Ceramic Vortex Finder

Improve cyclone operations at high temperatues

Vortex finders (also known as center pipes, dip tubes, immersion tubes, and thimbles) are installed in cyclones to improve dust separation between the raw meal and the hot gas, thereby increasing the efficiency and hence reducing  fuel consumption, usually in the range of 1-2%.

The HASLE Ceramic Vortex Finder (CVF) is designed to improve operations in industrial cyclones at elevated temperatures and provides an alternative to traditional steel dip tubes.

It is assembled on-site by individual ceramic elements, which interlock to form a stable tube hanging from a steel ring welded to the roof casing of the cyclone. 

 

  • Can withstand temperatures up to 1200 °C / 2200 °F
  • No corrosion – excellent resistance to chemical attacks
  • Does not buckle – high strength and dimensional stability
  • Smooth surface – minimal build-up and coating
  • The ceramic elements do not contains chromium, and is therefore safer and less complicated to maintain and service than its steel counterparts
  • Easy and quick to install
HASLE Ceramic vortex finder is an alternative to dip tubes in Cyclones

Designed for longevity and to streamline your process

smooth running process with HASLE ceramic Vortex finder

Minimizing the risk of blockage

The small-sized ceramic elements mean minimum risk of cyclone blockage if any of the elements fall down, as they can pass through the feed pipe and allow operations to continue.

 

Easy handling

Due to the low weight of 6-19 kg of the individual elements, no heavy lifting equipment is required for handling and it is possible to use the existing manholes for the installation.

Engineered to withstand the harsh conditions in cyclones

Originally developed in the 1980s, the latest generation 3 of the HASLE Ceramic Vortex Finder is completely re-engineered with an optimized element design system .

It is furthermore manufactured from a new non-cement castable developed to withstand the aggressive environment found in cyclones operating at high temperatures, including the burning of alternative fuels.

 

Keep the process running with high efficiency!

The smooth surface of the ceramic elements reduces build-up and coating.

Additionally, the ceramic material is corrosion-resistant and has high dimensional stability, meaning the CVF will not buckle.

Get aquainted with the HASLE Ceramic Vortex Finder

Modular system design for maximum flexibility

HASLE Ceramic vortex finder is an alternative to dip tubes in Cyclones

The HASLE Ceramic Vortex Finder (CVF) is based on a modular system of ceramic elements, which makes it possible to tailor the installation to individual operating conditions and cyclone dimensions.

The CVF system consists of standardized shapes in different angles which interlock via advanced tongue-and-groove joints, allowing:

 

  • Variable diameter options: 1,5m – 7,5m
  • Lengths up to 5 m (can easily be adjusted to suit changes in the process)

Meticulous manufacturing

High-performance materials
The ceramic elements are manufactured from a high-grade castable with pure synthetic and high-performance raw materials to ensure no impurities. Nanoparticles are included for high fracture toughness and optimal strength – even at elevated temperatures. In addition, the materials used are providing high resistance to chemical attacks, making the CVF suitable for plants burning alternative fuels.

Carefully manufactured for maximum strength
To achieve maximum strength, the ceramic elements are manufactured under strictly controlled conditions at our factory in Denmark; first, the shapes are carefully cast and cured in specialized molds to obtain a smooth surface and sustain their unique profile. Subsequently, they are pre-fired to elevated temperatures.

Selected references

Since the introduction in the 1980s, several hundres of the HASLE Ceramic Vortex Finder have been installed globally. Especially in the lower-stage cyclones of the prehating process in cement plants.  But also in for instance paper mills, wood processing plants, aluminum smelters and in boiler applications for power generation. 

Latest, the generation 3 of the CVF has been introduced to the market, and below you can read the most recent installation cases 

Cement plant in Germany – 2nd lowest stage cyclone

A 5.000 tpd cement plant in Germany operating on 95% RDF has installed a HASLE Ceramic Vortex Finder (generation 3) in the 2nd lowest stage cyclone in the preheating process, replacing a steel dip tube. Reaching temperatures up to 850 °C, the CVF has now been in operation for more than 2 years and is still running. 

 

Cement plant in Germany reach 1 year lifetime in lowest-stage cyclone

In the lowest-stage cyclone at a 5.000 tpd cement plant in Germany, a HASLE Ceramic Vortex Finder has acheived 1 year lifetime. The cement plant is running on 95% RDF and the operating temperature in the cyclone can reach up to 1050 °C. The HASLE CVF has achieved 3 times longer lifetime compared to the steel dip tube previously used.

 

 Cement plant in Spain – middle-stage cyclone

Installed in January 2020, a Ceramic Vortex Finder is running on its 4th year at a Spanish cement plant. It is installed in the middle stage cyclone, which operates at ca. 700 °C. 

 Cement plant in Spain – middle-stage cyclone

Installed in January 2020, a Ceramic Vortex Finder is running on its 4th year at a Spanish cement plant. It is installed in the middle stage cyclone, which operates at ca. 700 °C. 

Read more about the HASLE Ceramic Vortex Finder

Download our brochure as PDF and read more about the Ceramic Vortex Finder

HASLE Refractories A/S
Kanegaardsvej 1
DK-3700 Roenne, DENMARK
Phone: + 45 56 95 18 00

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