Effect of cyclone orientation on the collection efficiency of a hybrid cyclone for fly ash reduction in Kenyan sugar industries

The sugar industry in Kenya continues to grapple with significant air pollution challenges due to the release of particulate fly ash from bagasse-fired boilers. Existing single-stage cyclone separators exhibit limited efficiency in capturing fine particles, prompting the need for improved dust collection technologies. This study investigates the impact of cyclone orientation—specifically series versus parallel configuration—on the collection efficiency of a hybrid cyclone system. Using a combination of Computational Fluid Dynamics (CFD) simulations and physical experiments, the study evaluates gas flow behavior, pressure differentials, and particulate capture performance under varying orientation setups. Results indicate that the series configuration significantly enhances particulate collection, achieving efficiency levels between 81.26% and 81.95%, compared to only 30.6% for the parallel setup. The superior performance of the series orientation is attributed to improved pressure gradients, stable vortex flow, and reduced thermal instability, which collectively enhance fine particle capture. The findings offer actionable insights into optimizing cyclone layout for sugar mill operations and contribute to the design of more effective air pollution control systems in biomass combustion environments.