NUMERICAL STUDY OF AIR-SOLID FLOW IN ACYCLONE SEPERATOR:

A CFD INVESTIGATION
CHAPTER 1
INTRODUCTION
Cyclone Separators one of the most widely used air pollution control technology and also
known as pre-cleaners. They commonly remove large size-range of particulate matter. It has no
moving parts and works on the principle of centrifugal separation to eliminate dust particles from
the polluted gaseous stream or liquid stream. It is quite efficiently providing a better method of
removing particulate matter from the particle laden stream at low cost and maintenance. There
are various types of cyclone used in the industries but reverse flow cyclone with tangential entry
is the most widely used type of cyclone separator. High efficiency can be achieved by proper
designing the physical parameters of Cyclone Separator.

1.1 Working principal & governing parameters.

The cyclone separators work on a simple principle of centrifugal-separation. It’s quite

popular device for separating particles because of its simple working and efficient collection rate.
Cyclone Separator can be considered as a special type of settling chamber for discrete particles
with strong centrifugal force acting on them instead of gravitational force. Cyclone performance
is usually conveyed in terms of the overall pressure drop and collection efficiency through the
separator. The figure 1a comprises of an upper cylindrical and hollow part known as barrel and a
lower conical part signified to as cone which helps in the formation of vortex in the cyclone.
They basically change the inertial force of gas particle to a centrifugal force by means of a vortex
formation in the cyclone body & as shown in figure 1b. The contaminated gas stream with
particles enters extraneously from inlet which is situated at the highest point of the cylindrical
barrel. In the wake of entering, it descends into the conical area in spiral pattern forming an outer
vortex. As the air velocity increases in the outer vortex due to geometry transition, a centrifugal
force on the particles which separates them from the air stream starts acting on them. When the
air finally reaches at the bottom of the conical part, it begins to flow radially inwards and out the
top as clean air. The pollutants fall into the dust collector chamber attached to the bottom of the
cyclone

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NUMERICAL STUDY OF AIR-SOLID FLOW IN ACYCLONE SEPERATOR:

A CFD INVESTIGATION

Figure 1: (a) schematic diagram of cyclone separator (b) vortex flow with in cyclone separator

Advantage & Dis advantage of Cyclone separator

There are many advantages associated with cyclone separators, some of these include:
 Cyclone separator requires low capital investment.
 It has high efficiency for 5 - 200 µm particles.
 It produces a high volume flow rate.
 A lack of moving parts reduces wear and tear.
 It can be operated on a continuous or batch process.
 It requires virtually no downtime for maintenance or recovery.
 It has versatile applications.
 It is small in size relative to other separation equipment.
 It can be operated at a wide range of temperatures and pressures.
Disadvantages are associated with cyclone separators, but these disadvantages can be
reduced in severity if the correct separator is selected for the correct application.
Disadvantages may include:
 It shows reduced efficiency when overloaded than its capacity.
 It finds difficulty in obtaining good separation of substances with similar densities.
 It cannot handle the viscous flow

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1.3 Application of cyclone separator

 A cyclone separator is most often used to separate "heavies" from a liquid mixture
originating at a centrifugal pump or some other continuous source of pressurized liquid.
A cyclone separator is most likely to be the right choice for processes where "lights" are
the greater part of the mixture and where the "heavies" settle fairly easily. These may be
used to separate solids from water.
 A cyclone separator is used to separate the suspensions of a solid in a gas or air. It can be
used with the liquids suspensions of solids.
 It is used in the production of active pharmaceutical ingredients (API) through drying
systems such as spray or fluid bed drying.
 It can also be used for the separation of particles based upon the size, specific gravity,
porosity, and concentration from solids, liquids, and gases.
 In the pharmaceutical industry, it is mostly used for the separation of fines from coarse
granules.
 In tablet compression cyclone is used to extract waste powder before it reaches the
central extraction system.
It can be used in air-handling
 systems to produce particle-free clean air.
 It is used in the oil industry to separate oil from water or vice versa
INTRODUCTION TO CFD

Computational fluid dynamics (CFD) is a technique of flow predictions by numerically

solving governing equations of fluid flows. Governing equations are conservation of mass,
momentum, heat and mass transfer. Numerical methods are used to convert partial differential
equations in to algebraic set of equations. After solving iteratively using computer programs,
engineers visualize predicted velocity, pressure and temperature.
Brief History of CFD
The basic of CFD is rooted in the naiver stokes equations, which were determined by George
stokes, in the mid-19th century. The few history has been tabulated and shown below.

