Cyclone Separators

Cyclone separators as the first stage of compressed-air treatment

A cyclone separator is used to remove large quantities of free, liquid condensate from a compressed air stream. This is particularly useful in situations where water droplets are already present in the line after the compressor or aftercooler. A deliberately generated rotational movement forces the heavier liquid droplets outward, where they are collected in the housing and subsequently drained via a condensate drain.

The current product line offers solutions for various system sizes. The cyclone condensate separators cover flow rates from 1.2 to 36 m³/min and are designed for operating pressures up to 16 bar. Depending on the size, the connections range from compact thread sizes to larger versions for high air volumes. In addition, you will find accessories for installation, for connecting to downstream filters, and various solutions for the condensate drain.

What a cyclone separator actually separates

From a technical standpoint, it is important to distinguish between liquid water and water vapor. A cyclone separator very efficiently removes entrained liquid droplets but does not fundamentally alter the water vapor content of the compressed air. Water vapor remains in gaseous form and can condense again further down the compressed air network if the air cools sufficiently.

The cyclone separator therefore does not produce a defined pressure dew point and does not replace a refrigerated air dryer or desiccant air dryer. Nor is it a substitute for a particle or coalescing filter. Such filters perform other functions, such as separating fine solid particles or very small aerosols.

More than 99 percent separation efficiency for liquid condensate

For the current DFS series, a separation efficiency of over 99 percent is specified for liquid condensate. The separation efficiency remains stable across a wide operating range of approximately 20 to 120 percent of the nominal flow rate. The pressure drop at the rated volumetric flow rate is on the order of approximately 55 mbar. This makes the design well-suited as an upstream relief stage in professional compressed air systems.

The nominal flow rates for the individual models are specified under defined operating conditions. Therefore, the compressor’s motor power alone should not be used as the sole basis for selection. The decisive factor is the actual or maximum expected flow rate at the installation site.

Cyclone separator upstream of the filter and refrigerated air dryer

In many systems, the cyclone separator is located upstream of fine filters and refrigerated air dryers. This removes a large portion of the moisture that is already in liquid form before it reaches the downstream components. Filter elements are subjected to less liquid, and the air dryer receives more consistent inlet conditions.

A typical system may therefore consist of a cyclone separator, appropriate filtration, and a subsequent refrigerated air dryer or desiccant air dryer. Which stages are actually required depends on the required compressed-air quality and the application.

Condensate Drains and Accessories

The separated condensate must be reliably removed from the separator. The product line includes integrated or retrofittable condensate drains and adapters for this purpose. In the DFS series, the integrated mechanical float-type drain operates without an electrical power supply. Additionally, wall mounts and manifold connection kits are available, among other items, which allow separators and filters to be combined into a space-saving treatment unit.

Buy cyclone separators

Anyone looking to purchase a cyclone separator should, above all, know the actual flow rate, the maximum operating pressure, and how it will be integrated into the compressed-air treatment system. The separator is particularly useful for removing moisture that has already condensed, but it does not replace either fine filtration or drying to a defined pressure dew point. When properly sized, it serves as an effective first stage of treatment and reduces the load on the components downstream.