Search Results (20)

The cylindrical hydrocyclone can be regarded as a special-shaped hydrocyclone comprising entirely cylindrical sections without conical sections, featuring a unique flat-bottom design combined with central discharge, which promotes substantial particle circulation flow in the separation chamber, directly affecting separation performance. A validated TFM model is employed to investigate the flow field and particle motion behavior in the cylindrical hydrocyclone. The results indicate that the distributions of tangential velocity, radial velocity, pressure, and pressure gradient in the cylindrical hydrocyclone are consistent with patterns observed in the conventional hydrocyclone. The flat-bottom design combined with the central discharge configuration of the cylindrical hydrocyclone results in two distinct axial velocity transitions in the bottom region, forming downward axial velocity flow around the air core. Accordingly, particles moving toward the spigot must pass through the internal swirling flow region, facilitating the fine particles entrained by the coarse particles to enter the internal swirling flow, reducing the misplacement of fine particles in the underflow. Simultaneously, coarse particles entrained by the internal swirling flow return to the external swirling flow region under centrifugal force, forming a substantial coarse particle circulation flow. As a result, a mass of coarse particles accumulates in the separation chamber, hindering the centrifugal settling of medium particles and resulting in an enlarged cut size and severe coarse particle misplacement. Full article

The outlet diameter of hydrocyclones is a critical structural parameter that impacts product distribution and separation performance, drawing significant attention. In this paper, the separation efficiency and particle motion behavior in the cylindrical hydrocyclone with varying spigot diameters and vortex finder diameters are systematically analyzed using a TFM model. The numerical results indicate that a larger spigot diameter and a smaller vortex finder diameter reduce the axial velocity and expand the external swirling flow region, while a smaller spigot diameter and a larger vortex finder diameter enhance the particle circulation flow ratio and the coarse particle circulation flow proportion, thereby increasing the cut size. Slightly reducing the spigot diameter and increasing the vortex finder diameter enhances the separation accuracy. Nevertheless, for D_u = 0.075 D and D_o ≥ 0.4 D, the recovery rate in the underflow remains below 50% for all particle sizes, exhibiting severe particle misplacement and loss of separation efficiency. For D_u = 0.125 D, the reduction in coarse particle misplacement in the overflow is attributed to the abrupt changes in the coarse particle circulation flow proportion and medium particle circulation flow proportion. Generally, an appropriate coarse particle circulation flow proportion in the cylindrical hydrocyclone is beneficial for alleviating particle misplacement and improving separation accuracy. Full article

As an efficient solid–liquid separation device, the hydrocyclone is widely applied in various industrial fields such as coal preparation and oil impurity removal, and its classification performance directly determines the efficiency of industrial separation operations., As the core separation zone of the hydrocyclone, the cone segment, its structure and the number of cone angles directly affect the flow field distribution characteristics and particle classification performance of the hydrocyclone. To reveal the regulation mechanism of the combined cone angles on the classification performance of hydrocyclones, numerical analysis and experimental verification methods were adopted to investigate the internal flow field and classification performance of hydrocyclones under different cone angle combinations. The evolution laws of velocity field, pressure field, turbulence characteristics, and particle classification effect under different configurations were systematically explored. The results show that the basic characteristics of the core flow field of the hydrocyclone do not change essentially with the increase in the number of cone segments, but the amplitude, distribution, and stability of flow field parameters are significantly regulated. The three-cone configuration achieves the optimal flow field synergy effect: the amplitude of the high turbulence intensity zone is lower and concentrated near the central axis; the zero-velocity envelope surface is stably maintained at approximately 8 mm in the core separation zone; and the full axial fluctuation of the air core is gentle, which effectively inhibits random particle diffusion and flow pattern mixing. In terms of separation performance, the three-cone configuration exhibits the highest classification efficiency in the core range of sub-coarse particles (10~30 μm), with the cut size (approximately 17.5 μm) in a reasonable range, the steepness index reaching a peak value (approximately 0.55), and the pressure drop (approximately 1.8 × 10⁵ Pa) and split ratio (2.8%) achieving synergistic optimization, balancing separation accuracy and energy consumption control. The single-cone configuration causes flow field disturbance due to the one-time contraction of the flow channel, while the four-cone configuration falls into the dilemma of “high pressure drop–marginal performance gain”, and neither achieves optimal performance. The regulation law of the number of cone segments revealed in this study provides a scientific basis for the structural optimization and engineering application of multi-cone hydrocyclones, and is of great significance for improving the particle classification efficiency in fields such as wastewater treatment and mineral processing. Full article

