Hydrophysics

Hydrophysics

Investigating the Effect of Hydrocyclone Geometric Modifications on Particle Separation Performance Using CFD–DPMInvestigate the Hydrocyclone Geometric Modifications Effect on Particle Separation Performance Using CFD–DPM Simulation

Document Type : Original Article

Authors
Niloufar Yousefizoj 1
Sadegh Nikbakht Naserabad 2
Heidar Hashemi 3
1 Department of Mechanical Engineering, Faculty of Engineering and Technology, Yasuj University, Yasuj, Iran.
2 Energy Engineering Department, Faculty of Gas & Petroleum, Yasouj University, Gachsaran, Iran.
3 Department of Mechanical Engineering, Yas.c., Islamic Azad University, Yasuj, Iran
Abstract
In this study, the performance of a hydrocyclone is analyzed using Computational Fluid Dynamics (CFD) combined with the Discrete Phase Model (DPM) to predict the trajectories and fate of solid particles. The working fluid consists of water mixed with ferromagnetic powder, with an effective density of 2850 kg/m³, while the injected solid particles are copper (density 4000 kg/m³) and rock (density 1800 kg/m³), both with a diameter of 25 mm. Baseline simulation results show that all copper particles are discharged through the underflow, as expected, whereas a portion of the rock particles, due to having a lower density than the underflow fluid, become trapped in recirculation regions and a significant fraction exits through the overflow, which is undesirable for the separation process. To enhance separation efficiency, several geometric modifications are introduced, including extending the overflow pipe (vortex finder), reshaping the inlet cross‑section to a rectangular form while keeping the hydraulic diameter constant, and increasing the length of the conical section. After applying these modifications and injecting a larger number of particles (1398 copper and an equal number of rock particles), the results indicate a marked improvement in rock particle separation: the number of particles leaving through the overflow decreases by about 3%, and the fraction of rock particles discharged via the underflow increases by approximately 40–50% compared with the baseline configuration. These findings demonstrate that extending the vortex finder and optimizing the inlet and cone geometry can intensify the swirling flow field and promote the settling of lower‑density particles, thereby improving overall hydrocyclone performance.
Keywords
Separation
hydrocyclone
geometry
CFD
DPM
ferromagnetic powder
Subjects

1. Motsamai OS. Investigation of the influence of hydrocyclone geometric and flow parameters on its performance using CFD. Advances in Mechanical Engineering. 2010; 2:593689.

2. Delgadillo JA, Rajamani RK. Exploration of hydrocyclone designs using computational fluid dynamics. International Journal of Mineral Processing. 2007 Oct 19;84(1-4):252-61.

3. Narasimha M, Brennan M, Holtham PN. Large eddy simulation of hydrocyclone—prediction of air-core diameter and shape. International Journal of Mineral Processing. 2006 Aug 1;80(1):1-4.

4. Wang B, Yu AB. Numerical study of particle–fluid flow in hydrocyclones with different body dimensions. Minerals Engineering. 2006 Aug 1;19(10):1022-33.

5. Martínez LF, Lavín AG, Mahamud MM, Bueno JL. Vortex finder optimum length in hydrocyclone separation. Chemical Engineering and Processing: Process Intensification. 2008 Feb 1;47(2):192-9.

6. Mahat MM, Husain H, Mohamad NS. Separation efficiency analysis of multiphase flow inside hydrocyclone using CFD. Journal of applied engineering design and simulation. 2023 May 12;3(1):51-65.

7. Thiemsakul D, Piemjaiswang R, Sema T, Feng Y, Piumsomboon P, Chalermsinsuwan B. Effect of hydrocyclone design in microplastics-water separation by using computational fluid dynamics simulations. Results in Engineering. 2024 Jun 1; 22:102034.

8. Wang R, Zhang Z, Yan X, Zhang H, Wang L. Hydrocyclone separation enhancement of fine particles based on interface control. Minerals Engineering. 2024 Apr 1; 209:108628.

9. Hou D, Liu P, Zhao Q, Jiang L, Cui B, Wei D. Numerical study on the separation performance of Hydrocyclones with different secondary cylindrical section diameters. Processes. 2023 Aug 25;11(9):2542.

