Cyclone Dust Collector

1. Overview of Cyclone Dust Collector

During industrial production, waste gas generated by industries such as mining, metallurgy, refractory materials, coal, chemical engineering, and electric power often contains a large number of dust particles. These dust particles not only pollute the environment but also pose threats to equipment operation and human health. Traditional dust removal equipment has pain points such as complex structure, high maintenance cost, and poor high-temperature resistance, making it difficult to meet the needs of initial purification of high-temperature flue gas and large air volume treatment. The independently developed XFCC series cyclone dust collector by Henan Zhengkuang Machinery Co., Ltd., relying on its unique centrifugal separation technology, modular design, and high-temperature resistance, has become a core equipment for industrial waste gas purification. It is widely used in more than 2,000 projects across over 30 countries worldwide, with a single equipment's maximum air handling capacity reaching 283,600 m³/h, providing an efficient and economical solution for the industry.

2. Technical Principle

Technical Principle

Tangential Air Inlet Stage: Dust-laden gas enters the cylindrical body at a speed of 12-25 m/s along the tangential direction, forming a high-speed rotating outer cyclone flow.

Centrifugal Separation Stage: Due to the difference in density, dust particles are subjected to centrifugal force (Formula: Fc = rmv²). Large particles (>10 μm) are thrown to the equipment wall.

Gravitational Sedimentation Stage: The dust on the equipment wall slides down along the cone to the hopper, and the purified gas turns to form an inner cyclone flow and is discharged from the exhaust pipe.

Secondary Separation Stage: Some fine particles form a dust ring in the upper vortex, which are further captured through the bypass separation chamber.

This technology achieves a separation efficiency of over 90% for particles with a particle size >10 μm, and the pressure loss is controlled within 500-2000 Pa, which is 30% lower than that of traditional equipment.

3. Structural Composition

3.1 Air Inlet Pipe: Arranged tangentially to guide the dust-laden gas to form a spiral flow field.

3.2 Cylindrical Body: With a diameter ranging from 300 mm to 2500 mm, the ratio of height to diameter is optimized to 1.5-2.0 to ensure sufficient rotation of the air flow.

3.3 Cone: The cone angle is designed to be 15°-20° to promote the sliding of dust to the hopper.

3.4 Exhaust Pipe: Located at the center of the equipment, its diameter is 0.5-0.6 times that of the cylindrical body to reduce secondary entrainment.

3.5 Hopper: The volume is customized according to the air handling capacity, and an ash discharge valve is equipped to prevent dust back-mixing.

4. Performance Advantages

4.1 Efficient Separation Capacity: By optimizing the cone angle and the diameter of the exhaust pipe, the separation efficiency of particles with a size of 5-20 μm is increased by 15%, and the dust emission is reduced by 30% compared with traditional equipment.

4.2 High-Temperature Resistant Design: Adopting Q345B heat-resistant steel plate, it can operate stably for a long time in a high-temperature environment of 400℃, meeting the needs of the metallurgical and chemical industries.

4.3 Low Maintenance Cost: The design without moving parts reduces the failure rate to 0.5 times per year, and the maintenance cycle is extended to 6 months, saving 40% of the operating cost compared with bag filters.

4.4 Modular Expandability: The double-cylinder/quadruple-cylinder models support air volume superposition, and the handling capacity of a single equipment covers 670-283,600 m³/h, adapting to production lines of different scales.

4.5 Energy Conservation and Consumption Reduction: The pressure loss is 20% lower than that of traditional equipment. Taking the XFCC2000 model as an example, the annual operating electricity cost is saved by approximately 120,000 yuan (calculated at 0.6 yuan/kWh).

5. Industry Cases

5.1 Mining Industry: Dust Control in Crushing and Screening:

In the crushing workshop of a certain iron ore mine, the XFCC1500 equipment has an air handling capacity of 21,260 m³/h. The inlet dust concentration is 25 g/m³, and the outlet concentration is reduced to 82 mg/m³, meeting the requirements of the "Emission Standard of Pollutants for Iron Ore Mining and Dressing Industry" (GB 28661-2012). The equipment has operated continuously for 3 years without failure, with a dust recovery rate of 92%, and the annual value of recovered ore exceeds 500,000 yuan.

5.2 Metallurgical Industry: Blast Furnace Gas Purification:

The blast furnace gas purification system of a certain iron and steel enterprise adopts the XFCC2500X4 quadruple-cylinder equipment, with an air handling capacity of 236,000 m³/h and an inlet temperature of 350℃. It successfully reduces the dust content of the gas from 10 g/m³ to 8 mg/m³, ensuring the stable operation of the subsequent TRT power generation equipment, and the annual power generation is increased by 12 million kWh.

5.3 Chemical Industry: Catalyst Recovery:

In the PTA unit of a certain petrochemical enterprise, the XFCC800 equipment treats the gas containing catalyst dust, with a recovery efficiency of 95%. The annual value of recovered catalyst exceeds 3 million yuan, and at the same time, the hazardous waste treatment cost is reduced by 800,000 yuan.

5.4 Electric Power Industry: Flue Gas Purification of Biomass Boilers:

A certain biomass power plant adopts the XFCC1200 equipment to treat boiler flue gas. Under the conditions of an inlet temperature of 280℃ and an air volume of 14,600 m³/h, the outlet dust concentration is stably maintained below 30 mg/m³, meeting the requirements of the "Technical Guidelines for Environmental Impact Assessment of Biomass Power Generation Projects".

6. Application Prospects

With the core values of "high efficiency, reliability, and economy", the XFCC series cyclone dust collector continues to lead the technological innovation in the field of industrial waste gas purification, providing one-stop environmental protection solutions for global customers and contributing to green manufacturing and sustainable development.