Mannkind (PR - Food Ingredients)

Hurricane cyclone designed for product recovery on a GEA Niro SD Micro spray dryer, processing 39 m3/h at 165ºC.

The expected collection efficiency for this extremely fine and low dusting powder (median particle size of 1.7 ?m) is expected to reach around 73.49%. 
Expected efficiency: 70-73.5%

MannKind Corporation
USA
2012
Nestlé Prolacto (PR - Food ingredients)

Hurricane system for recovery of dried powder milk from the flue gases of a drying tower operating at 31,100 m3/h at 75 ºC.

  • This equipment is composed by two batteries of 8 hurricane cyclones with ø750mm 
  • The objective is to avoid the use of a bag filter and comply with regulatory emission limits
  • MVD: 10.5 ?m
  • Emissions: < 50 mg/Nm3
Nestlé - Prolacto
Portugal
2010
Confidencial 02 (PR - Food Ingredients) - AZO

Hurricane system designed for fat powder recovery with a flowrate of 3 900m3/h at 5ºC, 1.8 kPa in a food industry.

  • The system is composed by 4 hurricane cyclones with a ø900mm 
  • MVD: 65 ?m
  • Expected efficiency: 99,96% collection
AZO
UK
2010
Confidencial 03 (PR - Food Ingredients) - AZO

Hurricane system designed for increasing fat powder recovery with a flow rate of 4,875m3/h at - 5,5 ºC, 180mm w. g..

  • The system is composed by 3 hurricane cyclones with ø1 000 mm
  • MVD 75 µm
  • Efficiency: 99,94%
AZO
UK
2010
Arla Foods (RP - Food ingredients)

Hurricane system aiming to increase the recovery of milk proteins powder after a spray dryer. It has a capacity of 92 000m3/h at 65ºC effective flow rate.  

  • The equipment is composed by 2 cyclones. It was installed to replace an existing high efficiency cyclone from the spray dryer manufacturer in order to increase powder recovery. 
  • Expected efficiency: 98.9-99.3%
  • Measured efficiency: 99.1%
Arla Foods
Scandinavia
2012
Arla Foods 2 (RP - Food ingredients)

Hurricane system designed for product recovery of food ingredient on an air stream from a spray dryer with a 57 878 m3/h at 75ºC flow rate. 

Expected collection efficiency of 98.62 - 98.96% with a pressure drop of 2.3 kPa.
The system is composed by 2 Hurricane cyclones with ø2100 mm.
Arla Foods
Denmark
2013
Hurricane HR cyclones to reduce particulate matter emissions from a drying tower of powder milk at Nestlé

Hurricane HR cyclones to reduce particulate matter (pm) emissions under 75mg/Nm3 from a drying tower of powder milk at Nestlé ( 31 100 m3/h at 80ºC )

  • Inlet concentration (mg/Nm3) [245]
  • Gas flow temperature (ºC) [70-80]
Nestlé
Azores, Portugal
2012
Hurricane HR Cyclone System for Paprika Powder Recovery and Emission Control on three milling lines (11011 m3/h at 48ºC)
Hurricane HR Cyclone System for Paprika Powder Recovery and Emission Control on three milling lines at JUAN JOSÉ ALBARRACÍN, S.A (11 011 m3/h at 48ºC)
  • Powder concentration at inlet (mg/Nm3) [272]
  • Guaranteed maximum emissions (mg/Nm3) [30]
  • Expected separation efficiency (%) [97.4 - 97.9]
JUAN JOSÉ ALBARRACÍN, S .A.
Murcia
2015
Hurricane
Numerically optimized cyclones, considering particle agglomeration

Hurricane geometries maximize powder collection for each different application, while minimizing reentrainment and keeping pressure drop at reasonable levels.


These high efficiency cyclones are the output of nonconvex nonlinear problems formulated and solved after years of work in partnership with the Faculty of Engineering of Porto.


A single Hurricane is more efficient than any other known cyclone available in the market for the same pressure drop, usually resulting in less than half of the emissions of other high efficiency cyclones available.

Very high efficiencies: under 20 % of the emissions of other high efficiency cyclones. 

Custom geometry for each case (single or parallel arrangement)

Low pressure drop: < 100 mm w. g.

Direct product discharge avoiding product degradation and cross contamination

Flanged connection for easier installation

Inspection doors for cleaning

"2B" or Ra < 0.4 µm smooth surface finishing when needed

Materials of construction in Stainless Steel 304L or 316L

Absence of condensation with heat tracing systems

Clean in Place (CIP) cleaning systems

Very low maintenance and downtime costs

1. Air and Dust from Dryer or Boiler
2. Hurricane Cyclone
3. Valve
4. Collected Particles
5. Clean Air
Efficient recovery of active pharmaceutical ingredients (APIs), chemical substances or food powders after drying applications such as spray and fluid bed drying is frequently a problem. The same problem occurs in many milling and micronization applications.

The preferred way to recover these sensitive products is with cyclone collectors due to their direct powder capture. Unlike bag filters or wet scrubbers, cyclones minimize filter or product contamination and product cross contamination and can easily handle a wide range of operating temperature, pressure and moisture conditions.

The current problem with cyclones is their low efficiency. And therefore, when necessary, cyclones have to be complemented with expensive specialized bag filters or wet scrubbers to increase yield or to avoid emissions to the atmosphere.

Client's needs include a cyclone system that dramatically increases powder yield, is easy and fast to clean and is efficient enough to comply with regulatory PM limits, thus avoiding the use of secondary filters.
Food Ingredients
Food Ingredients
Food Ingredients
Food Ingredients

Spray Drying | General Arrangement

 

Usual spray drying arrangements (single point, two point and closed cycle) include a high efficiency cyclone and a bag filter.


The cyclone serves the purpose of separating and collecting the dried powder originated in the spray-drying chamber. In pharmaceutical/API powders, the fraction of product escaping to the bag filter is not considered as first grade product, and thus seen as losses. The main reasons for this are contamination with filter fibers, product cross contamination and risk of heat degradation.


For fine powders with a median diameter in volume (MVD) of less than 5 µm, losses due to low cyclone efficiency can rise to more than 25 %.

Fluid Bed Drying | General Arrangement

 

In fluidized bed arrangements, cyclones are used to recover the fine fraction of the dried powder, collecting or returning it to the bed.
This fraction frequently has a very small particle size distribution which results in low yields in the cyclone.
Improving the efficiency is crucial both to recover first grade product and to reduce filter bag cleaning and frequent change of bags.

Client needs include a cyclone system efficient enough in order to replace the bag filter and comply with regulatory emission limits.