In this study, we analyzed the migration and removal of microplastics (MPs) using a dual-cone mini-hydrocyclone, thereby addressing the research gaps in flow mechanisms and separation efficiency for low-density MPs. We constructed and experimentally verified a numerical model. We discussed the velocity distribution of the flow field and the effects of the feed flow rate, feed MP volume fraction, and density on the distribution of MPs. The flow field analysis demonstrated maximum axial velocity at the cylindrical axis and peak tangential/radial velocities in the large cone section, promoting MP enrichment along the axis. The separation efficiency was improved with higher feed flow rates (e.g., 78.56% at 10 m/s for 50 μm MPs) but decreased with an increase in the MP volume fraction due to particle collisions. The MPs with densities below water demonstrated near-complete separation (98.51%), whereas those larger than water density exhibited minimal efficiency. The MPs are concentrated in the large and small cone axes, with density differences that significantly affect the migration patterns. Full article

Since the mid-20th century, the quantity of microplastics (MPs) has increased significantly, becoming a persistent environmental pollutant widely distributed in global water bodies, soils, and the atmosphere. While plastic materials have brought significant convenience to daily life, the MPs resulting from their degradation pose increasing threats to ecosystems and human health. This comprehensive review examines the sources, migration pathways, and ecological impacts of MPs, and critically evaluates the current separation techniques from physical, chemical, and biological perspectives. In particular, numerical simulations of the hydrocyclone separation technique reveal its unique flow characteristics, including turbulent velocity gradients and axial pressure differences, with a separation efficiency of up to 93%. This technique offers advantages such as high efficiency, low energy consumption, and environmental friendliness. In response to the growing microplastic pollution issue, this review emphasizes that the development of future microplastic separation techniques should prioritize separation efficiency, sustainability, and environmental compatibility. Continued research in this field will provide theoretical support for optimizing microplastic pollution control technologies and contribute to achieving environmental protection and sustainable development goals. Full article

To enhance the classification efficiency of hydrocyclones, this study introduces a novel hydrocyclone design featuring a composite curved-inlet-body structure. Through numerical simulations, the internal flow field characteristics of this structure are thoroughly investigated. The results reveal several key findings: when the diameter of the overflow tube is reduced below a critical threshold, the axial velocity exhibits predominantly downward movement within the outer cyclone, accompanied by substantial recirculation, leading to a loss of effective separation. Moreover, both static pressure and tangential velocity are largely independent of the insertion depth of the overflow tube. In contrast, the diameter of the bottom flow opening plays a crucial role in determining flow dynamics within the hydrocyclone. An excessively large or small bottom opening leads to flow instabilities, causing fluctuations that disrupt the uniformity of the flow field. Additionally, a small height-to-diameter ratio exacerbates flow instability, increasing turbulence intensity and resulting in irregular fluctuations in the LZVV. These findings provide important theoretical insights for the design of more efficient hydrocyclone separation structures. Full article

The tubular dynamic hydrocyclone (TDH) holds great potential for the pre-deoiling of offshore oil platforms. However, the shear and turbulence in the flow field can cause the oil droplets, the dispersed phase in water, to break up when the swirling flow is produced by the swirler. A design method is proposed for the low-shear rotary swirler (LSRS) of TDH, the aim of which is to reduce the shear force and local turbulence during the fluid forming swirling flow. The blade setting angle of the LSRS is calculated based on the relative velocity vector between the fluid and the swirler. The distribution characteristics of the tangential velocity and turbulence in the TDH with LSRS are simulated by Computational Fluid Dynamics (CFD). The maximum stable droplet diameter is analyzed. The results show that the shear stress and turbulence energy dissipation rates are reduced by 74.6% and 68.5%, respectively, and that the stable droplet diameter is increased by more than 60%, compared to the conventional rotating swirler. In addition, a TDH prototype with LSRS was tested in an offshore oil field by continuous operation for more than 36 h. The average separation efficiency was 83%, and the average underflow oil concentration was 27 mg/L. The research also found that the drastic changes in the tangential velocity along the axial direction were critical to shear. Moreover, the results make up for the deficiency of the spatial variation of the tangential velocity in the dynamic cyclone separator. Full article

