Powder loss and emissions hurt the bottom line – optimizing cyclones with virtual testing
Emissions cut by
~50%
Meeting strict environmental regulations.
Pressure drop
Safe
Kept within cyclone operational window.
Powder loss
Minimized
Reducing downtime for exhaust duct cleaning.
For more information about how we can help you with similar projects, reach out to us
Challenge
A client’s fluid bed cyclone exceeded emission limits (25 mg/Nm³ vs. allowed 10 mg/Nm³). Contributing factors included an outdated vortex finder, oversized ducting, and false air. A solution was urgently needed to meet regulations without increasing smearing and maintaining an acceptable pressure drop.
Approach
We employed advanced CFD simulations to evaluate different configurations of inlet bends, outlets, and multiple vortex finder designs. Iterative testing and analysis led us to quickly identify an optimized cyclone design, which halved emissions while keeping pressure drop at a manageable level. More aggressive designs were tested but offered no further benefit.
Result
The new vortex finder reduced emissions by more than 50%, effectively solving the emission compliance issue. Pressure drop remained in the 20–24 mBar range—compatible with the existing fan system. The cyclone now operates more efficiently, with less powder loss and improved environmental compliance.
Cyclones can also suffer from product smearing, wear and vibrations
Through our iterative virtual testing method, we can eliminate the risks of these operational inefficiencies with unintrusive procedures. Furthermore, cyclones in parallel often face imbalance issues. All of these challenges can be analyzed and addressed with virtual testing.
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