CFD BASED DESIGN OPTIMIZATION OF

CYCLONE SEPARATOR
This project thesis is submitted in partial fulfillment of the requirements for the degree of
Bachelor of Technology of Chemical Engineering under the National Institute of Technology
Durgapur

Project submitted by:

RAJKUMAR DAS
20CH8031
BACHELOR OF TECHNOLOGY
IN
CHEMICAL ENGINEERING

Under the guidance of

Dr. ABHIRAM HENS

Assistant Professor, Department of Chemical Engineering,
National Institute of Technology, Durgapur

May 2024

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 ACKNOWLEDGEMENT

Foremost, I would like to express my sincere gratitude to my supervisor Dr. Abhiram Hens
Assistant Professor, Chemical Engineering Department, NIT Durgapur, for enlightening
me towards the research path. They have always motivated me and encouraged me to do the
work. I am grateful to them for believing in me and constantly supporting me for the job.
Their inspiring guidance, systematic approach, sensible criticisms, and close support
throughout this project work helped me overcome the problems at many critical stages of the
assignment leading and enabling towards the successful accomplishment of this project.

Finally, I feel great reverence for all my family members and the Almighty, for their
blessings and for being a constant source of encouragement.

RAJKUMAR DAS

20CH8031

Signature of the student/s with date

NATIONAL INSTITUTE OF TECHNOLOGY, DURGAPUR

DEPARTMENT OF CHEMICAL ENGINEERING

2
 Certificate

This is to certify that the thesis ‘CFD based design optimization of cyclone separator’,
submitted by RAJKUMAR DAS (20CH8031), in the fulfillment of the requirement of a
bachelor of technology degree in chemical engineering, is a bonafide record of the work
carried out by them at the Department of Chemical engineering, National Institute of
Technology Durgapur under my guidance and supervision.

..……………………………..
Dr. Abhiram Hens
Assistant Professor
Chemical Engineering Department
National Institute Of Technology,
Durgapur
Mahatma Gandhi Avenue
Durgapur, West Bengal, India - 713209

Certificate of Approval

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The foregoing thesis is hereby approved as a creditable study of engineering subject,

carried out and presented in a manner satisfactory to warrant its acceptance as a

prerequisite to the degree for which it has been submitted. It is to be understood that by

this approval the undersigned does not necessarily endorse or approve any statement

made, opinion expressed or conclusion drawn therein, but approved the thesis only for

the purpose for which it has been submitted.

BOARD OF THESIS EXAMINERS:

1. ………………………………………

2. ………………………………………

3. ………………………………………

4. ………………………………………

5. ………………………………………

6. ………………………………………

7. ………………………………………

Declaration

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I hereby declare that the thesis entitled, ‘CFD based design optimization of cyclone
separator’ submitted to the Department of Chemical Engineering, National Institute of
Technology, Durgapur in partial fulfillment of the requirement for the award of the B. Tech
Degree in Chemical Engineering is an authentic work carried out by us under the
supervision of Dr. Abhiram Hens Assistant Professor, Chemical Engineering
Department, NIT Durgapur. The matter presented in this thesis represents our ideas in my
own words and where other ideas or words have been included: citations and references of
the original work have been provided. I also declare that I have adhered to all academic
honesty and integrity principles and have not misinterpreted fabricated or falsified any idea/
data/ fact/ source in my submission. I understand that any violation of the above will be
cause for disciplinary action by the Institute and can evoke penal action from the sources
which have thus not been properly cited or from whom permission has not been received.

.....................................................

RAJKUMAR DAS

Department of Chemical Engineering

Roll No. : 20CH8031

Registration No. : 20U10437

CONTENTS

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TABLE OF CONTENTS
Acknowledgement…………………………………………………………………………….2
Certificate……………………………………………………………………………………..3
Certificate of Approval………………………………………………………………………..4
Declaration…………………………………………………………………………………….5
Contents……………………………………………………………………………………….6
List of Figure……………………………………………………………………………….…7
List of Tables………………………………………………………………………………….8
Abstract………………………………………………………………………………………..9
Chapter 1:
Introduction……………………………………………………………………….10
Chapter 2: Literature review and Objective ………………………………………………..19
Chapter 3: Methodology……………………………………………………………………...22
Chapter 4: Result and Discussion…………………………………………………………….29
Single-Phase flow…………………………………………………………………29
Multi-Phase flow………………………………………………………………….30
The separation efficiency of different cone tip diameters………………………………… 33
Variations in the flow rate and velocity of 12 mm cone tip diameter………………………..35
Chapter 5: Conclusion………………………………………………………………………..37
Prospects…………………………………………………………………………38
Chapter 6: References………………………………………………………………………..39

LIST OF FIGURES

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CHAPTER 1
INTRODUCTION
 FIGURE 1: Schematic diagram for the cyclone geometry and coordinate definition

CHAPTER 3
METHODOLOGY

 FIGURE 2: SpaceClaim Model

 FIGURE 3: 12 mm cone-tip diameter meshing
 FIGURE 4: 14 mm cone-tip diameter meshing
 FIGURE 5: 18 mm cone-tip diameter meshing

CHAPTER 4
RESULTS AND DISCUSSION

 FIGURE 6: Pathline Velocity Magnitude (a=12 mm, b=14, c=18 mm cone tip
diameter)
 FIGURE 7: Pathline velocity magnitude (a=12, b=14, c=18mm Cone tip diameter )
 FIGURE 8: Contours Velocity magnitude (mixture) (m/s) ( a=12mm, b=14mm, c=18mm
Cone tip diameter )
 FIGURE 9: Contours Static pressure (mixture) (pa) ( a=12mm, b=14mm, c=18mm Cone
tip diameter )
 FIGURE 10: Particle variables ( a=12mm, b=14mm, c=18mm Cone tip diameter)
 FIGURE 11: Pathline of particles ( a=12mm, b=14mm, c=18mm Cone tip diameter )
 FIGURE 12: Pathlines particle ( a=10, b=15, c=20 kg/s total flow rate )

LIST OF TABLES

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CHAPTER 1
INTRODUCTION
 Table 1: The geometrical dimensions of the three cyclones.

