Numerical investigation of hydrocyclone inlet configurations for improving separation performance

Optimizing hydrocyclone inlet design is regarded as an effective strategy to mitigate the adverse effect of particle misplacement and improves separation efficiency. This work proposes innovative hydrocyclone designs based on spiral inlet with a specific spiral angle and tangential inlet with a specific curvature radius. The new designs are evaluated and compared with a standard design using a validated two–fluid model. The separation performance, flow characteristics and volume fraction distribution are considered in the evaluation. An optimum spiral inlet design is identified, with an inlet spiral angle of 90° under the current conditions. This inlet design evidently improves the tangential velocity, strengthens the stability of the air core and reduces short-circuit flows. Additionally, the new inlets help improve the volume fraction of coarse particles in the region near the spigot, mitigating the misplacement of coarse and fine particles. This study offers a new perspective for improving hydrocyclone flows and performance. [Display omitted] •The new tangential and spiral inlet configurations are designed and investigated.•The innovative inlet designs significantly improve particles separation efficiency.•The multiphase flow characteristics are analyzed to elucidate the separation mechanism.•An optimum spiral inlet design is identified to effectively reduce particle misplacement.