Cyclone

General Information
The Cyclone unit operation models the separation of particulate solids from a solid and gas stream. The particulate collection efficiency is determined by the solids loading, component characteristics, particle size distribution, stream flowrate, and cyclone geometry. The Cyclone unit operation will calculate the collection efficiency for every particle size range of each solid component as well as the pressure drop through the unit. The Cyclone is assumed to operate isothermally and mechanisms such as agglomeration and crumbling are discounted.

Feeds and Products

A Cyclone may have up to ten feed streams. Unless otherwise specified, the inlet pressure will be taken as that of the feed stream with the lowest pressure. The feed streams may not contain a liquid phase, and there must be two product streams. The overhead stream will contain all the gas that comes in as well as any uncollected solids. The bottom stream will contain only the collected solids. All solid components that enter a cyclone must have a particle size distribution. This distribution may be set by another unit or defined by the user.

Unit Specification
A cyclone unit operation is specified by filling in the appropriate real and integer data variables for operating mode, geometry, pressure drop calculations, efficiency calculations, and multiple cyclone configuration in the Gas/Solid Cyclone main data entry window that is accessed by double-clicking the Cyclone unit icon on the PFD.

Rating Mode
If you select Rating Mode, you must supply the diameter of the cyclone. The other dimensions of the cyclone will be generated from the diameter. If you select User Defined Geometry, you must also enter all of the geometric ratios as described below. In Rating Mode, PRO/II will calculate: pressure drop, total efficiency, component efficiencies, grade efficiencies and weight percent solids in the overhead stream.

Chapter 9 Unit Operations and Utility Modules 203

Design Mode
If you select Design Mode, you need not provide the cyclone diameter. Again, if you select User Defined Geometry, you must enter all of the geometric ratios as described below. In addition, you must specify a target for total solids collection (see entry for RPARM(13) below). You may also wish to override the default maximum pressure drop of 10 inches of water by entering a value in whatever input pressure units you prefer (see entry for RPARM(16) below). In addition to the normal Rating Mode output, Design Mode will calculate the number and size of identical cyclones that are necessary to meet the specification. There may be many cyclone systems that meet the specification. In all cases, Design Mode will return the system requiring the fewest cyclones.

Multiple Cyclones
The Cyclone can model a system of identical cyclones that are arranged either in parallel or in series. In the case of parallel cyclones, the feed streams are split evenly among the cyclones. The overhead products from all cyclones merge into one overhead and the bottoms products from all cyclones merge into one bottom stream. In the case of series cyclones, the overhead from the first cyclone is the feed to the second and so on. The overhead product is the overhead product from the final cyclone while the bottom product is the combined bottom product from all the cyclones in the system. Both product streams are at the outlet pressure of the final cyclone in the system. It is not possible to specify recycle streams inside the unit or to reference intermediate stage data from the flowsheet. For example, if you wish to set a specification on the second cyclone in a three-cyclone series or set a recycle from the second cyclone to the first cyclone, you should model the system as three separate units. Note that while increasing the number of identical cyclones will increase efficiency and pressure drop in a series system, it will decrease the efficiency and pressure drop in a parallel system.

Integer Data for Unit

Calculation Mode (IPARM(1)) This input is optional. Options are: 1. Rating (default) 2. Design Efficiency Model (IPARM(2)) This input is optional. Options for Rating and Design mode are: 1. Koch & Licht 2. API (default) 3. Lapple The Lapple model is based on a ratio of particle diameter to cut diameter

204 PRO/II User Guide March 2007

(the diameter of the particles which are collected with 50% efficiency). The API method is based on a ratio of particle diameter to critical diameter (the diameter of particles which would be collected at 100%). The Koch & Licht method is not based on a particle size ratio. Pressure Model (IPARM(3)) This input is optional. Options for both Rating and Design mode are: 1. Koch & Licht (default) 2. API If the cyclone is inside another vessel, the API method allows values for the Inlet Width Ratio and the Superficial Gas Velocity (described later in the section titled Real Data for Unit) to be specified. Cyclone Geometry (IPARM(4)) This input is optional. Options for both Rating and Design mode are: 1. Stairmand (default) 2. High efficiency Swift 3. Lapple 4. General purpose Swift 5. Peterson & Whitby 6. User-defined geometry If the user-defined geometry is used, values must be specified for the inlet height ratio, inlet width ratio, cyclone dust outlet diameter ratio, cyclone gas outlet diameter ratio, gas outlet tube length ratio, height of cylindrical section ratio, and total cyclone height ratio as appropriate for the calculation method used as shown. Inlet Vane Flag (IPARM(5)) This input is optional. Options for both Rating and Design mode are: 1. No (default) 2. Yes Shape of Gas Inlet Flag (IPARM(6)) This input is optional. Options for both Rating and Design mode are: 1. Tangential (default) 2. Scroll or volute 3. Axial Cyclone is inside Vessel Flag (IPARM(7)) This input is optional. Options for both Rating and Design mode are: 1. No (default) 2. Yes

