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Cyclone collectors are machines that use an air vortex, inertia and gravity to separate contaminants from air or liquids. They are used in a variety of industries to promote better safety or to separate materials for processing. This technology is especially valuable in buildings where filters are either not available or cannot be used, because it requires no filtering to perform at maximum efficiency. These devices can be a major defense against explosions or fires caused by dust collection. They can also remove liquid contaminants from the air, which is useful in the petrochemical industry.
These devices use simple physical principles to perform at high efficiency. Most cyclone collectors are shaped like tubes that are conical on the bottom. A stream of contaminated air is directed into the top of the tube, where it begins flowing in a helical manner. It moves downward and as it nears the bottom of the tube, it flows in tighter and tighter helixes. Solid and liquid particles that are in the airstream have too much inertia to mimic the air flow patterns in the tube and strike the side of the tube. These particles descend through an opening at the bottom of the conical tapering, where they are collected. As the flow of air descends and is forced to move in tighter helixes, smaller and smaller particles exceed the inertia threshold for maintaining position in the air stream and are separated out. Some cyclone collectors are designed with a secondary air stream that pushes particles out through the opening at the base of the machine. This prevents particles from striking the walls of the device and causing abrasion. These designs also allow for horizontal mounting, because they do not solely rely on gravity to function.
The efficiency of the separator is determined by two factors. The speed of the air flow and the geometry of the machine alter the nature of the helical stream. This can either increase or decrease the amount of inertia particles experience while inside. The “cut point” is used to describe what particle size will be removed at 50 percent efficiency for a particular device. Smaller particles will be separated at a lower efficiency and larger particles will be removed at higher efficiencies.
The most common use for cyclone collectors is for dust separation and removal. Factories and processing plants that expel a lot of dust, like sawmills or mineral processing plants, must constantly remove particles from the air to reduce the risk of several dangers. In high enough concentrations, dust can provide enough fuel for a small flame to cause sudden and destructive combustion. If this combustion occurs in an enclosed area, the resulting spike in pressure may result in an explosion. In addition, workers exposed to high levels of dust may eventually develop major health complications of the lungs or heart. Cyclone collectors are also common in professional or industrial kitchens to remove grease from the air. This technology may be adapted for separating particles from streams of liquid. This is especially helpful at water treatment plants, where contaminants are removed from wastewater during processing. Downscaled versions make effective vacuums and are designed into high quality vacuum cleaners.
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