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Cyclone Separator Cut Size Simulator

Q: What should I read first in Cyclone Separator Cut Size?

Start with Cut size d50 and Pressure drop estimate. Then use Particle size and collection efficiency to confirm the assumed state and d50, pressure drop, and velocity to read distribution or bias. Use the main plot to read the controlling trend, including break points that a single result card can hide

Q: How do I judge whether Inlet velocity Vi or Gas viscosity mu matters more?

Move Inlet velocity Vi alone, then move Gas viscosity mu by a comparable amount and compare the change in Cut size d50. Velocity-density d50 map shows combinations where margin or performance changes quickly.

Q: How should this result be used in practice?

Use it for First-pass comparison of design options before review. Instead of trusting a single point, widen the input range and check whether Cut size d50 keeps enough margin before moving to detailed analysis.

Q: What are the limits of this simplified model?

This simplified model captures the main relationship only. Boundary conditions, losses, nonlinear effects, and code-specific corrections still need separate checks. Final decisions still require standards, measured data, detailed analysis, and vendor limits.

Estimate cyclone cut size, pressure-drop tendency, and collection efficiency from inlet velocity, particle density, viscosity, and inlet width.

Parameters

Inlet velocity Vi

m/s

Input Inlet velocity Vi.

Gas viscosity mu

uPa s

Input Gas viscosity mu.

Particle density

kg/m3

Input Particle density.

Inlet width b

Input Inlet width b.

Effective turns

Input Effective turns.

While paused, move the sliders to update the result instantly.

Particle separation inside the cyclone (size-dependent)

Coarse, collected (dp > d50) Fine, escaping (dp < d50) Swirling gas

Results

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Cut size d50

—

Pressure drop estimate

—

10 um efficiency

—

Velocity load

Particle size and collection efficiency

d50, pressure drop, and velocity

Velocity-density d50 map

Model and equations

$$d_{50}\sim\sqrt{\frac{9\mu b}{2\pi N_e\rho_p V_i}}$$

This simplified model captures the main relationship only. Boundary conditions, losses, nonlinear effects, and code-specific corrections still need separate checks.

How to read it

Use the main plot to read the controlling trend, including break points that a single result card can hide.

Use the sensitivity view to find input combinations where margin collapses quickly.

For early design, focus on which input controls margin before trusting the absolute value.

Learn Cyclone Separator Cut Size by dialogue

🙋

When reading Cyclone Separator Cut Size, where should I look first? Moving Inlet velocity Vi changes both the plots and the result cards.

🎓

Start with Cut size d50, but do not treat the number as the whole answer. Use Particle size and collection efficiency to confirm the assumed state, then read d50, pressure drop, and velocity for the distribution or trend. Use the main plot to read the controlling trend, including break points that a single result card can hide.

🙋

I can see why Inlet velocity Vi changes Cut size d50. How should I judge the influence of Gas viscosity mu?

🎓

Move Gas viscosity mu in small steps and watch Pressure drop estimate. That reveals which term is controlling the result. This simplified model captures the main relationship only. Boundary conditions, losses, nonlinear effects, and code-specific corrections still need separate checks. A single operating point is not enough; sweep the realistic scatter range.

🙋

What is Velocity-density d50 map for? It feels like the ordinary curve already tells the story.

🎓

Velocity-density d50 map is for finding boundaries where the condition becomes risky or margin collapses quickly. Use the sensitivity view to find input combinations where margin collapses quickly. In First-pass comparison of design options before review, the important question is often what happens after a small change, not only the nominal value.

🙋

So if Cut size d50 is within the target, can I accept the condition?

🎓

Treat this as a first-pass review. It helps with Narrowing controlling factors and worst-side conditions before detailed analysis and Teaching or explaining the equation, numbers, and visualization under the same inputs, but final decisions still need standards, measured data, detailed analysis, and vendor limits. For early design, focus on which input controls margin before trusting the absolute value.

Practical use

First-pass comparison of design options before review.

Narrowing controlling factors and worst-side conditions before detailed analysis.

Teaching or explaining the equation, numbers, and visualization under the same inputs.

FAQ

Start with Cut size d50 and Pressure drop estimate. Then use Particle size and collection efficiency to confirm the assumed state and d50, pressure drop, and velocity to read distribution or bias. Use the main plot to read the controlling trend, including break points that a single result card can hide

Move Inlet velocity Vi alone, then move Gas viscosity mu by a comparable amount and compare the change in Cut size d50. Velocity-density d50 map shows combinations where margin or performance changes quickly.

Use it for First-pass comparison of design options before review. Instead of trusting a single point, widen the input range and check whether Cut size d50 keeps enough margin before moving to detailed analysis.

This simplified model captures the main relationship only. Boundary conditions, losses, nonlinear effects, and code-specific corrections still need separate checks. Final decisions still require standards, measured data, detailed analysis, and vendor limits.

How to Use

Enter inlet velocity (m/s) in ViVal—typical cyclones operate 15–25 m/s; industrial dust collectors range 20–30 m/s
Input fluid viscosity (muVal, Pa·s) and particle density (rhoPVal, kg/m³)—for air at 20°C use 1.81e-5 Pa·s; for sand use 2650 kg/m³
Specify inlet width (bVal, mm)—smaller inlets (75–150 mm) improve cut size but increase pressure drop
Read cut size d50 (microns), pressure-drop estimate (Pa), 10 µm collection efficiency (%), and velocity load (dimensionless) in output panels

Worked Example

Industrial cement dust separation: inlet velocity 22 m/s, air viscosity 1.81e-5 Pa·s, cement density 3100 kg/m³, inlet width 120 mm. Simulator yields d50 ≈ 3.8 µm, pressure drop ≈ 580 Pa, 10 µm efficiency ≈ 68%, velocity load ≈ 0.34. Narrowing inlet to 85 mm drops d50 to 2.1 µm and efficiency rises to 91%, but pressure increases to 1240 Pa—requiring larger fan motor (5–7.5 kW vs. 3–4 kW).

Practical Notes

Pressure drop scales with inlet velocity squared; reducing inlet velocity from 25 to 18 m/s cuts drop by ~48% but enlarges d50 proportionally—balance filtration need against energy cost
For sticky materials (talc, clay), higher inlet viscosity (mu > 0.01 Pa·s) degradation occurs; validate with wet cyclone or electrostatic precipitator alternative
Velocity load above 0.5 signals re-entrainment risk in the dust outlet; reduce inlet width or split flow across multiple smaller cyclones
Collection of submicron particles (<1 µm) remains poor even at 25 m/s; pair cyclone with baghouse or HEPA stage for regulatory compliance