CHAPTER 3
METHODOLOGY
 TABLE 2: Simulation details

CHAPTER 4
RESULTS AND DISCUSSION

 TABLE 3: Calculation data of different cone tip diameter

 TABLE 4: Calculation table of different cone tip diameter
 TABLE 5: Data (total flow rate and velocity)
 TABLE 6: Calculation table (total flow rate and velocity)

ABSTRACT

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This thesis employs Computational Fluid Dynamics (CFD) analysis to optimize cyclone
separator performance for both single-phase gas and multiphase gas-steel mixture scenarios.
Cyclone separators are indispensable in various industrial processes for efficient particle
separation from gas streams. However, achieving optimal performance, especially in
multiphase environments like gas and steel mixtures, poses significant challenges.

The study begins by focusing on single-phase gas analysis, where CFD simulations explore
the effects of cone-tip diameter variations and flow dynamics within the cyclone separator.
Through systematic parametric analysis, the research identifies optimal cone-tip diameters
that strike a balance between pressure drop considerations and particle separation efficiency.

Expanding on these findings, the research transitions to multiphase analysis, specifically

investigating gas and steel mixture scenarios. CFD models intricately simulate particle-gas
interactions, considering variables such as cone-tip diameter adjustments and flow dynamics
manipulation. These simulations offer insights into particle trajectories, pressure distribution,
and flow patterns within the cyclone separator.

Validation of the CFD analysis is performed through experimental verification using scaled-
down prototype cyclone separators. The results corroborate the effectiveness of the optimized
parameters in enhancing cyclone separator efficiency for both single-phase gas and
multiphase gas-steel mixtures.

By leveraging CFD analysis, this thesis provides a comprehensive understanding of the

underlying mechanisms governing cyclone separator performance. The findings offer
valuable insights for engineers and researchers aiming to optimize cyclone separators in
industrial settings. Ultimately, the proposed strategies hold promise for improving process
efficiency and sustainability, particularly in industries dealing with gas and multiphase
mixtures.

Keywords: Cyclone separator, CFD, different cone-tip diameter, different flow dynamics,
Ansys fluent.

CHAPTER 1

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INTRODUCTION
The optimization of cyclone separator efficiency is crucial in various industries where the
separation of gas and particulate matter is essential for operational efficiency and
environmental compliance. Cyclone separators are widely used due to their simplicity,
reliability, and cost-effectiveness in separating solid particles from gas streams. However,
achieving optimal performance requires a thorough understanding of the fluid dynamics
within the cyclone, particularly around the cone-tip area, where the separation process is
intensified. This study aims to investigate the impact of different cone-tip diameters on the
flow dynamics within cyclone separators and their subsequent effect on separation efficiency.
Specifically, we focus on enhancing performance for both single-phase gas analysis and
multiphase analysis, particularly when dealing with gas and steel mixture, a scenario
prevalent in industries such as metallurgy and manufacturing. The importance of optimizing
cyclone separator efficiency cannot be overstated, especially in industries where the quality
of the separated gas and particulate matter directly influences product quality, equipment
reliability, and environmental emissions. By improving separation efficiency, industries can
reduce energy consumption, minimize equipment wear and tear, and mitigate environmental
impacts associated with emissions.

This research hypothesizes that variations in cone-tip diameter can significantly influence the
flow patterns within the cyclone separator, thereby affecting the efficiency of gas-solid
separation. Through comprehensive analysis and experimentation, we seek to identify the
optimal cone-tip diameter that maximizes separation efficiency for different operating
conditions and gas-solid compositions. The significance of this study lies in its potential to
provide insights into the design and operation of cyclone separators, leading to improved
performance and cost savings for industries reliant on efficient gas-solid separation processes.
Furthermore, the findings could contribute to the development of more sustainable practices
by reducing energy consumption and environmental pollution associated with industrial
processes.

In summary, this research addresses a critical need for optimizing cyclone separator
efficiency by investigating the influence of cone-tip diameter variations on flow dynamics
and separation performance. By focusing on both single-phase gas analysis and multiphase
analysis, particularly in scenarios involving gas and steel mixture, this study aims to

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contribute valuable insights to the field of gas-solid separation technology, with implications
for various industrial applications.

Table 1:

The geometrical dimensions of the three cyclones.

Dimension Length (mm) Dimension ratio

(dimension/D)

Body diameter, D 31 1

Gas outlet diameter, Dx 15.5 0.5

Inlet height, a 13 0.41

Inlet width, b 5 0.16

Cyclone height, Ht 77 2.5

Cylinder height, h 31 1

Gas outlet duct length, S 15.5 0.5

Cone tip diameter, Bc Cyclone 1 12 0.39

Cyclone 2 14 0.45

Cyclone 3 18 0.58

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 FIGURE 1: Schematic diagram for the cyclone geometry and coordinate definition

1.1 OVERVIEW OF CFD

CFD, or computational fluid dynamics, is a computational approach to simulating fluid
motion based on mathematical equations governing fluid mechanics. It employs numerical
methods to approximate these equations, enabling accurate predictions of various fluid-
related phenomena such as flow behavior, heat and mass transfer, and chemical reactions.
CFD leverages advancements in computer technology to tackle a wide range of fluid flow
scenarios, including compressible or incompressible, laminar or turbulent, and reactive or
non-reactive flows. Essentially, CFD allows for the emulation of real-life scenarios through
mathematical modeling, involving steps like formulating mathematical expressions for fluid
flow, creating numerical representations of these equations, subdividing the domain into
discrete components, and solving the equations with specified initial and boundary
conditions.

