AN

INDUSTRIAL INTERNSHIP PROJECT

REPORT ON
“A CFD STUDY ON MODELING & DESIGNING OF CYCLONE
SEPARATOR”
Submitted in fulfillment for requirement of the award of the degree of
BACHELOR OF TECHNOLOGY IN CHEMICAL ENGINEERING
Submitted By
HARSHAY BHAGWANT DOLAS
(PRN: 2030331507013)

Under the guidance of

Prof. Dr. RUTA KHONDE

DEPARTMENT OF CHEMICAL ENGINEERING

DR. BABASAHEB AMBEDKAR TECHNOLOGICAL
UNIVERSITY, LONERE, RAIGAD – 402103
Academic year 2023-2024
 A CFD study on Modelling & Designing of Cyclone Separator

DR. BABASAHEB AMBEDKAR TECHNOLOGICAL

UNIVERSITY, LONERE, RAIGAD – 402103
DEPARTMENT OF CHEMICAL ENGINEERING

CERTIFICATE

This is certified that the Internship report entitled “A CFD Study on Modeling & Designing
of Cyclone Separator” is bonafide work carried out by Mr. HARSHAY BHAGWANT
DOLAS (2030331507013) in final year of degree in chemical engineering. It is approved for
the fulfilment of requirement for B. Tech in Chemical Engineering of Dr. Babasaheb Ambedkar
Technological University, Lonere, Raigad 402103.

Guide Dr. A. R. Chavan

Prof. Dr. RUTA KHONDE Head of Department
Dr. Babasaheb Ambedkar Technological
University, Lonere, Raigad

EXAMINER: -
1._________________
2._________________

Place: Lonere
Date:

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ACKNOWLEDGEMENT

I would like to take this opportunity to express my gratitude and sincere thanks to the Director
and CEO of FLUIDIMENSIONS ENGINEERING SIMULATIONS & CONSULTING, Dr.
Vivek Vitankar who offered me the chance to study on CFD simulations used in chemical
industries. He helped me in coordinating and getting information.

I would also like to thanks management team, all colleague and all the staff members of
Fluidimensions Engineering Simulations & Consulting for guiding, helping me throughout the
course.

I also take this opportunity to express my sincere gratitude towards my guide Dr.Ruta Khonde
chemical Engineering Department of Dr. Babasaheb Ambedkar Technological University,
Lonere for his invaluable guidance. It would have never been possible for me to take this report
completion without her innovative ideas and relentless support and encouragement. I consider
myself extremely fortunate to have had a chance to work under her supervision. In spite of his
hectic schedule, she was always approachable and took her time off to attain my problem and
give the appropriate advice. It has been a very enlightening and enjoyable experience to work
under her I extend my profound sense of gratitude to all the faculty members, Department of
chemical Engineering for the encouragement and support during my work.

HARSHAY BHAGWANT DOLAS

(2030331507013)

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ABSTRACT

Cyclones are devices that employ a centrifugal force generated by a spinning gas stream to
separate particles from the carrier gas. Their simple design, low capital cost and nearly
maintenance-free operation make them ideal for use as precleaners for more expensive final
control devices such as bag30 houses or electrostatic precipitators. Cyclones are particularly
well suited for high temperature and pressure conditions because of their rugged design and
flexible component materials.

This work presents a Computational Fluid Dynamics calculation to predict and to evaluate the
effects of temperature, operating pressure and inlet velocity on the collection efficiency of gas
10 cyclones. A three-dimensional Eulerian–Lagrangian fluid dynamics (CFD) model was
developed to simulate the gas particulate flow inside cyclones. The simulation results also
confirmed the applicability of CFD modeling as a promising tool to study the cyclone size
effect on performance parameters

In this internship report, I explore the application of CFD simulation using Simcenter star-
CCM+ in the field of equipment modeling and simulation of reactors and cyclones. The report
focuses on design, fluid flow behaviour, and optimization of these equipment. Through the
simulation, insight was gained into the performance and efficiency of the reactors and cyclones.
The findings highlight the potential of CFD simulation in improving the design and operation
of such equipment.

Keywords: Cyclone, CFD, Efficiency, Temperature, Inlet Velocity, gas–solid; cyclone

separator; computational fluid dynamics (CFD).

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TABLE OF CONTENT

CHAPTER TITLE PAGE NO.

NO.

