Computational fluid dynamics (CFD) analysis of cyclone separators connected in series

Cyclone separators are very useful equipment for particle removal from gaseous streams. Their simple design and low capital and maintenance costs have made cyclones one of the most widely used gas-solid separators. Their dynamic behavior includes several phenomena, such as vortex breakdown, reversal of flow, and high turbulence intensity. Prediction of pressure drop and collection efficiency over a temperature range of several hundred degrees with a high solids loading flow and different cyclone dimensions is very difficult with simplified models. In this work, a model that is based on computational fluid dynamics (CFD) techniques is used to verify the performance of cyclone separators connected in series; this collection of separators is called a cyclone tower. The model is based on the Eulerian-Eulerian approach, and it is composed of several time differential equations in a two-dimensional (2-D) space domain with a three-dimensional (3-D) symmetric cyclone inlet. The model is solved using the finite volume method with staggered grids. The results on collection efficiency and pressure drop of an experimental study were used to validate the proposed model. After validation of the model, it was possible to examine the performance of the cyclone separators through a comparison of the numerical results and information obtained in the cement industry.