Cyclone Separator

WALTER cyclone separators are installed upstream of the actual filter unit and serve for pre-separation of dry and free-flowing dusts. Medium and coarse dust particles are already separated in advance, protecting the filter media and minimizing their wear. Used as spark pre-separators, they minimize fire risk. They are also suitable for recovery of bulk materials.

WL cyclones are deployed in woodworking, in foundries and fettling shops, in metalworking and wherever dry, heavy or spark-laden dusts are generated. As pre-separators upstream of bag or cartridge filters, they extend filter media service life and reduce maintenance effort across the entire installation.

Individually engineered

Made in Karlsruhe

Installed by our own fitters

Standards-compliant maintenance

Advantages

Low maintenance, no moving parts
High operational reliability in continuous operation
Low space requirement thanks to vertical design
Improves the efficiency of downstream filter systems
Low flow resistance and reduced energy demand
Minimization of fire risk through spark separation
Protection against overload and clogging of the main dust collector

Applications

Cyclone separators are used in many industries as pre-separators, spark traps or for bulk material recovery:

Wood and shaving dusts in woodworking
Chips and grinding dusts in metalworking
Blasting media and sparks in foundries and fettling shops
Bulk material recovery in process industries
Flue gas pre-separation at melting and drying plants
Pre-separation in pneumatic conveying systems
Recycling and processing plants

Suitable Dusts and Bulk Materials

Cyclones operate particularly efficiently on dry, free-flowing and medium- to coarse-grained particles. Typical applications include:

Wood and shaving chips
Metal dusts, blasting media and abrasive grit
Sand and mineral dust
Granulates, pellets and other bulk materials
Sparks and glowing particles

Operating Principle

The cyclone separators operate according to the centrifugal principle. The raw gas enters the cylindrical part via the tangential inlet channel. The dust particles are thrown against the outer wall by centrifugal force and separated downward via the funnel-shaped outlet into the settling tank below. The cleaned air leaves the pre-separator at the upper, central exhaust air outlet.

Since cyclones operate without moving components, they are robust, durable and virtually maintenance-free. By appropriately sizing inlet velocity, cyclone diameter and dip-tube length, the cut-off particle size can be tuned to the specific application.

Application Example: Multi-Stage Cyclone Installation

Multiple blue WALTER cyclone separators in a production hall, connected via spiral-seam ducts with settling tanks beneath the hoppers

Multi-stage cyclone separators in an industrial plant. Each cyclone with settling tank and tangential inlet channel.

The example shows a multi-stage cyclone installation in which several cyclones are arranged in parallel and in series to handle large volume flows while separating different particle size fractions. The individual cyclones are connected to the main system via welded pipes; the separated dusts fall into settling tanks beneath the hoppers.

Such installations typically operate as pre-separation stages upstream of a bag filter or cartridge filter system. The downstream main filter then achieves significantly longer service life because the coarse dust fraction has already been removed by the cyclone. In spark-laden processes, the cyclone additionally acts as a spark trap and protects the filter medium from glowing particles.

Technical Key Data

Volume Flow Range	1,000 to 60,000 m³/h, larger volumes via parallel arrangement
Construction	Tangential inlet channel, cylindrical vortex chamber, conical hopper, central clean gas outlet
Materials (standard)	Sheet steel, painted or galvanized
Special Materials	Wear-protection plates in inlet and hopper area, stainless steel and heat-resistant materials on request
Dust Discharge	Settling tank, optional rotary valve or screw conveyor

Options

Wear protection for abrasive dusts
Rotary valve for continuous dust discharge
ATEX-compliant safety equipment for combustible dusts
Thermal insulation for hot raw gas
Special materials for corrosive media

Versions

The cyclone separators are available from 1,000 m³/h to 60,000 m³/h. Larger air capacities are realized by arranging several cyclones in parallel or as customer-specific designs.

Cyclone Separators

Combination with Downstream Filters

Cyclone separators achieve a high separation efficiency for medium and coarse particles, but are not suitable for fine dust and aerosols. For complete cleaning of the exhaust air, the cyclone is usually combined with a bag filter, cartridge filter or pocket filter.

The connection dimensions of WALTER cyclones are matched to the SF (bag filter) and MPS (cartridge filter) series. On request we deliver the complete plant including ductwork, shut-off dampers, fan and control system from a single source and handle on-site installation.

Frequently Asked Questions

When does a cyclone separator make sense? +

A cyclone is worthwhile wherever coarse or heavy dusts and sparks occur at the same time. As a pre-separator upstream of a bag or cartridge filter it protects the filter medium, extends its service life and reduces fire risk. For pure bulk-material recovery without subsequent clean-air return the cyclone may also be used on its own.

What separation efficiency does a cyclone achieve? +

Separation efficiency depends on particle size, density and flow velocity. For particles from approximately 10 µm typical efficiencies are 90 % and higher. Fine dust below around 5 µm is only partially separated and should be retained by a downstream filter.

Is a cyclone alone sufficient as a dedusting solution? +

For very coarse and heavy dusts or pure bulk material recovery the cyclone alone is sufficient. However, if cleaned air is to be returned to the workspace or emission limits must be met, a combination with a bag, cartridge or pocket filter is required.

Which materials are used? +

Standard construction is painted or galvanized sheet steel. For abrasive dusts wear-protection plates are added in the inlet and on the inner hopper wall.

How is the separated dust discharged? +

By default the separated dust falls into a settling tank below the cyclone. For continuous operation or large dust volumes a rotary valve or screw conveyor is recommended; on request the discharge is fed directly into big bags or a collection container.

Which volume flow range is available? +

WALTER cyclones are built from 1,000 m³/h up to 60,000 m³/h. Larger plants are realized by arranging several cyclones in parallel or by customer-specific design.

Complementary Products

Cyclone separators are usually combined with other WALTER components to form a complete dust collection plant.

Main filter

Bag Filter

Modular bag filters of the SF series from 3,000 to 60,000 m³/h - the typical main filter behind a cyclone pre-separator.

Go to bag filter →

Main filter

Cartridge Filter

Compact MPS cartridge filter for workshop applications with high separation efficiency for fine dusts.

Go to cartridge filter →

Connection

Pipes and Ducts

Welded pipework according to DIN 24151 / EN 1506 to connect capture element, cyclone, main filter and fan.

Go to pipes and ducts →

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