Cyclone Separators
High-Efficiency, Compact, Robust, Dust Collection for Industrial Gas Streams
- Handles High Dust Loads
- Withstands Temperatures up to 1100°C and Pressure up to 33 BarG
- Customized design with single, twin, quad, six-pack cyclone arrangement
- Ultra high efficiency > 99% at 1 micron
Product Overview
Reliable Dust Collection Cyclone
TNBi’s Cyclone Separator uses centrifugal force and vortex motion to separate dust particles from air or gas streams. With no filters or moving parts, it is an ultra-reliable and low-maintenance solution for primary dust removal. TNBi cyclones are custom-built to suit your space, dust type, and operating pressure.
Product USP
Why TNBi Cyclones Outperform?
Performance
Dust collection efficiency > 99% @ 1 micron
Emission levels up to 25 mg/Nm³
Operates at high dust loads and fine particle sizes
Design Strength
Compact Ultra High Efficiency Design
Temperature rating up to 1100°C
Withstands vacuum to 33 bar pressure
Safety & Maintenance
Easy to clean and inspect
Low manpower and minimal wear & tear
ATEX compliance can be given
Installation Layout
Use Cases
Perfect for Primary Separation & Heavy-Dust Scenarios
Mill Outlet Pre-Filtration
Removes bulk dust before reaching bag filters or scrubbers.
Boiler & Furnace Dust Extraction
Withstands flue gas temperatures up to 1100°C.
Spray Drying & Powder Coating
Collects fine particles before the final product or packaging.
Combustible Dust Handling
Cyclones help reduce ignition risks in explosive environments.
Process Dust Control
From mixing, blending, drying, and material transfer points.
"Upstream" Pre-Cleaning
Improves service life, safety and efficiency of downstream scrubbers/bag filters.
Challenges vs TNBi's Solutions
How Do We Eliminate Choking, Fires, and Filter Breakdowns?
“Our filter bags can’t handle high dust loads”
High-volume cyclones handle heavy dust loads efficiently
“Frequent fires in bag filters”
No fabric design (combustion source) mitigates fire risk
“System chokes or breaks down often”
No moving parts = no choking, no mechanical failures
Case Studies
Proven in the Field
High-Efficiency Cyclone Replaces Fire-Prone Bag Filter
Challenge: A polymer processing facility handling ultra-fine powder after milling faced major operational setbacks due to an overloaded bag filter system. With dust loading at 8750 mg/Nm³ and over 90% of particles smaller than 9.1 µm, the existing setup couldn’t manage the fine particulate burden. This led to frequent fires, 18-hour downtimes, and repeated filter bag failures under heat and pressure.
TNBi Solution: To replace the breakdown-prone filter system, TNBi deployed a cyclone separator designed for high dust loads, eliminating the need for filter bags. The system featured a no-moving-parts design, which prevents choking, reduces maintenance, and ensures safe, spark-free operation. Its compact configuration also minimized noise and simplified integration into the plant’s layout.
Result
- Emission level brought down to <25 mg/Nm³ >
- 99.72% collection efficiency achieved
- Zero fire incidents
- Higher product recovery and uptime
Share Dust Load, We’ll Do the Engineering
No assumptions. Let’s customise a cyclone that’s built to the exact dust profile of your plant
Industry Application
Installed Across High-Dust, High-Heat Industries
Steel & Non-Ferrous Metals
Food, Agro & Tobacco
Cement & Aggregates
Paints, Pigments & Plastics
Pharmaceuticals
Pulp, Paper & Textiles
Power & Biomass Plants
Tyres, Rubber & Wood
Technical Specifications Table |
|
|---|---|
| Parameter | Specification |
| Separation Mechanism | Vortex-based inertial separation |
| Dust Size Range | Vacuum to 33 bar |
| Dust Discharge Options | < 3 µm to 100+ µm |
| Efficiency Achieved | > 99.7% with proper design |
FAQ's
Frequently Asked Questions
What is a cyclone separator and how does it work?
A cyclone separator uses centrifugal force to remove dust particles from gas streams, without any filters or moving parts. Dust swirls outward and downward while clean air exits from the top.
Can a cyclone replace a bag filter?
In some cases, yes, cyclones can replace bag filters. TNBi’s Ultra high-efficiency cyclones have replaced bag filters where fire risk, choking, or fine dust were the issues. They achieved <25 mg/Nm³ emissions and >99% collection for the plants.
Where should I use a cyclone in my system?
TNBi customises placement based on dust load, layout, and target emission limits.
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