1.2 ADVANTAGES OF CFD

Cost-effective and time-saving tool: CFD stands as a potent instrument for simulating and
replicating real-world scenarios through simulation and mathematical modeling, offering a
cost and time-effective alternative to physical experiments by eliminating the need for
physical modifications.

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 Reliable: The numerical methods and schemes on which CFD is based are advancing
quickly, making CFD results more and more trustworthy. Speed: CFD simulations can
be executed in a short period.
Ability to simulate real-life scenarios: It also accurately predicts fluid flow, heat
transfer, mass transfer, chemical reactions, and related phenomena. Through CFD a real-
life scenario can be imitated and solving it numerically through a mathematical model.
Comprehensive information: CFD allows the designer to examine any location in
the region of interest, and interpret its performance through a set of thermal and flow
parameters.

1.3. APPLICABILITY OF CFD

 Biomedical: Flow modeling with computational fluid dynamics (CFD) software
helps to visualize and predict physical phenomena related to the flow of any substance. It
is widely used in medical, pharmaceutical, and biomedical applications to analyze:

• Manufacturing processes,

• Device performance,

• Physiological flows,

• Fluid-structure interactions,

• The effectiveness of drug delivery systems, etc.

 Industrial applications: CFD is used in a wide variety of disciplines and industries,

including aerospace, automotive, power generation, chemical manufacturing, polymer
processing, petroleum exploration, pulp and paper operation, medical research,
meteorology, and astrophysics.

 Environmental: Protecting and improving the quality of our environment today

requires innovative design solutions that establish compliance with ever-expanding and
more stringent regulations. Flow modeling with Ansys’ computational fluid dynamics
(CFD) software helps to tackle our environmental flow problems most efficiently and
cost-effectively.

 Civil: Computational Fluid Dynamics (CFD) software is a powerful tool that allows
us to create a virtual airflow model of our building or urban environment to assess and

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 optimize these factors before construction commences. Modifications to an existing
building can also be simulated using CFD before any physical alterations. This approach
helps to prevent costly mistakes and minimize design risks while allowing innovation.

1.4. LIMITATIONS OF CFD

Numerical errors: Solving equations on a computer invariably introduces numerical errors.

• Round-off error: Due to the finite size available on the computer. Round-off errors
will always exist (though they can be small in most cases).

• Truncation error: Due to approximations in the numerical models. Truncation

errors will go to zero as the grid is refined. Mesh refinement is one way to deal with
truncation errors.

Boundary conditions: As with physical models, the accuracy of the CFD solution is only as
good as the initial/boundary conditions provided to the numerical model. Example: flow in a
duct with sudden expansion. If the flow is supplied to the domain by a pipe, you should use a
fully developed profile for velocity rather than assume uniform conditions. Boundary
conditions are of 3 types:

• Dirichlet Condition

• Neumann Condition

• Robbin’s Condition

1.5. How does the CFD code work?

CFD is the mathematical modeling of a fluid flow problem. It primarily comprises partial
differential equations. These equations are then discretized to produce a numerical analog of the
equations. The domain is then divided into small grids or elements. Finally, the initial conditions and
the boundary conditions of the specific problem are used to solve these equations . All commercial
CFD packages feature sophisticated user interfaces for entering problem parameters and
viewing the results to make it simple to use their problem-solving ability. As a result, there
are three main elements.

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 • Pre-processing

• Solver

• Post-Processing

 Pre-processing

Pre-processing entails the input of a flow issue using an operator-friendly interface and the
subsequent transformation of this input into a suitable form that the solver may use. Software
tools like GAMBIT, TGRID, and DM (Space claim of ANSYS) are used to complete this
step. The following stages are included in the pre-processing phase (Bakker, 2002).

• Outlining the geometry of the area for the computational domain.

• Generating the grids necessary to divide the domain into several more manageable,
nonoverlapping subdomains.

• Choosing the proper border and continuity conditions for cells that are next to or
touch the boundary.

Velocity, pressure, temperature, and other flow-related variables are determined in each cell
using different nonlinear equations. The number of cells in the grid determines how accurate
CFD solutions are. In general, the accuracy of the solution increases with the number of cells.

 Solver

The CFD solver is used to solve the governing equations of the flow subject to the conditions
provided. It performs the flow computations and generates the desired outcomes. The
governing equations for a fluid are resolved using the finite-volume approach by ANSYS
FLUENT 2023. It offers the option to employ several physical models, such as
incompressible or compressible, viscid or viscous, laminar or turbulent, etc. To get a
converged solution, the solver must conduct several iterations of the solution loop (Bakker,
2002).
The major functions of the solver are as follows:

• Using basic functions to approximate unknown flow variables.

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 • Discretization through the insertion of the approximation into the governing flow
equations and subsequent mathematical operations.

• Solving algebraic equations.

 Post-processing

This is the final step in CFD analysis, and it involves the results and interpretation of the
predicted flow data. ANSYS FLUENT software includes full post-processing capabilities and
exports CFD data to third-party post-processors and visualization tools such as Ensight, Field
View, and Tech Plot.

The main outcomes of post-processing are –

• Domain geometry & Grid display.

• Contour plot of all the properties.

• Vector plots.

• Animations.

• 2D & 3D surface plots.

• X-Y plots with different properties.

• Particle tracking.

• Plot convergence.

• View manipulation (translation, rotation, scaling, etc.)

