Dexera (PR - Milling and drying)

Single Hurricane cyclone designed for the collection of flakes and dust from a milling process, 6,769 m3/h flow rate of nitrogen gas at 35 ºC. 

Expected efficiency: 99.09 - 99.42 %

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]
Azores, Portugal
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]
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.

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

In order to obtain very high efficiencies and compliance with emission limits, an improve recirculation system has been designed to take advantage of the Hurricane cyclones. A mechanical ReCyclone®

(ReCyclone® MH) is made up of a Hurricane with a particle separator (straight-through cyclone), placed downstream of the cyclone - called the "recirculator".

The main purpose of the recirculator is to reintroduce the fine non captured particles into the cyclone after those have been driven to the outer walls of the recirculator by centrifugal forces. While this tangential gas stream is enriched in particles, the axial gas stream exhaust to the stack is clean of particles. Recirculation is achieved through an additional fan. 

Since the recirculation system only serves the purpose of dust separation (and not collection), the particles are exclusively collected in the cyclone and the need of rapping mechanisms is thus avoided. 

Efficiency increases due to recirculation and agglomeration of very small particles with larger ones coming directly from the process. 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. Finally, recirculation control provides the benefit of handling variable process flow rates.


The next figure exemplifies a ReCyclone® MH in stainless steel AISI 304L for particle recovery in drying process. Recirculators can be disposed vertically, as shown, or horizontally.


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
Milling and Drying Processes
Efficient recovery of active pharmaceutical ingredients (APIs), chemical substances and 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.   

To recover these sensible products, cyclone collectors are frequently irreplaceable equipments for allowing a direct powder capture and avoiding product holdup of filters. Cyclones also avoid contamination of filter bags, product cross contamination and product degradation with temperature.   However, product losses due to cyclones' low efficiency represents a high cost as a consequence of the value of particles.   

Where applicable, cyclones have to be complemented with specialized bag filters to increase yield or to avoid emissions to the atmosphere. These filters are usually associated with difficult cleaning and downtime.  

Client's needs include a cyclone system which dramatically increases powder yield and is efficient enough to comply with regulatory PM limits, thus avoiding the use of a bag filter.
Milling & Drying Processes
Milling & Drying Processes
Milling & Drying Processes
Milling & Drying Processes
Milling and Drying processes | General Arrangement

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