Hurricane

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Advanced Cyclone Systems’ Hurricanes are patented, numerically optimised cyclones which can be used for product recovery or for emissions control.

Hurricane geometries maximise particulate collection for each different application, while minimising re-entrainment.  Reasonable pressure drop is maintained for all application ranges.

A single Hurricane is more efficient than any other known cyclone available in the market, usually resulting in less than half of the emissions of the most efficient cyclones available.

Features of Hurricanes:

• Very high efficiencies
• Custom designs
• Low pressure drop: (<100 mm H2O)
• Direct product discharge
• Avoids product degradation and contamination by filters
• Very smooth surface finishing to meet hygienic requirements (if needed)
• Absence of condensation with Heat Tracing mechanisms
• Clean in Place (CIP) cleaning systems

Typical Hurricane Applications include:

• Powder Recovery in:
  • Pharmaceutical/Biopharmaceutical Industry
  • Fine chemicals
  • Food ingredients
  • Mineral processing
  • Catalyst recovery

• Air dedusting or PM emission control:
  • Cement industry
  • Textile industry
  • Wood processing industry
  • Mining industry

ReCyclone MH

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The Advanced Cyclone Systems’ Mechanical ReCyclone is made up of a numerically optimised cyclone, the Hurricane, and a particle separator (or recirculator) placed downstream of the cyclone.

The Hurricane collects most particles in the first iteration.  The main purpose of the recirculation system is to reintroduce the very fine uncaptured particles into the cyclone after they have been driven to the outer walls of the concentrator by centrifugal forces.  While this tangential gas stream is enriched in particles, the axial exhaust gas stream to the stack is completely clean.

Efficiency for fine particulate capture is further increased due to recirculation and agglomeration of very small particles and the reintroduction of larger agglomerate particles back to the system.  A Mechanical ReCyclone results is less than half of the emissions of a Hurricane alone.

ReCyclones MH are the most efficient purely mechanical collectors in the market.

Features:

• Very high efficiencies
• Pressure drop: [150-200] mm H2O
• Robust construction with abrasion resistance
• Low operation costs
• Near zero maintenance and downtime costs
• Low investment costs
• Normal materials of construction in Carbon or Docol Steel
• Modular design

Typical applications include:

• Particulate Matter emission control in:
  • Biomass boilers
  • Fuel oil boilers
  • Pyrolysis and incineration
  • Steel, iron and aluminium kilns
  • High temperature separation processes

• Powder recovery in:
  • Pharmaceutical/Biopharmaceutical Industry
  • Fine chemicals
  • Food ingredients
  • Catalyst recovery

ReCyclone EH

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Advanced Cyclone Systems’ Electrostatic ReCyclones are made up of numerically optimised cyclones, Hurricanes, and electrostatic recirculation systems.  The main purpose of the recirculation system is to reintroduce the very fine uncaptured particles into the cyclone after they have been driven to the outer walls of the concentrator by centrifugal forces.  Electrostatic forces ensure that the smallest particles, more resistant to the mechanical forces, are separated from the centre of the recirculator.

While this tangential gas stream is enriched in particles, the axial gas stream exhaust to the stack is practically invisible.  By not collecting any particles in the recirculator, but only in the cyclone, ReCyclones need a much lower field power than ESPs and are immune to high or low particle resistivity and back-corona.

Efficiency increases due to improved electrostatic recirculation and agglomeration of very small particles with larger particles entering the system for the first time.

As with cyclone systems, Electrostatic ReCyclones are very robust, easily cleanable, do not have temperature limitations and do not have replacement parts that require frequent changing.  The product is all collected in the cyclone itself.

When compared with Mechanical ReCyclones, Electrostatic ReCyclones require lower velocities to operate and, consequently, have a lower pressure drop (approximately 100mm w.g.)  Power needed to provide separation in the recirculator is only 5% of the power needed by the fans.

Electrostatic reciculation for fine particle capture was the winner of the Portuguese Environmental Press Award in 2008 and Nominee for the European Environmental Press Award 2008.

Features:

• Very high efficiencies
• Pressure drop: [100-150] mm H2O
• Low gas velocities
• Electrical field power consumption equals 5 % of fans.
• Robust construction with abrasion resistance
• Very low operating costs
• Near zero maintenance and downtime costs
• Reasonable investment costs
• Normal materials of construction in Carbon or Docol Steel
• Modular design

Typical applications for Electrostatic ReCyclones include:

• Particulate Matter emission control in:
  • Biomass boilers
  • Fuel oil boilers
  • Pyrolysis and incineration
  • Glass furnaces
  • Steel, iron and aluminium kilns
  • High temperature separation processes
  • Cement industry

• Powder recovery in:
  • Pharmaceutical/Biopharmaceutical Industry
  • Fine Chemicals
  • Mineral Processing
  • Catalyst recovery

A significant advantage of ACS installations is that they can easily be used in combination with NOx flue gas treatment technologies, such as SCR systems, as flue gas temperature can be optimally maintained, with minimal temperature losses over the ACS package.  The downstream SCR can thus be installed in a cleaner service at optimum operating temperatures.

Technology Comparison

The economic, technical limitations and operational problems associated with traditional cyclones, Bag Filters and Electrostatic Precipitators (ESPs) can be solved with the efficient Advanced Cyclone Systems’ Hurricane and ReCyclone Systems.

In contrast to the ACS Cyclone Systems, limitations of traditional dry PM removal equipment are as follows:

• With traditional industrial cyclones, only relatively low efficiencies can be achieved, particularly for small particles (< 10 µm). Many industries therefore complement cyclones with Bag Filters or Electrostatic Precipitators (ESPs) in order to achieve the required PM removal efficiencies.
• Bag filters are usually very efficient (> 99,9 %), however may be extremely maintenance demanding due to frequent changing and cleaning of filter elements. High temperatures and condensation may also cause particle cementation or caking in the bag filters. Apart from operating costs and technical limitations, bag filters are frequently attacked by glowing particles released from harsh combustion processes, such as industrial biomass boilers, which dramatically increases emissions.
• ESPs are robust equipment and are very effective for a given range of temperatures, however efficiency drops at higher temperatures due to particle resistivity and corona effect. Also, in several applications with high CO concentrations in the exhaust streams, explosion risks frequently necessitate that ESPs be shut down, thus increasing emissions to 100%. Ultimately, however, their high investment cost is out of reach for small and medium size companies.