Food, Chemical & Pharmaceutical Powder Recovery Hurricane & ReCyclone® Systems

Advanced Cyclone Systems (ACS) Towards total particle capture with optimized cyclone systems ACS is a company exclusively dedicated to the development and supply of the most efficient cyclone systems in the world. ACS Focus We focus on particulate matter (PM) emission control (EC) in boilers, furnaces and dryers. We also work on enhancing powder recovery (PR) in pharmaceutical, food and chemical processes. ACS Mission Achieving particle capture exclusively with cyclones by continuously researching and innovating, freeing the client from the costs and problems of Electrostatic Precipitators (ESPs),...

The problem with Powder Collection & Emission Control More efficient cyclones can play an important role after drying, milling and micronization processes Application Fields Food ingredients Pharmaceutical ingredients Chemicals Fertilizers In multiple industries, products are manufactured in the powder form in sources such as dryers, mixers, or mills. Examples go from dairy powders to pharmaceuticals and from fertilizers to nanoparticles. The separation of these products from the air is unavoidable. Multiple industrial filtration systems can be used for that purpose. Mineral processing powder...

About Hurricane Cyclones ACS numerically optimized cyclones How can cyclones be improved? Since the early 1900’s cyclones have been mostly designed and improved by empirical means, due to the difficulty of building a good prediction method that handles the modeling complexity related with multiphase and highly turbulent flows. Computerized Flow Dynamics (CFD) can be used for partial cyclone optimization but it is still incomplete for full cyclone optimization, due to the very large computational burden associated with highly vorticial, assimetrical and multiphase flows with polidispersity. Sub-optimization...

Alternative Cyclone Solutions Real Case Analysis: Fluidized Bed Drying of Sulphanilic Acid Designing cyclones to increase yield & reduce emissions: Processing industries are facing both an environmental and a plant efficiency challenge. For some clients ACS has come across, such as Bondalti in Portugal, high efficiency MK type cyclones were placed downstream of the process cyclones of the fluid bed dryer (see figure) in order to reduce emissions of sulphanilic acid under 40mg/Nm3. That’s a near 99.9% efficiency for particles escaping other cyclones! Other cyclone families could be used, producing...

ReCyclone Systems® Mechanical and Electrostatic Recirculation ReCyclone® (MH and EH) A ReCyclone is made up of a high efficiency Hurricane cyclone and a particle separator placed downstream, called the "recirculator" (please see figure) and which can be either purely mechanical or electrostatic. The main purpose of the recirculators is to reintroduce the uncaptured particles into the cyclones after they have been driven to the outer walls of the recirculators by centrifugal and/or electrostatic forces. While this gas is enriched in particles, the axial gas stream exhaust to the stack is clean....

Technology Comparison Hurricane® Cyclones | ReCyclone® MH | ReCyclone® EH | Other Technologies Approach to any new project Whenever it is possible to achieve a requested emission limit or powder collection objective with a given optimized cyclone family, ACS will avoid recirculation in order to reduce investment and operating costs (mainly power consumption of fans) and to improve the system cleanability. For the recovery of very fine products, such as nanoparticles, or when emissions need to be minimal, electrostatic recirculation may be mandatory. Ultimately, any hurricane family can be coupled...

Case Studies for Food Ingredients The need to separate powder based Food Ingredients occurs in many industries, from the dairy to chocolate making and from beverages to starches and yeasts. Spray Drying is commonly used to design and produce a variety of powders, many of those quite valuable and sensitive, such as Demineralized Whey or Whey Protein Concentrate. Frequently, Bag Filters are excluded to be used as powder collectors due to potential contamination with filter fibers, cross contamination or heat degradation. ACS cyclones are therefore a very good alternative both as process cyclones...

Case Studies for Active Pharmaceutical Ingredients ACS has multiple references for the separation of Active Pharmaceutical Ingredients (APIs) and Final Product Formulations (FPFs). These typically occur in Spray Drying arrangements where the cyclones are the exclusive powder collectors. Indeed, potential contamination with filter fibers and heat degradation precludes other filters, which results in important economical losses if cyclone efficiency is low. Other examples of applications include micronization, cryogrinding and the separation of powders after tablet pressing machines. Hurricane...

Case Studies for Chemical Powders Similarly to food and pharma, chemical powders are often obtained through drying processes. These include potash and other compounds for fertilizers, medical application chemicals, various inorganic compounds, such as lithium hydroxide, and many other powder based substances including tungsten carbides and zync oxides. In addition to Spray Dryers, Fluid Bed Dryers are also often used to dry chemical powders where process cyclones return the powder to the fluid bed and additional high efficiency cyclones are used to control emissions. Process cyclone Air inlet...

Case Studies for Air Capture, Dedusting & Recovery The fact that cyclones are relatively simple separators, have no moving parts and can be easily and effectively cleaned makes them ideal devices to be used for general dedusting applications where there is a need to recover the powder. Whenever there are processes involving coating, painting, cutting, filling or pressing, powder is released and typically captured in a central filter where it is mixed with other powders from different sources or from the same source. Compact high efficiency cyclones placed upstream of this filter can dramatically...