Cyclone Separator Cut Point & Pressure Drop Calculator

Calculate Stairmand and Lapple cyclone cut diameter (d50), pressure drop, inlet velocity, and particle collection efficiency curves.

Cyclone Design & Airflow

Cyclone Barrel Diam D (in):

Cyclone Standard:

Gas Flow Rate (ACFM):

Gas Temperature (°F):

Dust Particulate Properties

Particle Density (g/cm³):

Target Particle Size (µm):

Cyclone Separation Performance

Cut Diameter (d50)

-- µm

50% particle collection size

Pressure Drop (ΔP)

-- in H2O

-- mbar

Inlet Velocity (vi)

-- ft/s

Optimal: 50-70 ft/s

Target Size Efficiency: --% captured

Fan Power for Cyclone: -- BHP

Optimal cyclone inlet velocity is 50 to 70 ft/s; speeds below 45 ft/s cause poor centrifugal separation, while speeds above 75 ft/s cause particle saltation and rapid metal erosion.

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Frequently Asked Questions

What is the Stairmand high-efficiency cyclone standard?

The Stairmand high-efficiency geometry is a globally recognized design standard characterized by a narrow rectangular inlet (0.5D high × 0.2D wide) and a slender cone (height = 2.5D). It produces high vortex tangential acceleration, yielding a sharp cut point around 3 to 6 microns.

Why does cyclone collection efficiency plummet if the hopper airlock leaks?

The bottom cone of a cyclone operates under strong negative suction pressure. If the dust discharge rotary airlock or flapper valve leaks, atmospheric air rushes up through the dust chute, fluidizing and re-entraining separated powder directly into the clean gas vortex finder.

How does inlet gas velocity affect pressure drop and erosion?

Pressure drop scales with the square of velocity (ΔP ~ vi²). Operating at 85 ft/s instead of 60 ft/s double the pressure drop and fan energy costs, while quadrupling abrasive wall erosion rates.