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NUMERICAL STUDY OF AIR-SOLID FLOW IN ACYCLONE SEPERATOR:
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 1922-Lewis Fry Richardson- Basis of modern CFD and numerical meteorology
 1933-A Thom- a weather forecasting scheme using differential equations and
finite differences
 1953-Kawaguti obtains a solution for flow around a cylinder
 1955-Los Alamos National Lab- Particle-in-cell simulation method for transient
2D fluid flow developed
 1963-Theodore von karmananalysed von karman vortex street
 1975-Geoffrey Ingram Taylor analyzed statistical theory of turbulence and Taylor
microscale
 2000-George keithBatchelor analyzed contributions to the theory of homogenous
turbulence.

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NUMERICAL STUDY OF AIR-SOLID FLOW IN ACYCLONE SEPERATOR:
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CHAPTER 2
LITERATURE SURVEY

“CFD Analysis of Symmetrical Tangential Inlet Cyclone Separator “In this paper
AbhejitGayakwad and Dr. Shivarudraiah studies CFD analysis of symmetrical tangential
inlet cyclone separator. In this paper simulation is carried out using computational fluid
dynamics (CFD) for gas-particle flow with cyclone separator in one of the approaches. Most
of the attention is focused on improving the cyclone performance parameters. In this paper
the geometric effect on cyclone separator is studied with the creation of symmetrical
tangential inlet cyclone separator The Computation Fluid Dynamics (CFD) analysis is
carried out for both single inlet cyclone and symmetrical inlet cyclone separator under the
same condition of inlet velocity, flow rate and particle diameter and compared it with the
classical cyclone separator.
The review of the history of cyclones shows that the first cyclonic separator was patented
in 1885 by Finch (Slack et al., 2000). Stairmand and Lapple conducted pioneering work in
this area and proposed practical design formulas, which are still used for modelling most
industrial cyclones. Attempts made by Stairmand and Lapple from 1950 to 1990 resulted in
the design of classic cyclones and the development of equations that revealed the higher
efficiency of classic cyclones compared to other cyclones for different particle diameters
and inlet velocities (Altmeyer et al., 2004).
Hsiao et al. (2015) investigated the effects of inlet and outlet sections, and the geometry of
the conical section of the cyclone. According to their results, the performance of the cyclone
can be improved by decreasing the length and increasing the width of the conical section.
In order to achieve greater efficiency, the inlet and outlet sections should be made,
respectively, larger and smaller to the extent that the pressure drop does not increase. The
lack of a conical section or its replacement with a cylindrical section caused a decrease in
cyclone efficiency.
Bharat Raj Reddy Dere et al worked on the inlet dimensions and checked the variation of
pressure with the inlet dimensions. The maximum pressure in cyclone falls drastically by
decrease in the inlet dimensions. For every 2mm decrease in inlet height and 1mm

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NUMERICAL STUDY OF AIR-SOLID FLOW IN ACYCLONE SEPERATOR:
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decrease of width gives 20% decrease in the pressure. So, inlet dimensions show large
effect on the performance of the cyclone
Mahesh R Jadhav worked on the design of cyclone and study of its performance
parameters, it is observed that the pressure drop and cyclone efficiency varies with inlet
velocity. The efficiency of cyclone increases with the decrease in dimensions of cylinder
body diameter, cyclone inlet width, operating temperature, and cyclone width inlet. The
pressure drop increases with the increase in inlet velocity, but pressure drop decreases
significantly with the rise in temperature. A comparison of performance, between
symmetrical inlet cyclone and single inlet cyclone, shows that the symmetrical inlet cyclone
is optimum than the conventional cyclone with a single inlet.
Svarovsky , et al has found that if the centrifugal force is greater than drag force particle
moves towards the wall then pulled down in the axial stream and exit in the underflow. He
has also observed that particles rotate at a radius where centrifugal force is balanced by
drag force and larger, denser particles move selectively towards the wall

Objective

- To understand different empirical models & discretize phase modelling role in cyclone
separator.
- To recognize effects of velocity and particle size on cyclone efficiency & pressure drop
- Create geometry by designing modularly and learning various features in ansys
workbench.
- Identifying the efficiency of cyclone separator with two different discretization.