To enhance the separation efficiency of downhole oil–water hydrocyclones in co-produced wells, an axial center-piercing hydrocyclone structure is proposed. A mathematical relationship model between the structural parameters and separation efficiency of the axial center-piercing hydrocyclone is constructed based on the response surface methodology. The numerical simulation method is employed to analyze both the unoptimized and optimized hydrocyclone structures, and their separation performances are simulated under identical operational conditions. The results indicate that the optimal structural parameter values are as follows: main diameter D = 70.4 mm, large cone angle α₁ = 32.4°, small cone angle α₂ = 3.9°, bottom flow tube length L₃ = 311.7 mm, and inverted cone length L₄ = 166.0 mm. The optimal operation parameters of the optimized structure are also obtained. Under the same operating parameter conditions, the separation efficiency of the optimized structure is consistently higher than that of the unoptimized structure. The highest efficiency achieved by the optimized structure is 98.6%, which is a 2% improvement over the unoptimized state. Finally, experiments are conducted with the optimized hydrocyclone separator structure under different split ratios. This study significantly contributes to the field of injection and production in a single well, particularly in promoting the application of hydrocyclones. Full article

The particle motion behavior in hydrocyclones has received increasing attention, but the particle circulation flow has received relatively limited attention. In this paper, the particle circulation flow is regulated by changing the secondary-cylindrical section diameter to optimize the separation effect. The effects of secondary-cylindrical section diameters on flow field characteristics and separation performance are explored using the two-fluid model (TFM). The findings demonstrate that particle circulation flows are ubiquitous in the secondary-cylindrical hydrocyclone and are induced by the axial velocity wave zone. The increase in the secondary-cylindrical section diameter intensifies the coarse particle circulation and aggrandizes the coarse particle’s aggregation degree and aggregation region, leading to an increment in cut size. The circulation flow component can be regulated by adjusting the secondary-cylindrical section, thus improving the classification effect. An appropriate diameter of the secondary-cylindrical section facilitates improved particle circulation, strengthening the separation sharpness. Full article

Investigating the motion of discrete oil droplets in a rotating flow field can provide a theoretical basis for optimizing the flow field and structural parameters of hydrocyclones and centrifugal separation equipment. In the present work, the particle image velocimetry (PIV) method was applied to study the velocity distribution of a three-dimensional axial-rotor-driven rotating flow field and the influence of the velocity distribution of different rotor speeds on the flow field. The radial migration of oil droplets with different particle sizes in the rotating flow field was visually analyzed using high-speed video (HSV). The results showed that the oil droplets with the same radial position had diameters of 2.677 and 4.391 mm, whereas the movement times to the axis were 0.902 and 0.752 s. The larger the oil droplet size, the shorter the time to move to the axial center of the rotating flow field. The radial velocities of oil droplets with diameters of 2.677 and 2.714 mm were 0.0221 and 0.02 m·s⁻¹, respectively. In addition, a mathematical expression was established between the radial migration time and the oil droplet size in the rotating flow field. The accuracy of the proposed expression was verified using experiments. Full article

Hydrocyclones are devices used in numerous areas of the chemical, food, and mineral industries to separate fine particles. A hydrocyclone with a diameter of d50 mm was modeled using the commercial Simcenter STAR-CCM+13 computational fluid dynamics (CFD) simulation package. The numerical methods confirmed the results of the different parameters, such as the properties of the volume fraction, based on CFD simulations. Reynolds Stress Model (RSM) and the combined technique of volume of fluid (VOF) and discrete element model (DEM) for water and air models were selected to evaluate semi-implicit pressure-linked equations and combine the momentum with continuity laws to obtain derivatives of the pressure. The targeted particle sizes were in a range of 8–100 microns for a dewatering application. The depth of the vortex finder was varied to 20 mm, 30 mm, and 35 mm to observe the effects of pressure drop and separation efficiency. The split water ratio increased toward a 50% split of overflow and underflow rates as the length of the vortex finder increased. It results in better particle separation when there is a high injection rate at the inlet. The tangential and axial velocities increased as the vortex finder length increased. As the depth of the vortex finder length increased, the time for particle re-entrainment into the underflow stream increased, and the separation efficiency improved. Full article