CERTIFICATE ii

ACKNOWLEDGEMENT iii

ABSTRACT iv

TABLE OF CONTENT v

LIST OF FIGURES vi

LIST OF TABLES vii

NOMENCLATURE viii

INTERNSHIP CERTIFICATE ix

INTRODUCTION x

1 COMPUTATIONAL FLUID DYNAMICS 1

2 CFD SIMULATION IN CHEMICAL INDUSTRIES 4

3 CFD SIMULATION ALGORITHM 6

4 CFD SOFTWARE 9

5 CYCLONE SEPARATOR 11

6 CFD MODEL OF CYCLONE SEPARATOR 17

7 RESULTS & CONCLUSION 29

REFERENCES 32

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LIST OF FIGURES
Sr. No. Name of Figures Pg. No.

1 CFD simulation algorithm 8

2 CFD simulation stages 8

3 CFD simulation stages 9

4 Schematic Diagram of Cyclone Separator 11

(a) Schematic drawing of a conical reverse-flow cyclone.
(b) Qualitative patterns of axial, tangential, and radial
velocity components of the gas-flow field in cyclones.
5 15
(c) The secondary flow pattern caused by the swirl and
pressure gradients in the cyclone.

6 Geometry of cyclone 17

7 Actual cyclone separator model. 18

8 CAD model actual cyclone separator. 18

9 Front & Top View of Cyclone Separator 19

10 Meshed Model of Cyclone Separator 21

11 Velocity contour view at different planes of cyclone. 24

12 Pressure contour view at different planes of cyclone. 25

13 Velocity vector view at different planes of cyclone. 25

14 Streamline Flow of cyclone Separator. 26

15 Axial Velocity distribution at line probe of cyclone separator 27

Tangential Velocity distribution at line probe of cyclone
16 27
separator
Velocity (Magnitude) distribution at line probe of cyclone
17 28
separator
18 Variation of collection efficiency based on particle diameter 30

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LIST OF TABLES
Sr. No. Title of Tables Pg. No.

1 Dimensions of the cyclone 17

2 Mesher selected for mesh operation. 20

3 Properties for meshing operation 20

4 Mesh count of cyclone & diptube. 21

5 Physics model setup for simulation 22

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NOMENCLATURE
a cyclone inlet height
b cyclone inlet width
B cyclone dust outlet diameter
d50 cut diameter of particle which is collected with 50% efficiency
D cyclone body diameter
De cyclone gas outlet diameter
FD drag force per unit particle mass
g gravity acceleration
h height of cylindrical body of cyclone
H cyclone height
k turbulent kinetic energy
P pressure
R cyclone body radius
R radial dimension
S depth of vortex finder inside cyclone
vin inlet gas velocity
y radial coordinate
z axial coordinate

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INTERNSHIP CERTIFICATE

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INTRODUCTION
ABOUT COMPANY:

FLUIDIMENSIONS ENGINEERING SIMULATIONS & CONSULTING

FluiDimensions is founded formally in June 2016 by Dr. Vivek Vitankar, Ph.D., Chemical
Engineering, ICT, Mumbai (formerly UDCT). FluiDimensions is an Engineering Design and
Consulting company with its principle office in Pune, Maharashtra, India. FluiDimensions
believes in solving industrial problems by working very closely with the customers to improve
the efficiency of the equipment, optimize design and operating conditions and enhance quality.
FluiDimensions believes in solving industrial problems by working very closely with the
customers to improve the efficiency of the equipment, optimize design and operating
conditions and enhance quality. For us, protection of customers data and process information
is very critical.

FLUIDIMENSIONS offer end to end Engineering Simulation Services to Design,

Debottleneck, Enhance Equipment and Process Performance.

Equipment Design and Debottlenecking CFD Process Automation

Process Modelling Multiphysics Analysis

Customized software Product Artificial Intelligence and Machine

Development Learning

Molecular Modelling Research and Skill Development

FLUIDIMENSIONS offer our consulting services to enable you to model complex physics
involving Combustion, Multiphase flows, particulate flows, flows with chemical reactions,
Multiple Rotating Zones etc. The application of these physics could be wide range of Industry

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like Chemicals, Pharmaceuticals, Food, Agro Chemicals, Sugar, Oil and Gas, Petrochemicals,
Paints, Cement, Metals, Plastics.