Chapter 9 Unit Operations and Utility Modules 205

For a value of 2, the Inlet Width Ratio and the Superficial Gas Velocity must be specified. Dipleg Size is calculated if the value of 2 is entered. Efficiency Adjustment Due to Loading Flag (IPARM(8)) This input is optional. Options for both Rating and Design mode are: 1. Adjust (default) 2. Do not Adjust Automatically Switch Pressure Drop Model (IPARM(9)) This input is optional. Options for both Rating and Design mode are: 1. Do not Switch (default) 2. Switch This entry allows changes to be made automatically in the pressure drop model between the Koch & Licht and API methods based on solids loading. Configuration of Multiple Cyclones Flag (IPARM(10)) This input is optional. Options for both Rating and Design mode are: 1. Parallel (default) 2. Series Number of Identical Cyclones (Series or Parallel) (IPARM(11)) This input is optional and is for Rating Mode only. The default value is 1 cyclone. Number of Particle Size to be Specified (IPARM(12)) This input is optional and is for Rating Mode only. This and the following entry can be used together to specify the component and PSD size range whose weight fraction in the overhead will be output to RPARM(64). This latter value can be accessed by a Controller, MVC or Optimizer. For example, if a solid with PSD data: 10, 20, 30, 40 (in default input units) is required to have a weight fraction of 0.20 in size range 20 to 30, the value for this entry would be 2 (the second size range) and the value for a DEFINE statement would be 0.20. The default value is 1 (the first size range). Number of the Component to be Specified (IPARM(13)) This input is optional and is for Rating Mode only. This optional input is the number of the component with particle size distribution data to be used in the design. The default is the first solid component with a PSD that the design mode may evaluate. Maximum Number of Cyclones (IPARM(14)) This input is optional and is for Design Mode only. The value indicates the number of cyclones in parallel or series as appropriate based on the value specified above for the Configuration of Multiple Cyclones Flag. The default is 20 for parallel and 3 for series.

206 PRO/II User Guide March 2007

Real Data for Unit

The cyclone geometry is input as the ratio of length divided by overall cyclone body diameter, so that an inlet height of 0.1 meters on a cyclone of diameter 0.2 meters would have an inlet height ratio of 0.1/0.2 = 0.5. Diameter of Cyclone Cylinder (RPARM(1)) This input is required and is for Rating Mode only. Inlet Height Ratio (RPARM(2)) This Rating/Design Mode entry is optional. Inlet Width Ratio (RPARM(3)) This Rating/Design Mode entry is optional. Cyclone Dust Outlet Diameter Ratio (RPARM(4)) This Rating/Design Mode entry is optional. Cyclone Gas Outlet Diameter Ratio (RPARM(5)) This Rating/Design Mode entry is optional. Gas Outlet Tube Length Ratio (RPARM(6)) This Rating/Design Mode entry is optional. Height of Cylindrical Section Ratio (RPARM(7)) This Rating/Design Mode entry is optional. Total Cyclone Height Ratio (RPARM(8)) This Rating/Design Mode entry is optional. Diameter of Vessel Housing (RPARM(9)) This Rating/Design Mode entry is optional. Superficial Gas Velocity (RPARM(10)) This Rating/Design Mode entry is optional. Pressure Drop to Inlet (RPARM(11)) This Rating/Design Mode entry is optional. This value is the pressure drop between the feed stream and the inlet to the cyclone. The default is 0.0. Absolute pressure at cyclone inlet (RPARM(12)) This Rating/Design Mode entry is optional. For use if cyclone inlet pressure differs from feed stream pressure. The default is the lowest feed stream pressure. Goal Efficiency for Design Mode (wt%) (RPARM(13)) This Design Mode entry is required. Minimum Cyclone Diameter (RPARM(14)) This Design Mode entry is optional. The default is 0.1 m.