1.6. Discretization Methods in CFD

There are three discretization methods in CFD:

1. Finite difference method (FDM)

2. Finite volume method (FVM)

3. Finite element method (FEM)

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1.6.1. Finite difference method (FDM)

A finite difference method (FDM) discretization is based upon the differential form of the
PDE to be solved. An estimated difference formula (which is typically obtained from a
Taylor series expansion) is used to replace each derivative. The computational domain is
typically divided into hexahedral cells (the grid) and the solution will be found at each nodal
point. The FDM is simplest to comprehend when the physical grid is Cartesian, but it can be
extended to domains that are difficult to represent with brick-shaped pieces by using
curvilinear transforms. Once a solution is discovered, we get a discrete representation of the
solution as a result of the discretization, which creates a system of equations for the variable
at nodal points.

1.6.2. Finite volume method (FVM)

A discretization using the finite volume method (FVM) is based on the integral form of the
PDE that needs to be solved (such as the conservation of mass, momentum, or energy). The
PDE is expressed in a way that allows it to be solved for a specific finite volume (or cell).
The governing equations are then solved for each volume after discretizing the computing
domain into finite volumes. Calculating fluxes is crucial in FVM because the resulting system
of equations frequently incorporates fluxes of the conserved variable. This method has a
fundamental benefit over FDM in that it does not call for the usage of structured grids, and
the internal effort to transform the provided mesh into a structured numerical grid is entirely
avoided. Similar to FDM, the approximate solution that is produced is discrete, however, the
variables are often positioned at cell centers rather than nodal points. This isn't always the
case because there are finite volume approaches that are face-centered. In any instance, the
values of field variables at non-storage locations (for example, vertices) are derived using
interpolation.

1.6.3. Finite element method (FEM)

A discretization using the finite element method (FEM) is based on a piecewise description of
the solution in terms of predefined basis functions. The solution in each element is built from
the fundamental functions once the computational domain has been partitioned into smaller
domains (finite elements). The conservation equation is often restated in weak form, the field
variables are expressed in terms of the fundamental functions, the equation is multiplied by
the relevant test functions, and finally integrated over an element. This produces the real
equations that are solved. A lot more is known about the FEM solution than either the FDM

17
or the FVM because it is expressed in terms of particular basis functions. This has potential
drawbacks because boundary conditions could be more challenging to formulate and the
choice of fundamental functions is crucial. Once more, a set of equations is created (often for
nodal values) that must be solved to arrive at a solution. Due to the numerous differences
between all three systems, it is challenging to compare them. Discrete solutions are offered
by FVM and FDM, whereas a continuous (up to a point) solution is offered by FEM.
Although opinions on this subject differ, FVM and FDM are typically thought to be simpler
to be programmed than FEM. Although perspectives on this subject differ, it is widely
believed that FVM will offer better conservation properties.

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 CHAPTER 2

LITERATURE REVIEW AND OBJECTIVE

[1] Literature review of ‘Numerical modeling of the flow field and performance in
cyclones of different cone-tip diameters’

Khairy Elsayed et al. (10.1016/j.compfluid.2011.07.010) have developed the effect of cone

tip diameter on the flow field and the performance of cyclone separator was investigated
computationally and via mathematical models. Discrepancies and uncertainties exist in the
literature regarding the practical significance of cone-tip diameter, with some studies
suggesting its influence on particle re-entrainment and efficiency reduction, while others
downplay its importance. Existing models and theories, such as those proposed by Barth,
Leith, and Licht, and Iozia and Leith, are discussed, along with their limitations in accurately
predicting cyclone performance. The review highlights the need for computational fluid
dynamics (CFD) approaches, particularly large eddy simulation (LES), to better understand
cyclone flow characteristics and performance. Previous numerical investigations, such as
those by Chuah et al. and Xiang and Lee, are briefly summarized, focusing on their
methodologies and findings. These studies provide insights into the potential of CFD,
specifically LES, in predicting cyclone behavior. Overall, the literature review sets the stage
for the current study, emphasizing the gaps in understanding regarding cone-tip diameter
effects on cyclone performance and the potential of numerical modeling approaches to
address these gaps.

[2] Literature review of ‘the cyclone separator geometry for minimum pressure drop using
mathematical models and CFD simulations’
Vrije Universiteit Brussel et al. (10.1016/j.ces.2010.08.042) have developed an Optimizing
cyclone separator geometry to minimize pressure drop, employing mathematical models and
computational fluid dynamics (CFD) simulations. The authors utilize response surface
methodology (RSM) based on the Muschelknautz method of modeling (MM) to identify
significant geometrical factors influencing cyclone performance. They highlight strong
interactions among vortex finder diameter, inlet dimensions, and cyclone height, crucial for
achieving optimal performance. The integration of CFD simulations, particularly using the
Reynolds stress model, adds depth to their analysis, allowing for a thorough examination of
flow patterns and pressure distribution within cyclone separators. The study results in an

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optimized design with superior performance compared to the conventional Stairmand design,
as validated through numerical simulations. Overall, the paper contributes valuable insights
into cyclone separator optimization, with practical implications for industries reliant on
cyclone separators for particle removal and air pollution control.