They are actively providing our services to wide variety of process industry such as:

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CHAPTER 1
1. COMPUTATIONAL FLUID DYNAMICS

1.1. Computational fluid dynamics (CFD) is a branch of fluid mechanics that uses numerical
analysis and data structures to analyze and solve problems that involve fluid flows. Computers
are used to perform the calculations required to simulate the free-stream flow of the fluid, and
the interaction of the fluid (liquids and gases) with surfaces defined by boundary conditions.
With high-speed supercomputers, better solutions can be achieved, and are often required to
solve the largest and most complex problems. Ongoing research yields software that improves
the accuracy and speed of complex simulation scenarios such as transonic or turbulent flows.
Initial validation of such software is typically performed using experimental apparatus such
as wind tunnels. In addition, previously performed analytical or empirical analysis of a
particular problem can be used for comparison. A final validation is often performed using full-
scale testing, such as flight tests.

CFD is applied to a wide range of research and engineering problems in many fields of study
and industries, including aerodynamics and aerospace analysis, hypersonics, weather
simulation, natural science and environmental engineering, industrial system design and
analysis, biologicalengineering, fluid flows and heat transfer, engine and combustion analysis,
and visual effects for film and games.

The fundamental basis of almost all CFD problems is the Navier–Stokes equations, which
define many single-phase (gas or liquid, but not both) fluid flows. These equations can be
simplified by removing terms describing viscous actions to yield the Euler equations. Further
simplification, by removing terms describing vorticity yields the full potential equations.
Finally, for small perturbations in subsonic and supersonic flows (not transonic or hypersonic)
these equations can be linearized to yield the linearized potential equations.

CFD is one of the most effective techniques to characterize flow fields, given that the
simulation data are experimentally validated to prove, extend, and refine the formulated
models. This has stimulated the development of experimental fluid dynamics (EFD) involving
methods such as Laser–Doppler anemometry (LDA), particle image velocimetry (PIV), or
invasive electro diffusion measurement (EDM). The experimental set-up for such
investigations should be constructed most similarly to the real system studied. This has proven
valuable in recent studies where CFD simulations validated by experiments were found highly

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reliable and accurate. Today, the application of CFD is as a suitable tool to determine flow
fields, transport phenomena, energy consumption, and substrate uptake, and to identify
optimum operation settings for the process investigated. In this regard, the present article gives
a general overview on the fundamentals of CFD simulation and its application to real case
studies.

1.2. Why is CFD Modeling and Simulation important?

CFD modeling and simulation radically transform the design and manufacturing process.
CFD simulation can:
1.2.1. Reduce manufacturing costs
A significant application of CFD simulation is in the manufacturing industry. CFD modeling
and simulation gives insights into how well a design model will reciprocate under extreme
surrounding conditions before doing it in the real world.

1.2.2. Develop a design without expensive testing

In aerospace and many other industries, components are tested in a wind tunnel or
experimented on for their performance. CFD modeling and simulation tools dramatically
simplify this process by simulating a computer’s design. Several iterations of a component are
simulated without manufacturing them. On achieving an optimum design that matches the
customer requirements and market standards, the manufacturing process is initiated.

1.2.3. Understand how a product will work without building it

CFD simulation is also an excellent way of prototyping products. CFD modeling and
simulation tools can help understand if the assumptions about product performance are valid.
The CFD simulation results are helpful visual representations for in-depth research and the
study of different fluid-flow phenomena.

1.3. The Need for CFD

Applying the fundamental laws of mechanics to a fluid gives the governing equations for a
fluid. The conservation of mass equation is
∂ρ ∂t + ∇ · (ρV~ ) = 0
and the conservation of momentum equation is
ρ ∂V~ ∂t + ρ(V~ · ∇)V~ = −∇p + ρ~g + ∇ · τij

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These equations along with the conservation of energy equation form a set of coupled,
nonlinear partial differential equations. It is not possible to solve these equations analytically
for most engineering problems. However, it is possible to obtain approximate computer-based
solutions to the governing equations for a variety of engineering problems. This is the subject
matter of Computational Fluid Dynamics (CFD).

