Advanced Cyclone Systems

Cyclone Systems for API Recovery

Advanced Cyclone Systems (ACS) is exclusively dedicated to the most advanced cyclone systems worldwide. Applications include product (powder) recovery in the pharmaceutical, chemical and food industries. High-efficiency powder separation / filtration is frequently needed after spray dryers, fluid bed dryers, granulation and pneumatic transport.

Recovery of pharmaceutical ingredients with cyclone systems

Efficient recovery of active pharmaceutical ingredients (APIs), chemical substances and food powders after drying applications such as spray and fluid bed drying is frequently a problem. To recover these sensible products, cyclone collectors are frequently irreplaceable equipments for allowing a direct powder capture without filters. Cyclones also avoid contamination of filter bags, product cross-contamination and product degradation with temperature.

Client needs include a cyclone system which dramatically increases powder yield and is efficient enough to comply with regulatory PM limits, thus avoiding the use of a bag filter.

Cyclones for API recovery

Due to their unparalleled efficiency, Hurricane cyclones have been commercialized several times for the recovery of very fine APIs in the pharmaceutical / biopharmaceutical industries.

Common associated product losses due to low efficiency of cyclone separators are minimized with Hurricane geometries. These cyclones demonstrate impressive efficiencies even in capturing inhalable powders with a median volume diameter (MVD) of less than 3µm. This results in impressive improvements of high-value powder collection.

High-efficiency cyclones with recirculation

ReCyclone® MH Systems are ideal for upgrading Hurricane cyclones' performance and thus minimizing powder losses (down to 50%). This product is especially important for specific cases where electrostatic ReCyclone Systems cannot be applied, such as when organic solvents are used.

For the recovery of these sensible products, ReCyclone MH Systems maintain cyclones' advantages, since the product is only discharged through the Hurricane. These systems are perfectly aseptic, do not have moving parts and can easily be cleaned through clean in place (CIP) mechanisms. Recirculation can be provided through a venturi or a blower, depending on the type of powder processed.

This product is especially important for specific cases where electrostatic ReCyclone Systems cannot be applied, such as when organic solvents are used.

Recovery system for extremely fine APIs

ReCyclone EH Systems are the best technology available for the recovery of very fine and valuable APIs in pharmaceutical / biopharmaceutical drying processes. This is the case of nanoparticles.

ReCyclone EH Systems are ideal to maximize performance and thus minimize powder losses (down to 25% of Hurricane cyclones). This product is especially important for specific cases in the processing of very valuable powders for which no losses are admitted.

For the recovery of these sensible products, ReCyclone EH Systems maintain cyclones' advantages, since the product is only discharged through the Hurricane. These systems are perfectly aseptic and have no moving parts.

Cyclone systems for powder recovery

Our cyclone systems are used for powder recovery in the following applications:

  • Pharmaceuticals
  • Chemicals
  • Food ingredients
  • Nanoparticles
  • Mineral processing
  • Fertilisers
  • Catalysts
  • Milling and drying processes

Cyclone systems for emission control and air dedusting

Our cyclone systems are also used for emission control and air dedusting in the following applications:

  • Biomass and coal boilers and dryers
  • Fuel oil boilers
  • Steel and ferrous alloys
  • Clinker cooler air dedusting
  • Pyrolisis, incineration and gasification
  • Calcination processes
  • Glass and ceramic furnaces
  • Air caption and dedusting
  • High-temperature separation processes

Available White Papers

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Hurricane Case Study: Pharmaceutical Spray Dryer 08 March 2016 In 2008, a leading company in API development and manufacturing approached ACS to improve the yield of powder captured in the cyclone after its 1450kg/hN2 pharmaceutical spray dryer.

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Cyclone Optimisation Including Particle Clustering 03 March 2016 In this work, a new family of geometries of reverse-flow cyclones was obtained through numerical optimisation, using a stochastic random search global optimizer coupled with the PACyc model.