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NUMERICAL STUDY OF AIR-SOLID FLOW IN ACYCLONE SEPERATOR:
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CHAPTER 3

BASIC STEPS INVOLVED IN CFD

Fluid Domain

Modelling cleanup

Meshing

Boundary
Condition

Steady State & Viscous model

selection

Discrete Phase
modeling

Initialization &
Run setup

Post Processing (Velocity contour,

Pressure contour)
Figure 2: illustration of Steps involved in a CFD Simulation
The Figure 2 indicates the working procedure of CFD simulation model in ANSYS
workbench. Further in details as been explained as follows
Geometry
The initial stage in the CFD modeling process is to specify the geometry of the issue to
be addressed, which is often derived from a CAD model or a simplified representation. The
geometry may be included in a computational area. The computational domain is the area of
space where the solution is needed. In external flow issues, the computational domain is often a
volume centered on the geometry of interest with suitable dimensions
Mesh

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NUMERICAL STUDY OF AIR-SOLID FLOW IN ACYCLONE SEPERATOR:
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To solve the flow using a numerical approach, the computational domain and geometry
must be discretized in order to build the computational mesh. Meshing is often accomplished by
dividing the volume inside the computation domain but outside the simulated object into "mesh
cells." Fluid flow equations will be solved within each cell to calculate. These features are
conveyed by flow across the domain, influencing the solution at each cell.
Setup
In CFD modeling, selecting the most suitable models that accurately represent the
physics of the problem being solved is crucial. We can choose between transient or steady-state
simulations, depending on whether the flow varies only in space or time. Transient simulations
are necessary to capture a discharge's unsteady nature or temporal variations in the onset flow or
moving parts of the geometry. We may need additional physics models to describe the problem
accurately, such as determining if the flow is compressible, considering temperature as a
variable, and using turbulence models depending on the Reynolds number.
To achieve a flow solution, boundary conditions must be provided to the surfaces
defining the geometry and computational domain, and a starting value must be assigned to each
cell's flow variables (pressure, velocity, etc.). The beginning and boundary conditions are
mathematical presentations of real-world flow circumstances.
Solution
The CFD model is defined, a numerical algorithm is used to solve the mathematical
problem. An iterative process is used for steady-state simulations, and the solution evolves based
on the boundary conditions. The rate of change of the solution is measured by residuals, which
should decrease with each iteration until a small number is reached, indicating convergence. The
maximum number of iterations must be decided beforehand, but the correct number is difficult to
predict. Therefore, convergence criteria are defined to stop the solver when either the residuals or
physical quantities of interest no longer change significantly. Although slight variations in the
residuals might still exist, the results are considered stable enough for convergence.
Transient simulations advance the solution in physical time and require a time step to be defined
by the user. At each time step, the solution must be fully converged. The time step choice is
crucial for solution stability and quality.

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Post-processing
The CFD simulation, the solution provides the values of flow variables, such as pressure
and velocity, in every node of the computational grid. However, interpreting these raw numbers
can be difficult, so post-processing is carried out to obtain integral quantities, graphs, and plots
for straightforward interpretation and comparison. Post-processing aims to make the final user's
data and flow structures intuitive. It typically presents values in graphical form with colors that
vary according to user-defined settings. It allows users to create colored surface plots, such as a
pressure field on a motorbike surface, in order to gain insights into flow physics and design.
Post-processing is essential to identify design improvements and compare designs to determine
the best solution.

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NUMERICAL STUDY OF AIR-SOLID FLOW IN ACYCLONE SEPERATOR:
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CHAPTER 3
PROBLEM STATEMENT AND SOLUTION

3.1 METHODOLOGY

The geometric structure of cyclone separator in this study was commonly used straight
inlet structure and the schematic diagram as shown in the figure. The dimension of the cyclone
separator was in accordance with the geometry adopted by Standard Stairmand design with the
entrance of 00, the angle increased along the direction of flow. Specific basic dimensions were
listed in Table 3.1.

