This study investigates the performance of cyclone dust separators using the Discrete Phase Model (DPM) via ANSYS Fluent. Cyclone separators are commonly used in industry to separate gas lines from particles. They use centrifugal forces to push particles to the walls of the cyclone so they can be collected. The DPM method lets us look closely at particle paths, how they interact with the flow field, and how well they collect within the cyclone shape. The goal of this study is to validate the numerical results given in the reference paper called “Effect of varying diameter on the performance ofindustrial scale gas cyclone dust separators [1]”.

• Reference [1]: Brar, L. S., and R. P. Sharma. “Effect of varying diameter on the performance of industrial scale gas cyclone dust separators.” Materials Today: Proceedings4-5 (2015): 3230-3237.

Figure 1: The cyclone schematic given in the reference paper [1]

Simulation process

The cyclone geometry configuration is designed and discretized into 657478 Polyhedral cells using Design Modeler & Fluent Meshing software. There are many turbulence models in FLUENT, including the Spallart-Allmaras (SA), k-λ k-ω, and Reynolds stress model (RSM). The RSM (7-equation) has been used a lot and is said to work well in a lot of references on cyclonic flows. The dust dispersed phase is modeled by Discrete Phase Model (DPM), resulting in Lagrangian tracking framework. Turbulent dispersion of the particles is taken into consideration by using the discrete random walk model. Plus, Saffman lift force effects are included. The dust particles dimeters varies with mean diameter of 3.66 micron. This requires the use of Rosin-rammler diameter distribution model.

Figure 2: Mesh generated over cyclone dust separator – Validation study

Post-processing

For the CFD model to be valid, the simulated axial and tangential mean velocity profiles must match the actual data from Figure 3 of the reference paper. The axial mean velocity profile plot shows that the CFD results and the numerical results are very close to each other. This shows that the numerical model is successful at simulating how the flow behaves inside the cyclone separator. The CFD predictions correctly show the axial velocity’s characteristic double-peak profile, with peaks and dips that are very close to the experimental data. This strong connection backs up the turbulence model and mesh resolution that were chosen, giving us faith in the model’s ability to guess flow patterns and particle behavior inside the cyclone. The simulated and experimental velocity profiles agree with each other, which makes it possible to use the confirmed CFD model for more analysis and optimization studies.

Figure 3: Cyclone Dust Separators Using DPM CFD Simulation, Numerical Paper Validation

By looking at the fluid physics inside the cyclone, we can see the complicated flow patterns that separate the particles. The high-speed swirling flow that is typical of cyclones is shown by the velocity magnitude curve and streamlines. The gas stream comes in from the side, making a strong vortex core that goes all the way down through the cyclone body. The fastest speeds are seen near the entrance and in the outer vortex region. As you move toward the center and bottom of the cyclone, the speeds slowly slow down. This difference in speed is very important for separating particles because it creates centrifugal forces that push heavier particles toward the outer wall, where they are gathered. The streamlines show the gas flow’s helical path and draw attention to the rotating motion that keeps the centrifugal separation system going. The CFD modeling showed that the velocity distribution and flow patterns were similar to what would be expected from a cyclone separator.

Figure 4: Velocity & Streamlines inside the cyclone dust separator using DPM – Numerical paper Validation