Chapter 9 Unit Operations and Utility Modules 207

Maximum Cyclone Diameter (RPARM(15)) This Design Mode entry is optional. The default is 0.5 m. Maximum Pressure Drop (RPARM(16)) This Design Mode entry is optional. This value is the maximum pressure drop across cyclones in a unit The default is 2.488 kPa. Tolerance for Cyclone Body Diameter (RPARM(17)) This Design Mode entry is optional. The default is 0.001.

Real Number Output from Cyclone

The output values calculated by the Cyclone model are stored in the indicated locations in the RPARM() array and can be accessed by a Controller, MVC or Optimizer. All RPARM() outputs are produced in both Rating and Design modes. Overall Efficiency (wt%) (RPARM(51)) In Design mode, this is an input value included in the output report for the cyclone unit. Diameter Of Cyclone Cylinder (RPARM(52)) In Rating mode, this is an input value included in the output report for the Cyclone model. Pressure Drop (RPARM(53)) This is adjusted for loading by the user. Total Solids In Overhead (RPARM(54)) This is the weight % of the total overhead stream. Inlet Height Dimension (RPARM(55)) Inlet Width Dimension (RPARM(56)) Cyclone Dust Outlet Diameter Dimension (RPARM(57)) Cyclone Gas Outlet Diameter Dimension (RPARM(58)) Gas Outlet Tube Length Dimension (RPARM(59)) Height of Cylindrical Section Dimension (RPARM(60)) Total Cyclone Height Dimension (RPARM(61)) Dipleg diameter (RPARM(62)) This requires that the cyclone be located above a fluidized bed, i.e., the cyclone must be located inside a vessel. This value is output in the cyclone output report only if applicable. PSD weight fraction in the overhead RPARM(64) This value is the particle size

208 PRO/II User Guide March 2007

distribution weight fraction in the overhead of the size and component specified. See entries for IPARM(12) and IPARM(13) above. This is the ratio of weight in the specified size range divided by the weight of the component in the overhead. This value is output in the cyclone output report only if applicable.

Chapter

Solid Separator
General Information
The Solid Separator unit models the separation of solid phase material from a mixture of feed streams. The unit operates adiabatically at the lowest of the individual feed stream pressures.

Feed and Product Streams

The solid separator unit can have up to ten (10) feed streams. The inlet thermal condition is determined by an adiabatic flash calculation at the lowest feed stream pressure. The solid separator requires both overhead and bottoms product streams.

Calculation Method
The solid separator provides the option of specifying the fraction of the solid components in the total feed that is removed in the bottoms stream. The default fraction of the solid components removed in the bottoms stream is 1.00. An adiabatic flash calculation is used to determine the product phases and the outlet temperature based upon the thermal condition of the combined feed. The solid separator unit supports both VLE (two phase) and VLLE (three phase) calculations to determine the individual phase compositions. See the online Technical Information discussion entitled VLE Model and VLLE Model for more details. To access the main data entry window for VLE and VLLE calculations, select Tools/Binary VLE from the menu bar.

308 PRO/II User Guide March 2007

Splitter
General Information
This unit may be used to split a single feed or mixture of feeds into two or more products of identical composition and phase condition. The outlet stream pressure may be specified, if desired, and an adiabatic flash used to determine the outlet temperature and phase. A choice of options is provided for splits in which insufficient feed is available to meet the specified product rates.

Feeds and Products

A splitter may have multiple feed streams. The lowest feed pressure is used for the pressure of the combined feed. A splitter must have two or more product streams. All product streams have identical compositions and phase conditions. Phase separation of product streams is not available in this unit, and, if desired, a Flash unit operation must be used for this purpose.

Product Rate Specifications

For a splitter with N product streams, N-1 product stream rates must be specified. Product rate specifications are supplied by clicking on the underlined hypertext strings in the Product Rate Specifications section of the Splitter main data entry window. All of the splitter product streams are listed and any one may be used for the unspecified rate. Specifications use the general specification format and are further described in the SPEC/VARY/DEFINE section of this chapter. Only specifications that are rate dependent are allowed, e.g., stream or component(s) rate total, stream or component(s) recovery, stream enthalpy, etc.

Chapter 9 Unit Operations and Utility Modules 309

Outlet Pressure Specification

The outlet pressure for the splitter products may be changed by applying a pressure drop to the lowest feed pressure. This value is supplied in the Pressure Specification window, which is accessed by clicking Pressure Specification on the Splitter main data entry window. When a pressure drop is supplied, the resulting outlet temperature and phase condition are determined by an adiabatic flash calculation from the composite feed inlet conditions.

