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Performance of a Cyclone Scrubber in Removal of Fine Available on line at Association of the Chemical Engineers of Serbia AChE Chemical Industry & Chemical Engineering Quarterly www.ache.org.rs/CICEQ Chem. Ind. Chem. Eng. Q. 26 (1) 31−40 (2020) CI&CEQ ANA ELISA ACHILES PERFORMANCE OF A CYCLONE SCRUBBER VÁDILA GIOVANA GUERRA IN REMOVAL OF FINE PARTICULATE Department of Chemical MATTER Engineering, Federal University of São Carlos, Brazil Article Highlights • Cyclone spray scrubber is an effective device for the removal of fine particles SCIENTIFIC PAPER • Great performance on fine particulate removal at low L/G flow ratio and pressure drop conditions UDC 621.928.3+641.513:66.074.2 • Inlet air velocity and water injection position influence the collection efficiency • Liquid-to-gas flow ratio strongly affects the performance of cyclone spray scrubber • Smaller droplet sizes increase the collection efficiency of fine solid particles Abstract Cyclones are not classified as effective devices for removing fine particles, while high efficiency wet scrubbers usually have high operational costs. In order to achieve better performance, the aim of this study is to evaluate, for the first time, a cyclone scrubber design based on the dimensions of a Stairmand cyclone separator with the inclusion of liquid injection nozzles located in differ- ent positions to improve the separation of fine particles. Given the lack of stu- dies considering the effect of liquid injection and other operational conditions in the removal performance of a cyclone scrubber with Stairmand dimensions, the present paper provides a complete evaluation of these effects for the separation of sugar cane bagasse ash from air. The parameters investigated were inlet gas velocity, liquid injection position, liquid-to-gas flow ratio and droplet size distribution. The cyclone scrubber performance was evaluated considering collection efficiency and pressure drop. Overall efficiency of almost 99% and low-pressure drop was achieved by employing a liquid-to-gas flow ratio of 0.43 L/m³ for the collection of ash from the combustion of sugar cane bagasse. Grade efficiencies revealed that injecting droplets into cyclones sig- nificantly improved the removal of fine particles with an aerodynamic diameter less than 2.5 µm. Keywords: cyclone scrubber, collection efficiency, fine particle separ- ation, liquid injection. Cyclones and wet scrubbers are applied in removal of this particulate matter from gas streams many industrial processes to separate the particles can lead to negative consequences, including chronic laden in gas stream. An example of a process that respiratory problems in humans [1]. Consequently, uses such equipment is the production of sugar and the removal of particulate matter from these industrial ethanol. The bagasse is generated in the production exhaust streams is essential in order to avoid air process and this waste is used for cogeneration of pollution [2,3]. electricity by burning it in boilers and at the end, it Dry cyclones are frequently employed in indus- produces sugar cane bagasse ash. The inadequate trial applications, due to their low operating costs, simple construction and maintenance, compactness, Correspondence: V.G. Guerra, Federal University of São Carlos. and suitability for use under harsh conditions [4]. Via Washington Luiz, km 235, 13565-905, São Carlos, SP, Brazil. However, dry cyclones are inefficient in collecting E-mail: [email protected] Paper received: 20 December, 2018 very fine particles smaller than 5 μm [5], so they are Paper revised: 11 July, 2019 mainly used for initial pretreatment, upstream of other Paper accepted: 6 August, 2019 more expensive air pollution control equipment [6]. https://doi.org/10.2298/CICEQ181220022A 31 A.E. ACHILES, V.G. GUERRA: PERFORMANCE OF A CYCLONE SCRUBBER... Chem. Ind. Chem. Eng. Q. 26 (1) 31−40 (2020) Wet scrubber techniques are applied in many erical investigation of the effects of the different col- industrial processes, due to their better capacity to lection mechanisms (Brownian diffusion, interception remove fine particles and soluble pollutants from gas and impaction) on the separation efficiency of a streams [7]. Nonetheless, major drawbacks of these gravitational wet scrubber. It was found that droplet scrubbing systems are related to the high energy cost residence time, liquid-to-gas flow ratio, and droplet associated with successful removal of submicron par- size distribution had significant effects on the wet ticles. Venturi scrubbers exhibit significant pressure scrubber efficiency. Therefore, the water droplet size drops, ranging from 2942 to 8826 Pa [8], while some is one of the most important considerations in design- types of scrubbers require the use of high liquid-to- ing a wet scrubber. gas