How To Determine the Cost of a Cyclone – Part 6 | Aerodyne
Part 6: Scope of Supply
Cyclones do not stand alone in most applications; rather, they require additional equipment to function properly. Depending on your specific application, this equipment can include an airlock, exhaust fan, explosion protection, instrumentation, insulation, vibrator, and even ductwork. Moreover, a cyclone can be purchased either as a complete system with all the necessary equipment or by itself to be integrated into an existing system. In either case, the system is then assembled by the end user or a third party. Often, the total cost of the accessory equipment exceeds that of the cyclone itself. Below is a brief description of these potential accessories and how they impact the cyclone’s performance.
Airlock
An airlock is essential for the proper operation of a cyclone. It isolates the cyclone from the outside atmosphere. Without it, material will fly out the bottom or get re-entrained in the system. Airlocks could be a simple extended hopper (55 gallon drum), rotary valve, or specialized valves like the double dump valve or trickle valve. Special designed valves are available for quick cleaning applications and explosive applications.
Explosion Protection
Explosion Protection is a very important consideration for dust collectors as about 70% of dusts are explosive. The equipment that protects against explosions can add significant cost the cyclone. Explosion protection equipment such as explosion vents, isolation valves, chemical suppression, and isolation systems can all quickly increase the price of a cyclone. This equipment is required for explosive applications.
Exhaust Fans
Exhaust fans are required on every dust collection system. They provide the motive force required to pull air through the system. When selecting the fan, be sure to take into account all ductwork and equipment. It is best to install the fan downstream of all dust collectors so that the most efficient impeller designs can be used. This will save money on operational costs. However, if the fan needs to be installed in high dust areas, there are impellers designed for these operations.
Instrumentation
Instrumentation for cyclones are rather simple compared to other dust collectors. The main instrumentation used on cyclones are differential pressure gages/transmitters and level switches for the hoppers. Explosive applications can have special instrumentation and some applications will monitor temperature and humidity for equipment downstream of the cyclone. But for most standard cyclone applications, differential pressure is the only recommended measurement.
Insulation, Heat Tracing, Steam Jacketing
Insulation, heat tracing, steam jacketing are required for special applications. These can add significant expense to the cyclone. Insulation and heat tracing can be done at the fabricator but usually are done onsite to prevent damage in shipping and installation. Steam jacketing must be done in the design and fabrication phase and can add significant cost to the cyclone.
Vibrators or Air Jets
Vibrators or air jets are used in applications where material tends to bridge in the hopper. Typically, vibrators can be added after installation and help prevent the hopper from bridging. Similarly, air jets blast air into the hopper to break up any bridges, allowing material to flow smoothly through the airlock. Ideally, however, the connections for these devices should be included in the cyclone design and installed on-site from the start.
In summary, cyclone design and costs depend on the size and construction needed for your specific application. Furthermore, special applications may require expensive equipment and design modifications, which can significantly increase the overall cost. Therefore, when selecting a cyclone for your application, it is important to consider all factors in your cost estimate to ensure an accurate and realistic budget.
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