[3] Literature review of ‘the inlet angle on the performance of a cyclone separator using 5
CFD-DEM’
Shuyan Wang et al. (https://doi.org/10.1016/j.apt.2018.10.027) have developed the effect of
inlet geometry on cyclone separator performance has been extensively studied, revealing its
significant influence on separation efficiency and pressure drop. Investigations by Misiulia
and colleagues indicated that increasing the inlet angle enhanced cyclone cut size within a
certain range, while Fuping Qian identified optimal inlet section angles that maximized
separation performance. Similarly, S. Bernardo reported higher collection efficiency with an
inclined inlet, underscoring the importance of inlet section angles in cyclone optimization.
Computational fluid dynamics (CFD) simulations have emerged as valuable tools for
exploring the complex gas-solid flow behaviors within cyclone separators, enabling the
prediction of particle trajectories and performance metrics such as separation efficiency and
pressure drop. Understanding the relationship between inlet geometry and cyclone
performance is crucial for optimizing cyclone design and improving industrial processes
reliant on cyclone separators for particle separation and air pollution control.

[4] Literature review of ‘multi-inlet guide channels on the performance of a cyclone

separator’
Omid Reza Nassaj et al. (https://doi.org/10.1016/j.powtec.2019.08.038) have developed The
study focuses on optimizing cyclone separators, essential for particle separation in industries.
While previous research has explored various cyclone geometries and turbulent models,
limited attention has been given to cyclones with multiple inlet channels. The current study
investigates the impact of multi-inlet guide channels on cyclone performance using
computational fluid dynamics (CFD) simulations. By developing a unique design with four
inlet channels, the study aims to enhance cyclone efficiency. This research addresses a gap in
the existing literature and contributes to the ongoing optimization of cyclone separators for
industrial applications.

[5] Literature Review of ‘The Separation Performance of Fine Particles in Cyclone

Separator Systems’
Pan Zhang et al. (https://doi.org/10.1016/j.seppur.2018.08.008) have developed an

20
experimental evaluation of a novel circumfluent circulatory separator system (CCSS)
designed to efficiently remove fine particles from exhaust gases. Traditional methods for
particle separation often incur high costs and maintenance, prompting the need for innovative
solutions. The CCSS comprises two circumfluent cyclones and a separation column, offering
high removal efficiency with minimal pressure drop. Previous research has explored various
techniques to enhance cyclone performance, but significant improvements in fine particle
collection remain elusive. The CCSS system shows promising results, achieving 100%
removal efficiency for particles ≥1.0μm and 97% for particles sized 0.3-0.6μm, with only a
modest increase in pressure drop compared to conventional cyclones. Experimental
investigations into inlet gas velocity and refluxing patterns further validate the system's
efficacy. Overall, the CCSS presents a cost-effective and efficient solution for fine particle
removal from gas streams, addressing a critical need in industrial applications.

OBJECTIVE:
This study aims to optimize cyclone separator efficiency by investigating the impact of
different cone-tip diameters and different flow dynamics for enhanced performance.
1. Numerically investigate the hydrodynamics and flow profile inside a cyclone
separator.
2. Analysing the performance of industrial-scale cyclone separators with different cone-
tip diameters considering a mixture of gas and steel particles.
3. Identification of the optimized cone-tip diameter that produces the best separation
efficiency
4. Analysing the effect of flow rates and velocities on the separation efficiency
considering a fixed optimum cone-tip diameter

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 CHAPTER 3

METHODOLOGY

GEOMETRY:

The actual model of the cyclone separator was designed in the SpaceClaim 2022 R2 software
according to the given dimensions as a space claim model. Three different cone tip diameter
geometries were created using SpaceClaim software. After the design of the space claim, we
give all the names of the cyclone parts. After exporting to Fluent 2022 R2 software for
meshing. Fluent 2022 R2 software imports space entitlement design and converts space
entitlement design to CAD design. Products enter from the inlet of the cyclone and products
exit from the bottom outlet and the top part is a gas outlet. The vortex creates an intermediate
part of the cyclone. We create BOI (body of influence) to create a proper vortex in the
cyclone separator. BOI is not part of the geometry.

22
 FIGURE 2: SpaceClaim Model

MESHING:
The geometry was then imported into Fluent 2022 R2 by exporting the CAD product to the
cyclone_for_meshing file. All the bodies were then combined into a multi-body part to create
a single mesh containing all the cyclone's bodies. To generate the mesh, meshing parameters
were specified, namely physical preference, solver preference, inflation, size, and method
used for meshing. This is how the mesh was created. 12 mm cone-tip diameter mesh
maximum skewness is 0.90, 14 mm cone-tip diameter mesh maximum skewness is 0.91, and
18 mm cone-tip diameter maximum skewness is 0.91. The statistic representing the number
of nodes and the number of elements of the meshed component indicates the quality of the
mesh. We create BOI (Body of Influence) in the local sizing part. Grouth rate of BOI is 1.2
and my target mesh size is 0.5 mm. After generating the surface mesh and surface mesh
minimum size is 0.1 mm the maximum size is 2 mm and the size function is curvature and
proximity. I used curvature normal angle is 18 and after generating the surface mesh I
describe the surface mesh. The surface mesh type is only fluid and solid regions with no
voids. The volume mesh type is polyhedra and the maximum shell length is 1 mm. Total cells
12 mm, 14 mm, and 18 mm cone-tip diameter mesh is 179823, 168888, 266563 This type of
condition I applied for generating good quality mesh. The minimum orthogonal quality of
mesh 12 mm, 14 mm, and 18 mm is 0.20, 0.09, 0.17.

23
FIGURE 3: 12 mm cone-tip diameter meshing

FIGURE 4: 14 mm cone-tip diameter meshing

24
 FIGURE 5: 18 mm cone-tip diameter meshing

GRID GENERATION:
Grid generation is a critical aspect of computational fluid dynamics (CFD) simulations,
particularly in the accurate prediction of flow behavior and separation efficiency within
cyclone separators. A well-structured grid is essential for capturing the complex flow
phenomena and turbulence characteristics inherent in cyclone geometries. In this study, we
focus on the grid generation process using ANSYS Fluent to investigate gas and steel particle
separation efficiency in cyclone separators with varying cone-tip diameters.