10. Thiemsakul D, Kuang S, Sukmas W, Bumrungthaichaichan E, Korkerd K, Piemjaiswang R, Piumsomboon P, Chalermsinsuwan B. Effect of Hydrocyclone Size on Microplastics Separation: A Computational Fluid Dynamics Investigation. South African Journal of Chemical Engineering. 2025 Nov 2.

11. Pukkella AK, Vega-Garcia D, Hadler K, Cilliers J. The influence of surface-wall roughness on hydrocyclone performance. Separation and Purification Technology. 2025 Jul 8;360:131109.

12. Dai Y, Yang X, Du J, Yu W, Wang D, Yuan F. Migration and Removal of Microplastics in a Dual-Cone Mini-Hydrocyclone. Symmetry. 2025 Sep 17;17(9):1559.

13. Razmi H, Goharrizi AS, Mohebbi A. CFD simulation of an industrial hydrocyclone based on multiphase particle in cell (MPPIC) method. Separation and Purification Technology. 2019 Jan 31;209:851-62.

14. Kang SG, Kim KC, Ryom SC, Ri JH. Turbulence models and simulation method in the CFD simulation of 75-mm hydrocyclone. Scientific Mining Journal. 2022 Sep 30;61(3):127-34.

15. Zhang Y, Liu P, Jiang L, Yang X, Yang J. Numerical simulation of flow field characteristics and separation performance test of multi-product hydrocyclone. Minerals. 2019 May 16;9(5):300.

16. Venkatesh S, Sivapirakasam SP, Sakthivel M, Krishnaraj R, Leta TJ. Investigation on hydrocyclone for increasing the performance by modification of geometrical parameters through cfd approach. Desalination and Water Treatment. 2021 Dec 1;244:157-66.

17. Xu X, Liu P, Zhang Y, Hu W, Zhang Q. Numerical Simulation of the Separation Performance of a New Type of Two-Stage Column-Cone Hydrocyclone Based on CFD. InIntelligent Equipment and Special Robots 2024 (pp. 605-610). IOS Press.

18. Li F, Zou C, Li P, Huang G, Liu G, Zhang C. Performance Optimisation of Hydrocyclones with Complex Curved Feed Chambers: A CFD-Experimental Study. Chemical Engineering Research and Design. 2025 Oct 1.

19. Hou D, Zhao Q, Cui B, Wei D, Song Z, Feng Y. Geometrical configuration of hydrocyclone for improving the separation performance. Advanced Powder Technology. 2022 Feb 1;33(2):103419.

20.  de Sa da Silva DP, Morimoto MG, de Oliveira Silva D, Barrozo MA, Vieira LG. Effect of operational and geometric variables in hydrocyclones to improve separation efficiency and reduce energy consumption: A review and new insights. Mineral Processing and Extractive Metallurgy Review. 2024 Oct 28:1-32.

21. Pandey S, Wasilewski M, Mukhopadhyay A, Prakash O, Ahmad A, Brar LS. Multi-Objective Optimization of Cyclone Separators Based on Geometrical Parameters for Performance Enhancement. Applied Sciences. 2024 Feb 29;14(5):2034.

22. Sardar R, Oh J, Kim M, Lee JE, Kim S, Kim KC. The effect of inlet velocity, gas temperature and particle size on the performance of double cyclone separator. Chemical Engineering and Processing-Process Intensification. 2023 Sep 1;191:109469.

23. Wang L, Bai B, Chen P. A study on the characteristics and geometric optimization of a cyclone filter. Separation and Purification Technology. 2024 Oct 1;345:127313.

24. Li F, Liu P, Yang X, Zhang Y, Li X, Jiang L, Wang H, Fu W. Numerical analysis on the effect of the length of arc-shaped vortex finder on the hydrocyclone’s flow field and separation performance. Minerals Engineering. 2021 Oct 1;172:107172.

25. Zhang Y, Liu P, Ge J, Yang X, Yang M, Jiang L. Simulation analysis on the separation performance of spiral inlet hydrocyclone. International Journal of Coal Preparation and Utilization. 2021 Jul 3;41(7):474-90.

26. Zheng Y, Wang JG, Wang HL, Sun MC, Liu XY. Parametric design of curved hydrocyclone and its optimization based on artificial neural networks prediction. Separation and Purification Technology. 2025 Jan 19;353:128445.

 

 

 

  • Receive Date 30 January 2026
  • Revise Date 05 April 2026
  • Accept Date 12 April 2026