Inadequate Feed Rate Options

There are two options for situations in which insufficient feed is available to satisfy all product stream rate specifications. They may be selected by radio buttons on the Splitter main data entry window: Satisfy Each Specification in Order Until Feed is Exhausted: Each specification is satisfied in the order of the products until the feed is exhausted. The product stream that encounters insufficient feed is limited to the feed available and the remaining products are assigned zero rates. (This is the default option.) Satisfy Each Specification and Normalize Flowrates if Needed: All specified product rate specifications are satisfied and the resultant rates are normalized to the total feed rate. The product with the unspecified rate is assigned a zero flow. The order of the product streams in the list box may be changed, if desired, by clicking Change Stream Specification Order on the Splitter main data entry window. You can reset a stream specification by clicking Reset Stream Specification on the Splitter main data entry window.

Thermodynamic System
The thermodynamic system of methods to be used for splitter calculations may be selected by choosing a method from the Thermodynamic System drop-down list box on the Splitter main data entry window.

310

Mixer
General Information
The Mixer unit combines two or more streams into a single product stream. The outlet pressure may be specified if desired. The outlet temperature and phase condition are always determined with an adiabatic flash from the feed conditions. This unit supports both VLE and VLLE calculations.

Feeds and Products

The inlet pressure is assumed to be the lowest feed pressure. There is no limit on the number of feed streams to a mixer. Only one product stream is allowed for a mixer. PRO/II automatically sets the temperature and phase condition for the product. If phase separation of the product is desired, a separate flash unit must be used for this purpose.

Outlet Pressure Specification

The pressure specification for the mixer product is selected with the appropriate radio button on the Mixer window: Pressure drop from feed conditions, or Outlet pressure If neither entry is supplied, the default is a pressure drop of zero.

Thermodynamic System
The thermodynamic system of methods to be used for mixer calculations may be selected by choosing a method from the Thermodynamic System drop-down list box on the Mixer main data entry window

7Solid Component Properties

Note:Solid Components are not recommended with the pressure drop correlations built

into NETOPT. Users can create their own pressure drop correlations to handle solids using NETOPT's user-added subroutine feature.

General Information
Components that can exist in the solid phase are identified on the PHASE statement. They may be molecular (molecular weights are given), or non-molecular (molecular weights are not given). Molecular solid components may exist in any phase, but must be given sufficient component properties to support the thermodynamic generators used to predict multi-phase behavior. Non-molecular solids may exist only in the solid phase. Solid attributes are defined in the Component Data Category. For pure component data the PROCESS bank is searched first by default (see Table 2-1). However, the PROCESS bank does not have data for VLS components. For these cases the user should select the SIMSCI bank to search first for pure component data. This program supports two classes of solid attributes: 1.Particle size distribution (PSD). The user defines the size intervals for each grouping of particles. For instance, the first interval could be all particles between 0.0 and 0.02 mm, the second between 0.02 and 0.10 mm, etc. In the Stream Data Category, the actual fraction of each solid component will be I-7-2 Solid Component Properties

distributed to the corresponding interval. Solids with PSD attributes may be either molecular or non-molecular. 2.User defined GENERAL attributes. These are not used in any of the standard PRO/II unit operations or calculational procedures, but may be accessed via User-added Subroutines or InLine Procedures. A maximum of 100 GENERAL attributes may be provided to each component.

Input Description
Solid Attributes (optional)
ATTRCOMP= i, j, {PSD(unit)= s0, s1,...,}GENERAL= 10, {GNAME=text1, text2,...}

Solid attributes may be assigned to each solid component identified on the PHASE statement. This program supports particle size distribution and general, user-defined attributes.
COMP=i,j The component number or range of components having the attributes described on this ATTR statement. If i and j are both given, all components from i to j have these attributes. If j is not given, only component i has these attributes.

PSD

Particle size distribution, defaulting to problem fine length units. The first range has particles with diameters ranging from s0 to s1. The second range has particles from s1 to s2, etc. The last range is sn-1 to sn, where n is the number of sizes given for this component. Number of user defined solid attributes. Defaults to 10. Must be less than 100. User defined names for each of the GENERAL attributes. A maximum of 4 alphanumeric characters are allowed. If the number of GNAME arguments are less than the GENERAL integer value, in the remaining names are filled in. The default assigned names are AT01, AT02, etc.

GENERA L GNAME