GOVERNING EQUATIONS:
The governing equations for simulating gas and steel particle separation in cyclone separators
typically include the following:
1. Conservation of Mass:
∂
∂ ϰi
( ρui ) =0

This equation represents the conservation of mass, where 𝜌 is the density of the fluid
mixture, µi is the velocity vector field, and 𝑡 is time.

25
2. The Navier-Stokes equation in its full form is:
∂u −1 2
+ ( u ⋅ ∇ ) u= ⋅ ∇ P +v ∇ u+ f
∂t ρ
Where:
u is the velocity vector field,
It is time,
ρ is the fluid density,
p is pressure,
ν is the kinematic viscosity, and
f represents external forces (like gravity).
3. For the specific case of a cyclone separator, we are interested in energy conservation,
which involves the kinetic energy of the fluid flow and the potential energy due to
gravity. Assuming an incompressible fluid and neglecting viscous effects for
simplicity, the equation simplifies to:
∂u −1
+ ( u ⋅ ∇ ) u= ∇ p+g
∂t ρ
Where:
 𝑔 is the gravitational acceleration vector.
In a cyclone separator, the flow is rotational, and the centrifugal force plays a
significant role. To incorporate this, we need to include the centrifugal acceleration
term, which arises from the change in velocity direction as the fluid spirals around the
cyclone. The centrifugal acceleration term ac can be expressed as u×(∇×u).

So, the equation for conservation of energy in a cyclone separator can be written as:

∂u
+¿
∂t
4. To calculate the separation efficiency of the cyclone separator, we can use the
formula:
Efficiency (%)= {(Number Tracked−Escaped)/Number Tracked}×100
5. Euler's Equation of Motion: Euler's equation relates the pressure gradient, velocity,
and fluid density in a moving fluid. It can be expressed as:

26
 6. Turbulence Modeling: Turbulence models, such as the k-ε models, are employed to
account for the effects of turbulence on the flow field. These models provide
additional transport equations for turbulence kinetic energy (𝑘k) and its dissipation
rate (𝜀ε or 𝜔ω).
7. Particle Tracking: For simulating steel particle separation, additional equations are
used to track the trajectories of individual particles. These equations account for
particle motion under the influence of fluid forces (drag, lift, gravity) and particle-
particle interactions.
These governing equations are typically solved numerically using computational fluid
dynamics (CFD) software packages like ANSYS Fluent. Boundary conditions, initial
conditions, and appropriate models for turbulence and particle interactions are specified to
simulate the gas and steel particle separation process accurately within cyclone separators.

BOUNDARY CONDITIONS:
The cyclone separator's boundary conditions state that the velocity inflow momentum is
magnitude, that I utilized the normal to boundary method to specify the velocity, and that the
velocity magnitude (Gas flow rate/area) is 5 m/s and mixture flow rate 5 m/s. The area and
perimeter of the 12 mm Cone-tip diameter geometry are 113.0973 mm^2 and 37.6991 mm.
The area and perimeter of of 14 mm Cone-tip diameter geometry is 153.938 mm^2 and
43.9823 mm. The area and perimeter of the 18 mm Cone-tip diameter geometry are 254.496
mm^2 and 56.35487 mm. The temperature of the applied incoming gas and mixture is 300 k.
I used the bottom of the internal cyclone, where the shear condition is no slip and the wall
motion is a stationary wall.

SINGLE-PHASE ANALYSIS:

Pre-processing of single-phase flow:

27
The analysis was carried out considering a single phase, i.e. only considering air as the
inflowing fluid. The analysis started by importing the mesh file into fluent 2022 R2 pre as a
mesh file, each part has been categorized into three domains, namely inlet, outlet, and wall
domain. According to the boundary conditions such as the mass flow rate of the incoming gas
(0.00005 kg/s) and the total pressure is 1 atm was applied. The run was then defined by
specifying the required parameters, i.e. N number of iterations, specified mix factor, etc. with
the specified mix factor between 0.0 to 1.0 for the advection scheme. A value of 0.0
corresponds to using the first-order advection scheme and is the most robust option, while a
value of 1.0 uses second-order differentiation for the advection term scheme.

MULTI-PHASE ANALYSIS:
Pre-processing of multi-phase flow:
The analysis was carried out considering a multi-phase, i.e., considering air and steel particles
as flow inflow fluid. The analysis started by importing the mesh file into fluent 2022 R2 pre
as a mesh file, each part has been categorized into three domains, namely inlet, outlet, and
wall domain. According to the boundary conditions a mass flow rate of the incoming mixture
(0.00005 kg/s) and a total pressure is 1 atm were applied. The run was then defined by
specifying a mix factor between 0.0 to 1.0 for the advection scheme. A value of 0.0
corresponds to using the first-order advection scheme and is the most robust option, while a
value of 1.0 uses second-order differentiation for the advection term scheme.

SIMULATION DETAILS:
The finite volume approach solved the governing equations of continuity, momentum, and
energy in steady-state conditions. A second-order upwind technique and turbulent dispersion
rate second-order upwind technique are employed for the energy-momentum equations. For
coupling pressure and velocity, a simple algorithm was used. The initialization method
chosen was standard, computed from the inlet, patch-solid used, z velocity -5 m/s, and a
maximum value of 500 iterations was set for the solution to converge.
The table presents the details of the simulation.

