Computational investigation of a novel hydrocyclone for fines bypass reduction

Hydrocylones offer a process intensified environment for rapid, high-throughput and relatively sharp particle classification or phase separation. One of the main performance limitations of hydrocyclone is bypassing of fines to the underflow. To address this limitation, a novel design modification of fitting thin concentric rings to the cylindro-conical section has been proposed. The Computational Fluid Dynamics (CFD) modeling based methodology has been adopted to validate the hypothesis. Predictions using Realizable k-e, Reynolds Stress Model (RSM), and Large Eddy Simulation Wall Adopting Local Eddy viscosity (LES-WALE) turbulence models has revealed that LES-WALE matched better with the experimental observations. The experimental data included overall performance parameters and detailed observations of axial and tangential velocity profiles across the hydrocyclone. The validated CFD model and the methodology was then used to predict the behavior of the proposed designs. They established that the modifications held promise in reducing the bypass with additional benefits of sharper separation curve and finer D50.