and Climate
The control of clinker fines emissions after the heatexchanger, placed downstream of the clinkercooler,is usually a problem for cementplant managers. The process is characterized by high material abrasiveness, high loads and variable flow ratein normal and maximum conditions.
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Emission control solutions for calcination processes sector - Energy
In calcination processes, solid intermediates and products are regularly handled in the fine powder form (ex: kaolin or metakaulin). There is a need to separate these very fine powders from the exhaust streams of calciners, fluid bed dryers or incinerators, often at critical temperature conditions. For PM emission control at very high temperature ( >600 ºC), traditional bag filters following temperature exchangers or scrubbers are used as end stage dedusters.
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Emission control solutions for high temperature separation & energy recovery sector - Energy
Given the difficulties in achieving results by increasing revenues, companies are turning more and more to cutting costs. Reducing energy consumption has become the target for many companies. In sectors as the cement, particleboard manufacturing, inceneration,among others, energy is demanded mostly in the form of heat. Most companies are retrofitting their boilers and thermal oil heaters to run with biomass, instead of oil or coal, to reduce costs and become more eco-friendly. Still too, much of the generated ...
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Emission control solutions for biomass milling & drying sector - Energy - Bioenergy
Pelletsare typically manufactured from wood chips and sawdust. The wet raw material in usually grinded in a hammer mill and then dried in a rotary dryer heated by a biomass furnace. The material is then collected in dryer cyclones to be pelletized. The air conveying the wet grinded material is cleaned with a particulate filter before going to the atmosphere. A common type of filter used for this application is the cyclo-filter, which combines the operating principles of cyclones with a cartridge filter on top to ...
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Product recovery solutions for chemicals industry - Chemical & Pharmaceuticals
Efficient recovery of active pharmaceutical ingredients (APIs), chemical substances or food powders after drying applications such as spray and fluid bed drying is frequently a problem. The same problem occurs in many milling and micronization applications. The preferred way to recover these sensitive products is with cyclone collectors due to their direct powder capture. Unlike bag filters or wet scrubbers, cyclones minimize filter or product contamination and product cross contamination and can easily handle a ...
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Product recovery solutions for nanoparticles industry - Chemical & Pharmaceuticals
An increasingly high number of industries, from the fine chemicals to the cosmetics industry, are investing on the design and production of nanoparticles, such as metal oxides, in specific reactors. There is a need to recover these very fine powders from the exhaust streams often at high temperature, pressure and moisture. The very fine particle size precludes the use of mechanical collectors by themselves. The main problem of using barrier filters is product hold-up and breakage of the nanoparticles. Client`s ...
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Emission control & air dedusting for Fertilizers - Agriculture
The recovery of fertilizers typically after drying tunnels or drum dryers is associated with a high load of particulates and very humid gas streams. The recovery of these products is commonly performed by dryer cyclones as they allow for a direct powder capture and avoid filter clogging due to condensation. Arrangements with cyclones and/or with bag filters are usual in the industry.
Videos related to this product
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Hurricane High Efficiency Cyclone System at Sonae Wood Panel Board Plant in Mangualde, Portugal Video
Please have a look at this drone recorded video showing our cyclone system for Sonae, one of the largest wood-based panel producers in the world.
This project, promoted by EDP - Comercial in the scope of an integrated energy efficiency plan, with the collaboration of CCEnergia, was about thermal energy recovery at Mangualde`s manufacturing plant by reducing fly ash particulate at high temperature after a wood waste thermal oil heater. -
Hurricane System - High Efficiency Cyclones Video
Optimizing Cyclone`s Efficiency
Supported by the PACyc Model, and considering several economical and operation constraints (such as size and pressure loss), with numerical optimization it is possible to generate millions of virtual prototypes within an affordable time period, and to observe the impact of each dimension ratio on the cyclone performance.
Considering this approach as the best path to obtain truly optimized cyclo -
Advanced Cyclone Systems Institutional Video
Advanced Cyclone Systems Institutional Video.
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ACS Hurricane and ReCyclone Systems - 3D Video
ACS Hurricane and ReCyclone Systems
This is our newest video, where we explain the various technologies we provide, such as the Hurricane Cyclone, Mechanical ReCylone and the Electrostatic ReCyclone.
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