TABLE 2: Simulation details

PARAMETERS MODEL SET UP
Gravitational effects Present ( Y axis- -9.81 m/s^2)

28
 Vicious model K-Ɛ model (Realizable)
Multiphase Gas and Steel particle mixture
Energy equations Yes
Discrete phase On (tracking parameter-500000 max
number of steps and step length factor-5)
Injection properties Injection type- surface from inlet
Material Steel
Diameter distribution uniform
Turbulent dispersion Discrete random walk model
Number of tries 30
Initialization Standard
Spatial discretization Second order upwind

CHAPTER 4

RESULTS AND DISCUSSION:

SINGLE-PHASE FLOW:
The single-phase gas flow analysis was conducted to explore the performance of cyclone
separators with different cone-tip diameters. The simulations focused on understanding how
variations in cone-tip diameter affect separation efficiency within the cyclone.
Effect of different Cone-Tip Diameter:
 Smaller cone-tip diameters led to more intense swirling motion near the cone-tip area,
enhancing particle separation efficiency.
 Larger cone-tip diameters resulted in broader flow patterns with reduced swirl
intensity, potentially compromising separation efficiency.
Effect of Velocity Magnitude on Single-Phase Gas Flow:

The analysis delved into the influence of velocity magnitude on the efficiency of cyclone
separators for single-phase gas flow scenarios. Here are the key findings:
1. Particle Trajectories:

29
  Variation in velocity magnitude led to distinct particle trajectories within the cyclone
separator.
 Higher velocity magnitudes resulted in increased centrifugal forces, leading to more
efficient particle separation.
 Lower velocity magnitudes exhibited reduced centrifugal forces, potentially causing
particles to remain entrained in the gas stream.

FIGURE 6: Pathline Velocity Magnitude (a=12 mm, b=14, c=18 mm cone tip diameter)

Separation Efficiency:
 Higher velocity magnitudes generally correlated with improved separation efficiency,
as particles experienced greater inertial forces, enhancing their divergence from the
gas stream.
 However, excessively high-velocity magnitudes could lead to diminishing separation
efficiency.

MULT-PHASE FLOW:

In multiphase flow scenarios where the inlet consists of a mixture of gas and steel particles,
the efficiency of cyclone separators is influenced significantly by the flow field dynamics and
the performance of cyclones with varying cone-tip diameters.
When considering the separation efficiency of such multiphase flows, the cone-tip diameter
plays a crucial role. A larger cone-tip diameter can promote stronger centrifugal forces,
facilitating the separation of heavier steel particles from the gas stream. Conversely, a smaller
cone-tip diameter might encourage tighter gas-solid interaction, potentially leading to
improved separation efficiency in certain conditions.
Optimizing the cyclone's design parameters, including the cone-tip diameter, is essential for

30
enhancing the separation efficiency of gas and steel particle mixtures. Computational
modeling is often employed to understand how different cone-tip diameters affect the flow
field and separation performance within cyclone separators.
Ultimately, by studying the multiphase flow dynamics and carefully adjusting the cyclone's
design, engineers can develop cyclone separators tailored to efficiently separate gas and steel
particle mixtures, thus achieving higher overall separation efficiency in industrial
applications.

PERFORMANCE COMPARISON:
 Velocity magnitude results for different cone tip diameters were compared to assess
their effectiveness in promoting gas-steel mixture separation.
 Cone tip diameters associated with more uniform velocity distributions and reduced
turbulence were considered favorable for enhanced separation efficiency.

FIGURE 7: Pathline velocity magnitude (a=12, b=14, c=18mm Cone tip diameter )

VELOCITY MAGNITUDE CONTOURS:

 The velocity magnitude contour plot will show how the flow velocity varies
within the cyclone separator.
 Higher velocities usually indicate better separation efficiency as they promote
better particle separation from the gas stream.

31
FIGURE 8: Contours Velocity magnitude (mixture) (m/s) ( a=12mm, b=14mm, c=18mm Cone
tip diameter )

STATIC PRESSURE:
 The static pressure contour plot will display the pressure distribution within the
cyclone separator.
 Variations in pressure can affect the trajectory of particles and influence separation
efficiency.

FIGURE 9: Contours Static pressure (mixture) (pa) ( a=12mm, b=14mm, c=18mm Cone tip
diameter )

PARTICLE FLOW :

 This contour plot can represent particle variables such as concentration, size

32
 distribution, or trajectory.
 It gives insights into how particles are distributed and separated within the cyclone
separator.

FIGURE 10: Particle variables ( a=12mm, b=14mm, c=18mm Cone tip diameter)

SEPARATION EFFICIENCY OF DIFFERENT CONE TIP

DIAMETER

FIGURE 11: Pathline of particles ( a=12mm, b=14mm, c=18mm Cone tip diameter )

TABLE 3: Calculation data of different cone tip diameter

Cone tip Total Number Escaped Separated
Design diameter of particles particles particles
(mm) tracked

33
 1 12 4791 141 4650
2 14 4565 161 4484
3 18 6653 583 6070

CALCULATION:
To calculate the separation efficiency of the cyclone separator, we can use the formula:
Efficiency (%)= {(Number Tracked−Escaped)/Number Tracked}×100
Let's plug in the values given:
1. For the first set of data:
Efficiency (%)={(4791−141)/4791}×100 =(4649/4791)×100
≈ 97.00%
2. For the second set of data:
Efficiency (%) = {(4645−161)/4645}×100=(4484/4645)×100
≈96.54%
3. For the third set of data:
Efficiency (%)={(6653−583)/6653}×100=(6069/6653)×100
≈91.22%
So, the separation efficiency for the three sets of data is approximately 97.00%, 96.54%, and
91.22%, respectively.

TABLE 4: Calculation table of different cone tip diameter

Cone tip Total Escaped Separated Separation
Design diameter Number of particles particles Efficiency
(mm) particles (%)
tracked
1 12 4791 141 4650 97.00
2 14 4565 161 4484 96.54
3 18 6653 583 6070 91.22

SEPARATION EFFICIENCY:
 Different cone tip diameters were studied to understand their influence on the cyclone
separator's ability to separate gas and steel particles effectively.

