Problem
Cyclone separators are fairly common and there are multiple tools online which provide estimates of pressure losses and separation efficiencies. However, “the devil is in the detail” and seemingly harmless modifications to the standard design can lead to unexpectedly high pressure losses and ineffective particle separation.

Solution
Computational fluid dynamics (CFD) simulations of cyclones provide design validation and help to develop accurate pressure losses verses flow rate curves. The use of Lagrangian multiphase analyses allow the calculations of particle trajectories, temperatures and residence times.

Result
CFD modelling allows for a substantial improvement in performance and efficiency. CFD calculated data points can be used to optimise the cyclones performance for the specific application being considered and ensure that the particle cut-off diameter produced by the design is fit for purpose.