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How Cyclone Separators Work

Overview
Cyclone separators are used with shop vacs and dust collectors to remove 85% to over 99% of all of the dust before it gets to the filter.   

Without a cyclone separator you will have to clean your filter 5x to 100x more often, depending on the type of dust you are collecting.  If you use a shop vac or dust collector very often a cyclone separator is more than worth the investment.
Cyclone separators typically separate 99% of the dust particles >10 microns from the air stream    and deposit them into a collection bin before reaching the filter.  This means you won't have to clean your shop vac or dust collector filter nearly as often if you use a cyclone separator.   This convenience has made cyclone separators a very common workshop accessory.   Cyclone separators are just one of four common types of filtration systems.   Other types of filtration systems include  filters, wet collectors and electrostatic  precipitators.  Wet filters are not  common in home workshops because they require frequent maintenance and raise humidity levels.    Filters can remove particles down to 0.3 microns.  

How does a cyclone separator work?
The air/dust entering the cyclone from a hose connected to a dust producing tool is forced into a circular path, circulating at thousands of rpm.  This creates a centrifugal force that forces any heavier than air particles to the outside wall.  Gravity causes the dust and debris to spiral down until it eventually lands in the collection bin.  An easy way to picture how a cyclone works is to think of rolling a marble along with air into the inlet shown in the figure below. The marble stays pinned to the outside wall by centrifugal force as it spirals down into the collection bin below.  The air and the very fine dust are buoyant and are not affected by the centrifugal force so they easily flow  toward the center of the cyclone and through the outlet tube to the dust collector or shop vac filter or they are vented outside.  
Picture
NOTE:  any leaks into the collection bin will force the dusty cloud of air inside of the dust bin up into the cyclone and out.  This greatly reduces the cyclone's collection efficiency. It's very important to ensure your system doesn't have any leaks between the bottom of the cyclone and the collection bin.

​Cyclones very effectively separate anything that is heavier than air from the air, including  liquids.  Dust particles that are large enough to see with the naked eye are separated nearly 100%.   Almost 100% of the very fine dust (under 2.5 microns) bypasses the cyclone because it is buoyant in air and therefore it is not affected by the centrifugal forces as much as the drag forces of the airflow.  Particles under 10 microns are the most harmful to your health because they travel to the full extents of your lungs and pass the chemicals used to treat and bind wood directly into your bloodstream. That's why cyclones should never be vented indoors without using a quality filter downstream.    The chart below illustrates this point by showing which particles cyclones will remove  and which particle sizes are most dangerous.
Picture
Cyclones greatly increase the time your vac filter will last before needing to be cleaned.   However, if you frequently vacuum  fine dust you may still have to clean your filter regularly.  Click on the following link if you want to know how you can NEVER have to clean change your shop vac filter again.
​

To see how two of the most popular shop vac cyclone separator systems compare  in rigorous testing, check out Dust Deputy and Dustopper Review and Comprehensive Scientific Testing

Dust Sheriff - the most effective shop vac cyclone dust collector on the market.   Collects 5x more fine dust than the Dust Deputy and flows 30% more air.

​​Next Article - Resource Links

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© Copyright, Shop Hacks 2019
  • Home
  • Improve your Workspace
    • Dust Collection and Air Filtration >
      • Table Saw Dust Collection
      • All About Cyclone Separators
      • Dust Deputy and Dustopper Review and Comprehensive Scientific Testing
      • Dust Sheriff Cyclone Separator
      • Dust Collection System Options
      • Air Filtration System Options
      • Why clean air matters
      • Is your shop air safe???
      • How to maintain healthy air in your shop
      • Dust Collection Resources and Links
      • Why I became obsessed with dust collection and air filtration
    • Storage, Organization, Efficiency >
      • How to organize your tools and materials
      • Workbench Build and Restoration Options
    • Improve your workshop floors and lighting >
      • Improve your floors
      • Improve your lighting
  • Improve Your Tools
    • CNC Routing / Milling >
      • What you can make with a CNC router
      • What are your options?
      • Getting Started with a CNC
      • CNC Enclosures
      • My Journey to CNC Machines
      • CNC Router Resources and Links
    • Laser Cutting / Engraving >
      • What you can make with a laser
      • Types of Laser Cutters
      • Laser Cutting Resources and Links
    • 3D Printing >
      • What you can make with a 3D Printer
      • Which 3D Printer Should I Buy?
      • 3D Printing Tips and Tricks
      • 3D Printing Resources and Links
      • My Journey to 3D Printing
      • Modified Makergear M2 with Heated Build Chamber
    • Vinyl Cutting / Graphics
  • Shop
    • The Ultimate Air Filtration System
    • Dust Sheriff Cyclone Dust Collector
    • Shop Vac Hose Connector
    • Drill Organizer with Easy Access Charger Shelf
    • Quik Cleat Organization System
    • Ultimate Flip Top Workbench Plans
    • DIY Hydraulic Lift Mobile Tool Base
    • Chop Stop
  • Community
    • Social Media Channels
    • The Shop Hacks Story
    • Blog
    • Shop Hacks Innovators Program