There are many factors that affect the separation performance of the hydrocyclone, including the structure of the feed body, but the mechanism of influence of the internal flow field of the hydrocyclone on the Axial Velocity Wave Zone (AVWZ) is not yet clear. Based on the numerical test method, this paper analyzes the influence of the feed body structure on the internal flow field and the particle distribution characteristics of the AVWZ and its internal relationship with its separation performance. The results show that the influence mechanism of the structural parameters of the inlet structure on its separation performance is extremely complex, but all of them are reflected in the AVWZ’s characteristics, including the flow field characteristics, spatial distribution characteristics, and internal particle distribution. The changes on the inlet diameter will also influence the flow field, centrifugal strength, turbulence strength, and particle distribution, while the inlet aspect ratio is altered largely by changing the settling distance of particles. Finally, effects of inlet structure on the separation performance of the hydrocyclone can be explained from the AVWZ, which provides the basis for designing the inlet structure to improve separation performance. Full article

In order to clarify the influence of feed rate on a hydrocyclone flow field, numerical simulation was employed to model the influence of feed rate on the pressure field, velocity field, air column, turbulent kinetic energy, and split ratio. The results revealed that static pressure, tangential velocity, and radial velocity increased with an increase in the feed rate. When the feed rate at the inlet increases from 1 m/s to 5 m/s, the static pressure increases from 5.49 kPa to 182.78 kPa, tangential velocity increases from 1.97 m/s to 11.16 m/s, and radial velocity increases from 0.20 m/s to 1.16 m/s demonstrating that a high feed rate facilitated the strengthening separation of the flow field. Meanwhile, with the increase in the feed rate, the split ratio of the hydrocyclone decreased, indicating that the concentration effect of the hydrocyclone improved. Additionally, the formation time of the air column was reduced, and the flow field became more stable. Nevertheless, the axial velocity and the turbulent kinetic energy also increased with the increase in the feed rate, and the increase in the axial velocity reduced the residence time of the material in the hydrocyclone, which was not conducive to the improvement of separation accuracy. In addition, the increase in turbulent kinetic energy led to an increase in energy consumption, which was not conducive to the improvement of the comprehensive performance of the hydrocyclone. Therefore, choosing an appropriate feed rate is of great significance to the regulation of the flow field and the improvement of hydrocyclone separation performance. Full article

The high-ash tailings produced by flotation contains a large number of minerals that can be recycled. However, as the separation and purification technology for flotation tailings is not mature and separation efficiencies are low, it is generally treated as separation waste, resulting in the waste of mineral resources. In view of this phenomenon, the particle size composition and density composition of high-ash minerals in flotation tailings of coal slime as well as the type and content of mineral elements were measured. It was determined that the main mineral composition is quartz, and there is also a certain amount of chlorite (silicate mineral). A self-spinning hydrocyclone used for flotation tailings separation and purification was designed, and numerical simulation was carried out by fluent software. The internal flow field-, tangential velocity-, and axial velocity-distribution characteristics of the hydrocyclone at different rotational speeds were investigated. The physical model of the hydrocyclone was set up and the separation efficiency improvement test of fine particles was carried out. The results show that the overflow yield of −0.045 mm particles increased gradually with the increase in cylinder rotation speed. When the rotation speed increased to 900 r/min, the overflow yield of −0.045 mm particles can reach more than 90%, which can effectively realize the material classification according to 0.045 mm. Full article

The density of tar vapor and water vapor produced by coal pyrolysis is different. Different centrifugal forces will be generated when they flow through the hydrocyclone. The water vapor and tar vapor are divided into inner and outer layers. According to this phenomenon, the moisture in the tar can be removed. In this paper, a Eulerian gas–liquid two-phase flow model is established by numerical simulation to study the effect of inlet velocity on the separation effect of a designed hydrocyclone (split ratio 0.2). The results show that the inlet velocity and moisture content have an influence on the volume distribution characteristics, tangential velocity, axial velocity, pressure drop distribution, and separation efficiency of tar vapor and water vapor in the hydrocyclone. When the inlet velocity increases from 2.0 to 12.0 m/s, the central swirl intensity increases, and the negative pressure sweep range at the overflow outlet increases. The axial velocity increased from 2.8 to 14.9 m/s, tar vapor content at the overflow outlet decreased from 74% to 37%, and at the underflow outlet increased from 89% to 92%. When the moisture content is lower than 10%, the hydrocyclone with the split ratio of 0.20 is no longer suitable for the separation of oil–water two-phase vapor. However, when the water content is higher than 20%, the purity of tar vapor at the underflow outlet can reach 92%, and the overflow outlet needs multistage separation to realize tar purification. Full article