DC series Cyclone Separators

Overview

Remove water droplets entrained in steam or air with TLV's DC series steam separators and air separators.

The DC cyclone separators can be installed on steam lines, air lines, and at the inlet side of equipment to enable removal of virtually all water droplets within the flow. This can significantly improve heat quality, preventing problems such as:

• Low Heating Efficiency
• Product Defects or Off-spec
• Erosion of piping or valve parts, and other related problems

Condensate Separation

Why a Separator is Necessary

Drip legs are designed to remove a considerable portion of the condensate flowing through piping – that which has fallen out of the steam or air flow, but cannot remove the water droplets entrained within the flow itself.

Entrained condensate is not all discharged

Drip legs alone cannot discharge all water droplets entrained within the steam or air.

These droplets may lead to problems such as erosion of valve parts and piping from liquid droplet impingement (LDI) and product defects from water droplets creating cold spots on steam heating surfaces or actually coming in direct contact with the product. In steam heating processes, the thickness of the water film significantly reduces heating, so removing as much water as possible will provide a more effective overall improvement.

Cut-view of Condensate Discharge Through Drip Leg

Water droplets entrained in steam will be carried over and pass by the drip leg because of the speed at which steam/air flows through piping.

Negative Impact of Condensate Droplets in Steam Processes

Negative Impact of Condensate Droplets in Air Processes

Features

DC Series Separator Features

Cyclone Separator

The DC series separators use a cyclone separator to separate and remove water droplets from steam and air with 98% efficiency. High velocity centrifugal force and directional changes are key factors that enable such a high degree of separation.

Built-in Free Float® Trap

The Free Float® enables continuous discharge of condensate while still keeping a steam-tight / air-tight seal. This rapid discharge design with no back-up is essential to prevent condensate from being re-entrained into the steam or air flow.

Cut-view of DC Series Separator

Separating Condensate from Steam/Air

DC Series: Up to 98% Separation Efficiency

Condensate entrained in steam is mechanically removed using a steam separator.

Sample Calculation: Steam Dryness Improvement of 10% Wet Steam at 10 barg (145 psig)

When calculated, the increase in steam dryness is quite significant, reaching up to 99.8% steam dryness as shown in the sample calculation below:

• Total Latent Heat of 10% Wet Steam = 1999 kJ/kg · 0.9 = 1799 kJ/kg [860 BTU/lb · 0.9 = 774 BTU/lb]
• 10% Wetness Loss = 200 kJ/kg [86 BTU/lb]
• Removing 98% of Wetness = 1799 kJ/kg + (200 kJ/kg · 0.98) = 1995 kJ/kg [774 BTU/lb · (86 BTU/lb · 0.98) = 858 BTU/lb]
• Improved Steam Dryness = 99.8% (1995 kJ/kg / 1999 kJ/kg [858 BTU/lb / 860 BTU/lb])

Key Points:

• Heating Efficiency Improved / Time Reduced
• Cold Spots Removed / Heating Quality Improved

For additional Information about Dry Steam, please read:

• Wet Steam vs. Dry Steam: The Importance of the Steam Dryness Fraction

Applications

For Steam Applications

• Steam distribution lines
• Turbines
• Steam heating processes (indirect heating):
• Reaction kettles, dryers, heat exchangers, jacketed vessels, presses, etc.
• Steam heating processes (direct heating):
• Steamers, cookers, cylinder dryers, kneaders, steam atomization systems, etc.

For Air Applications

• Air distribution lines
• Before Filtration
• Air processes:
• Coaters, etc.

Line-up

DC Series Line-up

Model	Appearance	Fluid Type	Max Operating Pressure (MPaG)	Body Material	Specifications
DC3S		Steam	2.1	Ductile Cast Iron	View All
DC5S			1.6	Bronze
DC3A		Air	1.0	Ductile Cast Iron	View All
DC5A			1.0	Bronze
DC7*		Steam or Air	2.5	Cast Stainless Steel	View All

* Requires a separate steam trap.