Part Name Dimensions Actual Values

Cyclone diameter (D) 290mm
Inlet height, a 0.5 D 0.5X290 =145mm
Inlet Width, b 0.2 D 0.2X290 =58mm
Cone tip diameter (DC) 0.37D 0.37X290 =107.3mm
Exit pipe diameter (Dx) 0.5 D 0.5X290 =145mm
Cylindrical part height, (h) 1.5 D 1.5X290 =435mm
Cone part height (hc) 2.5D 2.5X290 =725mm
Length of inlet section (Li) 1.38D 1.38X290 =400.2mm
Length of cylindrical barrel top, Le D 290mm
Exit pipe length 0.5D 0.5X290 =145mm

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3.2 Selection of Fluid Domain (Geometry)

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3.3 BOOLEN OPERATIN

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3.4 Mesh quality metrics

Regardless of the type of mesh, it is important to evaluate the quality of the mesh before
performing the simulation. Mesh quality metrics are numerical indicators that measure how well
the mesh represents the geometry and the physics of the problem. Some common mesh quality
metrics are aspect ratio, skewness, orthogonality, smoothness, and distortion. These metrics
reflect the shape, size, alignment, and variation of the elements, and how they affect the
accuracy, stability, and convergence of the solution. Ideally, a good mesh should have low values
of these metrics, meaning that the elements are close to equilateral, orthogonal, smooth, and
undistorted.

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NO OF NODES =45238
NO OF ELEMENTS=228504

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3.6: Boundary Condition

Air was used as the default fluid in this problem. Assuming the presence of impermeable cyclone
walls and non-slip conditions, the atmospheric pressure was used as the boundary condition at
output. An inlet turbulence intensity of 5% was considered, and the hydraulic diameter was used
as the longitudinal scale of turbulence.
A homogeneous particle distribution was assumed at the inlet, and the particles were injected at
the same velocity of the fluid. The boundary conditions for the particles were set to allow the
reflection of the solid particles from the walls and their escape from the vortex finder. The
SIMPLE design was used for pressure–velocity coupling and the first-order upwind method with
greater stability was employed to discretize all equations.

Fluid Air
Inlet Velocity 4 m/s
Outlet-1 Pressure Atmospheric condition
Outlet-2 Pressure Atmospheric condition
Wall Boundary Enclosure No slip condition

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3.7: Material Selection

3.8: Discretization
(a) (b)

Discrete Phase Model

Material Type Wood
Particle type Spherical
Density of the material 1500 kg/m3
Injection Velocity 4m/s
Particle Diameter 5μm

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Structured meshes are meshes with implicit connectivity whose structure allows for easy
identification of elements and nodes. Often structured meshes have orthogonal quadrilateral (2D)
or hexahedral (3D) elements. A structured mesh is composed of regular and uniform elements,
such as hexahedra, quadrilaterals, or prisms, that are arranged in a logical pattern. Structured
meshes are easier to generate and store, as they require less data and can be mapped by simple
indices. They also offer higher accuracy and lower numerical errors, as they conform well to the
boundary conditions and have smooth transitions between elements. However, structured meshes
have some limitations, such as difficulty in handling complex geometries, curved boundaries, or
irregular regions. They may also require more elements to capture fine details or local variations,
which can increase the computational cost and memory usage.
Unstructured meshes are meshes with general connectivity (GCON) whose structure is arbitrary
and therefore the connectivity of elements must be defined and stored. GCON element types are
non-orthogonal, such as triangles (2D) and tetrahedra (3D). Unstructured meshes are more
flexible and adaptable, as they can handle any geometry and topology, including holes, cracks, or
curved surfaces. They can also use adaptive mesh refinement techniques, which allow for local
adjustments of the element size and shape according to the solution features or error estimates.
However, unstructured meshes have some drawbacks, such as higher complexity and overhead,
as they require more data and connectivity information. They also tend to have lower accuracy
and higher numerical errors, as they may not fit well to the boundary conditions and have abrupt
changes between elements
The Discretization for fluid domain has been constructed in two ways i.e unstructured &
structured which shown in the above figure (a) & (b). The unstructured mesh which consists of
45,238 & 228504 nodes & elements respectively. Similarly, for the structured mesh the number
of nodes& elements are 92,258 & 90,405 respectively. The element quality has been observed i.e
0.45 for unstructured & 0.69 for structured mesh.