ratios, resulting in the generation of large amounts Mohan and Meikap [11] reported on detailed of sludge [8,9]. experimental studies on the removal of dust particles In attempting to improve the collection efficiency from hot gases by using a spray-cum-bubble column of dry cyclones for smaller particles and decrease the with twin-fluid atomizers using water as the scrubbing operational cost associated with wet scrubbers, the medium. The results indicated that the spray-cum- cyclone spray scrubber combines the particle collect- -bubble column achieved almost 75-99% removal effi- ion mechanisms of these techniques, in a single dev- ciency of particulates. In addition, a comparison of the ice. This apparatus essentially consists of a dry cyc- experimental and theoretical efficiencies was made lone adapted with nozzles that inject atomized liquid and analyzed. (usually water) into the inner chamber. The addition of Lee et al. [8] developed a novel system con- droplets within the equipment leads to improvement sisting of a cyclone and a swirl scrubber with an imp- of its performance, because in addition to the centri- act cone and plates, and evaluated the particle col- fugal force acting on the particles, other collection lection efficiency and the applications of this appar- mechanisms (impaction, interception, and Brownian atus. The parameters investigated were the plate diffusion) also operate, hence increasing the probabil- angles, nozzle size and pressure, and volumetric flow ity of removing the particles from the gas stream. In rate of the scrubbing medium. The results demon- general, the removal rate of the small particles is con- strated that particle separation efficiency improved trolled by Brownian diffusion, while impaction and with decrease of the plate angle, increased pressure interception are significant for removal of large par- of the scrubbing medium at the nozzle tip, and inc- ticles [3,10]. reased volumetric flow rate of the scrubbing medium. The performance of the cyclone spray scrubber, Ahuja [2] studied a novel type of wetted wall including its collection efficiency and pressure drop, cyclone scrubber, where wetting of the cyclone walls depends mainly on the method of liquid injection, the led to an improvement of up to 33% in the collection droplet size distribution, the droplet number, the liquid efficiency for fine particles in the size range from 1 to flow distribution and the initial liquid momentum 3 μm. Higher inlet air velocity resulted in greater [3,11]. Several previous studies have investigated the separation efficiency for all particles, under both dry influence of these parameters on the performance and wet conditions. and applications of cyclone spray scrubbers. Yang et al. [16] studied an innovative type of Krames and Büttner [12] investigated a cyclone cyclone, called a “cyclone splitter”, using numerical scrubber with dimensions based on the Barth [13] and simulation to evaluate its performance, considering Muschelknautz [14] equations. Droplets were gener- the pressure drops obtained with pure and droplet- ated by a pneumatic atomization nozzle that was laden gasses. The effect of droplets loading on the arranged at the cyclone inlet in the direction of the pressure drop was determined using droplet volume flow. A key finding of this study was an empirical rel- concentrations in the inlet gas ranging from 0.1 to ation between the residence time and the separation 1.0%. Experimental results showed that the two- result. When the cyclone was operated in dry mode, phase Euler numbers decreased with increasing the separation efficiency declined with decreasing droplets loading, and a new pressure drop model for a inlet velocity. In contrast, operation in wet mode res- gas-liquid cyclone was established by introducing a ulted in the best separation at the lowest volumetric liquid phase correction coefficient. flow rate. According to the authors, the cyclone spray The aim of the present work was to evaluate the scrubber could be classified as a high efficiency performance of a Stairmand-type cyclone adapted separator. with water injection nozzles, considering the effects of In order to improve understanding of submicron inlet air velocity, droplet size distribution, number of particle removal, Kim et al. [15] conducted a num- droplets, droplet initial velocity, liquid injection posit- 32 A.E. ACHILES, V.G. GUERRA: PERFORMANCE OF A CYCLONE SCRUBBER... Chem. Ind. Chem. Eng. Q. 26 (1) 31−40 (2020) ion, and liquid-to-gas flow ratio. To this end, several that their sprays are oriented down. Considering the experiments were performed under defined conditions nozzles located at side configuration were in the hori- in order to investigate the separation efficiency and zontal direction: 1S and 3S nozzles are facing
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