A hybrid multiphase model accounting for particle agglomeration for coarse-grid simulation of dense solid flow inside large-scale cyclones

A hybrid multiphase model (Dense Discrete Phase Model, DDPM) coupled with an agglomeration model and a sub-grid drag model was developed for simulation of industrial-scale cyclones with high solid loading. The model is validated by experimental results of pressure drop and separation efficiency from a pilot-scale cyclone with a diameter of 1.6 m. Key trends such as improvement in separation efficiency and reduction in pressure drop of cyclone due to an increase in particle load are well captured by the model. It is concluded that including the agglomeration model is crucial in particular in cases involving very fine particles (d < 15 μm) for accurate predictions of pressure drop and separation efficiency, while using the sub-grid drag modification improves the prediction of separation efficiency. [Display omitted] •Dense Discrete Phase Model was modified for simulation of large-scale cyclones.•The model was validated against separation efficiency and pressure drop measurements.•The improvement in separation efficiency due to an increase in solid load is captured.•The agglomeration model is crucial in cases with very fine particles.•Sub-grid drag modification improves the prediction of separation efficiency.