Numerical simulation investigating the impact of regulated underflow rate on the performance of a cyclone with split flow

A novel cyclone design called enhanced cyclone with split flow (ECSF) incorporates bypass flow and underflow to eliminate or suppress localized secondary flow observed in conventional cyclones. The present study aims to investigate the mechanism of ECSF in suppressing localized secondary flow and explore methods for regulating the bottom flow rate. The turbulent characteristics within the ECSF are obtained using Reynolds stress model, while the trajectory of particles is predicted using discrete phase model to derive the separation performance. The accuracy of the simulation model has been validated through experimental verification. The results demonstrated that the full separation efficiency of ECSF for PM10 and PM2.5 remained above 90 % and 70 %, respectively. Moreover, it exhibited an increasing trend with the rise in the full split ratio, eventually stabilizing at approximately 95 % and 77 %, correspondingly, when the full split ratio reached 20 %. The bypass flow and underflow effectively eliminated or suppressed the upper ash ring and processing vortex core (PVC) phenomenon, respectively. However, the exacerbation of the short-circuit flow phenomenon hindered further improvement in separation efficiency beyond a full diversion ratio of 20 %. When the full split ratio is relatively small, particles may accumulate in the discharge pipe, which can be resolved by introducing auxiliary airflow; however, it is crucial to ensure that the flow rate of auxiliary flow does not exceed 14.29 % of that of feed flow to avoid compromising the separation efficiency. Furthermore, the split flow induces an additional reversed vortex within the ECSF, which extends from the overflow pipe to conical section. Its structural characteristics are influenced by both back pressure of discharge outlet and diameter of underflow pipe. To ensure optimal performance of the ECSF, it is recommended that the underflow pipe diameter should not be smaller than that of the outlet in conical section.