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3.9: INPUT PARAMETERS

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3.9.1: Massflow vs number of iterations

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CHAPTER 4
Result & Discussion

4.1 :Pressure drop for Unstructured mesh & Structured Mesh

In general, the term pressure drop means drop in total pressure i.e static & dynamic
pressure. The pressure drop can have estimated between inlet & outlet, due to existence of
frictional losses in the cyclone. It is difficult to measure pressure drop due to presence of swirl in
the existing air. The pressure drop over a cyclone is normally in the entry losses in cyclones with
tangential inlets are negligible since the flow is linear, and it moves to the main cyclone body
without many obstructions. Once the flow enters the cyclone body, the linear flow transforms
into a swirl flow due to the shape of the body. So, the dynamic pressure increases accordingly.
But, this increase in dynamic pressure is lost due to the friction in the walls. Therefore, the
losses in the cyclone body are much higher to the other section. In the vortex finder, the clean
gas comes out through it, but due to the swirl present in the flow, some pressure is lost. Thus,
these are the main sections of pressure drop.

(a) (b)

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For a single inlet of a cyclone, pressure contours obtained from fluid flow (fluent) show that
unstructured mesh and structured mesh pressures are in the ranges of - 1.64 Pa to 13.9Pa & -
7.34 to 32.53Pa, respectively. Pressure rises from the heart of the wall surface but falls towards
the cyclone's base. It is also observed that the cyclone's entry has the highest pressure and the
lowest pressure.
4.2: Velocity contour for Un Structured mesh & Structured mesh

Figure shows the contour of tangential velocity at a vertical plane of Stairmand cyclone both
unstructured & unstructured mesh, where the maximum value of the tangential velocity occurred
at a region between the wall and the core of rotating flow, then it begun to decrease at the center
of cyclone to be very low at the axis. This flow behaviour known as a Rankine vortex type,
including a quasi-forced vortex in the central region and a quasi-free vortex in the outer region.
The maximum value of the tangential velocity was 5.503 m/s. The result gives an indication that

the maximum tangential velocity was about 1.375 times the air inlet velocity.

(a) (b)

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4.3: Particle track for Unstructured & Structured mesh

Figure shows the trajectories of particle arrangements at the entrance section have significant
effects on the cyclone separation efficiency. Regardless of the cylinder or the upper and the
lower part of conical section. As shown, the particles with diameters of 5 µm all flow into the
inner cylinder and helically move upward around the inner cylinder wall which is observed in
figure b i.e structured mesh. They move into the annular space by centrifugal force from the top
of the inner cylinder and continue to flow downward to the cone zone. The larger particles, with
5 µm diameter, flow further down to the cone zone and ash collector, then can be trapped (figure
b-Structured mesh).

(a) (b)

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4.4: RESULT

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CHAPTER 5
CONCLUSION

There are different models used for cyclone separator but CFD is the best method to simulate the
cyclone separator.
Cyclone separator have high efficiency or majorly remove particles of size above 5 μm but it is
not effective for below 1 μm particle size.
Increase in velocity also increases efficiency of cyclone separation but it also increases the
pressure which results into high power consumption

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REFERENCES

[1].Advances in cyclone modeling using unstructured grid M.D. Slack, R.O. Prasad, A. Bakker,
F. BoysanAIChE J, 78: 1098-104, 2000
[2].Comparison of different models of cyclone prediction performance for various operating
conditions using a general software S. Altmeyer, V. Mathieu, S. Jullemier, P. Contal, N.
Midoux, S. Rode, J.P. Leclerc Chem. Eng. Process: 511-22, 2004
[3].Effects of the geometric configuration on cyclone performance T.C. Hsiao, S.H. Huang,
C.W. Hsu, C.C. Chen J. Aerosol. Sci, 86: 1-12, 2015
[4].AbhijitGaikwad and Dr. Shivarudraiah “CFD Analysis of Symmetrical Tangential inlet
Cyclone Separator” IRJET Vol. 04, No- 08 , Aug. 2017
[5].Bharat Raj Reddy Dere, “Design and Analysis of Cyclone Separator”, “IJERT”, Vol -3,
Issue-8, 2014
[6].Mahesh R. Jadhav, “Design of Cyclone and Study of its Performance Parameters”,
“International Journal of Mechanical Engineering and Robotic Research”, Vol.3, No. 4 2014
[7].Muhammad I. Taiwo, “Design and analysis of cyclone dust separator”, “American Journal of
Engineering Research (AJER)”, Vol-5, Issue-4, 2016
[8].Svarovsky, “Solid Liquid Separation”, “ScienceDirect” , 4th edition, chapter-6, Page 191-
245, 20

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