HR (Cement) Duna Drava
Hurricane HR cyclone system to limit ash particle content in the exhaust hot gases of the preheater tower at Duna-Dráva Kft ( 37 513 m3/h at 327ºC ).
  • Inlet concentration (mg/Nm3dry) [42 100]
  • Guaranteed efficiency (%) [>87]
Duna Drava Cement
Hungary
2013
Hurricane HR Cyclones for Sonae Indústria, Mangualde
Hurricane HR Cyclones to capture fine fly ash particulate enabling the use of wood waste fired thermal oil heater for Sonae Indústria ( 104 140 m3/h at 303ºC )
Verified Separation Efficiency (%) [91.2]
Verified Outlet Concentration (mg/Nm3dry) [<77]
Verified total pressure drop (Kpa) [1]
Sonae Industria
Mangualde, Portugal
2015
Hurricane
Numerically optimized cyclones, considering particle agglomeration

Hurricane lines of cyclones are the ideal solution to clean hot gases for energy recovery purposes. They can be designed to be very efficient while having a low pressure drop and very low maintenance. The total cost of acquisition is therefore much lower than that of an ESP or a ceramic filter and the range of applicability much broader.


ACS has experience in several energy recovery applications, including gas cleaning after the pre-heater tower in cement plants (MVD=2,5µm; µ=90%) or gas cleaning after a biomass boiler in particleboard manufacturing plants (MVD=11µm; µ =85%).

  • Very high efficiencies: down to 10-20% of the emissions of other high efficiency cyclones;
  • Custom designs (single or parallel arrangement)
  • Low pressure drop: [100 - 150]mm w.g.
  • No temperature restrictions with the right choice of steel. Carbon Steel - P355NH Steel - 16M03 Steel - 253MA Steel
  • Robust construction with no moving parts
  • Near zero maintenance and downtime costs
  • Very low operating costs
  • Pre-assembled modular system with very easy and fast installation. Batteries of 2, 4, 6 or 8 cyclones are shipped pre-assembled in a supporting structure with or without thermal insulation.
  • Low investment cost
1. Air and Dust from Dryer or Boiler
2. Hurricane Cyclone
3. Valve
4. Collected Particles
5. Clean Air
ReCyclone MH
Optimized cyclones with mechanical recirculation

Mechanical ReCyclone Systems (ReCyclone MH) are a solution to improve cyclone efficiency, when working as a final dedusting system. They can work with several lines of Hurricane cyclones with different performances depending on the requests of the clients.


A ReCyclone® MH decreases emissions of Hurricane cyclones alone by 40 to 60 %


As with cyclone systems, ReCyclone® MH systems are very robust, do not have temperature limitations and do not have moving parts to be frequently changed.


In calcination lines, concerns have to be taken regarding the peripheral equipment, namely recirculation fan and rotary valves to stand abrasive dusts and high temperatures.   

  • Very high efficiencies: decreases emissions of Hurricane Cyclones by [40-60]%
  • Pressure drop: [150-220]mm w.g.
  • No temperature restrictions with the right choice of steel. Carbon Steel à P355NH Steelà 16M03 Steelà 253MA Steel
  • Robust construction with no moving parts
  • Near zero maintenance and downtime costs
  • Low operating costs
  • Pre-assembled modular system with very easy and fast installation. Batteries of 2, 4, 6 or 8 cyclones or mechanical recirculators are shipped pre-assembled in a supporting structure with or without thermal insulation.
  • Low investment costs
Features

1. Air and dust from boiler or dryer
2. Hurricane cyclone ( Batteries of 2, 4, 6 or 8 units )
3. Discharge valve
4. Collected Particles
5. Clean air
6. Recirculator
7. Fan

Note: supporting structure, insulation and ductwork are not represented
High Temperature Separation & Energy Recovery
Given the difficulties in achieving results by increasing revenues, companies are turning more and more to cutting costs. Reducing energy consumption has become the target for many companies.

In sectors as the cement, particleboard manufacturing, inceneration, among others, energy is demanded mostly in the form of heat. Most companies are retrofitting their boilers and thermal oil heaters to run with biomass, instead of oil or coal, to reduce costs and become more eco-friendly. Still too, much of the generated heat is being lost throughout the manufacturing process.

In the cement industry, most plants intentionally cool the exhaust stream of the pre-heater tower from 400ºC down to 120ºC, so it can be cleaned in bag filters, dissipating all that heat into the atmosphere.

In the particleboard industry, many plants use extra diesel or natural gas generators to heat the rotary dryers, despite having more than the necessary amount of energy from biomass boilers to produce the steam or heat for the entire plant. The high concentration of fly ash in the hot gas stream produced by the biomass boiler does not allow it to be put back into the process. 

In waste to energy incinerators, the ash in the flue gas is usually captured in a pre-separator such as a multicyclone (MC) before going into the economizer, followed by reagent injection to neutralize gaseous effluents and finally a bag filter to comply with emissions standards before going to the stack. The cost for the hazardous ash disposal captured in the bag filter is nearly 4 times higher than the disposal of the ash captured in the MC due to the reagent injection.

The main obstacle to improve the energy efficiency of these processes lies generally on how to effectively clean the gases at high temperature without thermal losses, so that they can be recirculated into a heat recovery system, such as a recovery boiler, or directly back into the process.

Client's needs include a high efficient dedusting system to reduce particles to a level that the air can be used for energy recovery purposes and is robust enough to operate at high temperatures with low maintenance/operating costs.
High Temperature Separation & Energy Recovery
High Temperature Separation & Energy Recovery
High Temperature Separation & Energy Recovery
High Temperature Separation & Energy Recovery
Particle Board and Pellet plants | General Arrangement

Having High Efficiency Cyclones or High Efficiency Cyclones after a Multicyclone to capture exclusively the very fine particles, effectively reduces the fly ash from the biomass furnaces allowing the exhaust gases to be used in the rotary dryers instead of totally or partially wasted.

Indeed, fly ash mixed with dried wood results in high Silica contents and black spots in the panel boards due to unburnt carbon, diminishing the quality of the end product. As a consequence, many manufacturers are forced to use expensive diesel or natural to produce hot gas generators. This can be avoided by increasing the efficiency of the cyclones.
Waste Management | General Arrangement

The general arrangement of a waste to energy incinerator has a pre-separator to reduce the concentration of particles after the boiler to prevent plugging of the economizer and capture as much ash as possible before the injection of reagent to neutralize gaseous effluents. 

Either replacing the MC by more efficient cyclones or adding a second stage deduster such as a Hurricane or Mechanical ReCyclone system before the economizer reduces the chances of plugging but above all significantly reduces the overall ash disposal costs.
Waste Management | General Arrangement

The general arrangement of a waste to energy incinerator has a pre-separator to reduce the concentration of particles after the boiler to prevent plugging of the economizer and capture as much ash as possible before the injection of reagent to neutralize gaseous effluents. 

Either replacing the MC by more efficient cyclones or adding a second stage deduster such as a Hurricane or Mechanical ReCyclone system before the economizer reduces the chances of plugging but above all significantly reduces the overall ash disposal costs.