34
  In this study The separation efficiency is therefore very good at a cone tip diameter
of 12 mm.

VARIATIONS IN THE FLOW RATE AND VELOCITY OF

THE 12 MM CONE TIP DIAMETER

FIGURE 12: Pathlines particle ( a=10, b=15, c=20 kg/s total flow rate )

TABLE 5: Data (total flow rate and velocity)

35
 Design Cone tip Total Z Velocity Total Escaped Separated
diameter flow rate (-10 m/s) Number particles particles
(mm) (kg/s) of
particles
tracked

1 12 10 -10 4791 188 4603

2 12 15 -15 4791 204 4587

3 12 20 -20 4791 145 4646

CALCULATION:
To calculate the separation efficiency of the cyclone separator, we can use the formula:
Efficiency (%)= {(Number Tracked−Escaped)/Number Tracked}×100
Let's plug in the values given:
1. For the first set of data:
Efficiency (%)={(4791−188)/4791}×100 =(4603/4791)×100
≈ 96.07%
2. For the second set of data:
Efficiency (%)={(4791−204)/4791}×100 =(4587/4791)×100
≈ 95.74%
3. For the third set of data:
Efficiency (%)={(4791−145)/4791}×100 =(4776/4791)×100
≈ 99.68%
So, the separation efficiency for the three sets of data is approximately 96.07%, 95.74%, and
99.68%, respectively.

TABLE 6: Calculation table (total flow rate and velocity)

Cone tip diameter Total flow rate Z Velocity (-10 m/s) Separation
(mm) (kg/s) Efficiency (%)
12 10 -10 96.07
12 15 -15 95.74
12 20 -20 99.68

36
SEPARATION EFFICIENCY:
 To comprehend their impact on the cyclone separator's efficacious ability to separate
gas and steel particles, 12 mm cone tip diameters with varying flow rates and
velocities were investigated.
 As a result, the separation efficiency in this investigation is 99.68% and very good at
a 20 kg/s flow rate.

CHAPTER 5
CONCLUSION:
K-Ɛ model has been used to study the effect of cone-tip diameter on cyclone efficiency and
performance. The cyclones with different values of Bc/D (where Bc is cone tip diameter and
D is body diameter) viz 0.38, 0.45, 0.58 (at constant vortex finder ratio Dx/D = 0.5, where,
Dx is gas outlet diameter and D is body diameter) have been investigated. The following
conclusion can be drawn:

1. The influence of different cone tip diameters on cyclone separator efficiency

has yielded valuable insights for optimizing particle separation processes.
Through systematic experimentation, we have explored how variations in cone
geometry affect the ability of cyclone separators to effectively separate gas
and steel particles.
2. Our findings indicate that cone tip diameter plays a crucial role in determining
separation efficiency. Specifically, we observed that a cone tip diameter of 12
mm consistently resulted in optimal performance, achieving high separation

37
 efficiencies across a range of flow rates and velocities. This suggests that
careful selection of cone geometry can significantly enhance the effectiveness
of cyclone separators in industrial applications.
3. The exploration of different flow dynamics within cyclone separators revealed
crucial factors influencing particle separation efficiency. Through a systematic
investigation of varying flow rates and velocities, we have gained valuable
insights into how flow dynamics impact the performance of cyclone separators
in separating gas and steel particles.
4. Our findings reveal that optimizing flow dynamics can significantly enhance
the efficiency of cyclone separators. Specifically, we observed that at a flow
rate of 20 kg/s, the separation efficiency reached an impressive 99.68%. This
highlights the potential for substantial improvements in industrial applications
through careful manipulation of flow parameters.
5. Moreover, the comprehensive examination of both different cone tip diameters
and varying flow dynamics within cyclone separators has provided a holistic
understanding of the factors influencing their efficiency and performance in
particle separation processes

FUTURE PROSPECTS:

Multi-Objective Optimization: Future research can focus on multi-objective optimization

techniques to balance conflicting objectives such as pressure drop and overall system cost.
Evolutionary algorithms like genetic algorithms and particle swarm optimization can
efficiently handle such complex optimization problems.
Advanced Materials and Manufacturing Techniques: The use of advanced materials such
as nanostructured coatings can improve the wear resistance and durability of cyclone
separators.
Renewable Energy Integration: Cyclone separators play a crucial role in renewable energy
systems, such as biomass combustion and solar thermal power generation. Future research
can focus on optimizing cyclone separator configurations to maximize energy capture
efficiency and minimize environmental impact in these applications. Integration with
renewable energy systems can enhance overall system performance and contribute to the
transition towards sustainable energy sources.

38
 CHAPTER 6
REFERENCES:
Cyclone separator
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performance in cyclones of different cone-tip diameters. Publication date 2011,
(10.1016/j.compfluid.2011.07.010)

[2] Khairy Elsayed, Chris Lacor, cyclone separator: Optimization of the cyclone separator
geometry for minimum pressure drop using mathematical models and CFD simulations.
Publication date 2010, (10.1016/j.ces.2010.08.042)

[3] Shuyan Wang, Haolong Li, Ruichen Wang, Xu Wang, Ruichao Tian, Qiji Sun, cyclone
separator: Effect of the inlet angle on the performance of a cyclone separator using 5 CFD-
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[4] Omid Reza Nassaj, Davood Toghraie, Masoud Afrand, cyclone separator: Effects of
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[5] Pan Zhang, Guanghui Chen, Jihai Duan, and Weiwen Wang, cyclone separator:
Experimental evaluation of separation performance of fine particles of circulatory

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