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CHAPTER 2

2. CFD SIMULATION IN CHEMICAL INDUSTRIES

2.1. CFD simulation can be applied in chemical industries to analyse and optimize the design
of chemical processes, such as reactors, distillation columns, and heat exchangers. CFD can be
used to predict the flow of fluids, heat transfer, and chemical reactions in these processes. CFD
can also be used to optimize the design of chemical plants, such as the layout of pipes and
equipment, to maximize efficiency and safety. CFD can also be used to analyse the
environmental impact of chemical processes, such as the release of pollutants into the
atmosphere, air pollution ventilation, and combustion pollutants prediction.

CFD is widely utilized in various professions and sectors, including aerospace, chemical
production, polymer processing, petroleum exploration, and medical research. Chemical
engineers now routinely study and model the interaction between fluid flow and chemical
processes using the power of computational fluid dynamics simulation. CFD, for example, may
be applied to reactive flows, combustion and heat transfer, and mass transfer. Using CFD tools
will assist a chemical engineer in better understanding physical and chemical processes,
resulting in significant process and product advancements in the industry.

The use of CFD in the chemical engineering and process industries has reduced the cost of
product and process development and optimization activities, shortened time to market,
improved design reliability, increased conversions, and yields, and aided in the resolution of
environmental, health, and right-to-operate issues. Chemical engineering CFD simulation
includes models prepared for flow splits, reactor vessels, gaseous emissions, dosing points,
process optimization, membrane impact, contaminated waste, and hazardous emissions. 3D
modeling can confirm whether a new chemical engineering design meets objectives or
examines why a poorly operating system fails.

The chemical industry is full of applications for CFD, from chemical reactors to investigate
fluid flow parameters in each cell to the simulation
of evaporation and condensation phenomena in different situations and to melting and
solidifying fluids. Fluid dynamics are fundamental to most facets of the Chemical sector.
Although real prototypes are standard for later stages of

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development, design, and optimization during earlier stages can be significantly accelerated
with CFD studies.

2.2. CFD on Simulating Different Reactors

Computational fluid dynamics (CFD) is a powerful tool for simulating different types of
reactors. It can be used to simulate the flow of fluids, heat transfer, and chemical reactions in
a variety of reactors. CFD can be used to study the performance of different reactor designs,
optimize the design of existing reactors, and predict the behaviour of new reactor designs.
CFD can also be used to analyze the safety and environmental impact of different reactor
designs. CFD can be used to simulate a wide range of reactors, including chemical reactors,
nuclear reactors, and biological reactors.

Reactor design includes several vital facets: Phase, or state of the reactants and products,
reaction type (single, multiple, parallel series, or polymerization); whether a catalyst is
involved; flow distribution and mixing; transport of the species; and mode of operation (i.e.,
batch, semi-batch or continuous). The underlying transport processes are crucial—fluid flow,
heat transfer, mass transfer, and reactions—where CFD simulation can add substantial value.

2.3. CFD to Predict pollutant in Combustion Chamber

Knowledge about the system’s fluid mechanics must be understood to simulate combustion.
All transportation phenomena should be correctly represented in such models. Chemical
reaction schemes must also be known to estimate the formation of combustion products and
species and predict the ignition, stabilization, and extinction of flames. Radiation also occurs
due to the presence of soot formed during combustion, and there is radiative heat transfer from
the wall of the combustion chamber. Fuel combustion is a multiphase system, with liquid fuels
being a two-phase system consisting of liquid and gas phases and solid fuel being a three-phase
system. The challenges faced are to model the breaking up of the liquid fuel, its reaction, and
the distribution of the reactants in three-dimensional spatial systems. These models, which
form part of CFD, have become an indispensable tool for combustion modeling.

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CHAPTER 3

3. CFD SIMULATION ALGORITHM

3.1. HOW DOES CFD SIMULATION WORK?

The CFD simulation process consists of 5 steps, explained briefly below:
3.1.1. Importing the CAD geometry
Every CFD simulation process involves importing a geometry model into the CFD
software. The geometry is typically an assembly designed in a parametric 3D CAD
program. Once imported, it forms the basis of your CFD modeling and simulation
work.
3.1.2. Setting up domain
The next step is to assist the CFD simulation software with the fluid properties. Here,
a user provides property inputs such as density, thermal conductivity, and viscosity—
the more accurate your fluid properties, the better your CFD modeling.
3.1.3. Create boundary conditions
The next phase is to define the boundary conditions. These boundary conditions are
typically needed to describe the fluid flow at the inlet and outlet of the model.
3.1.4. Analysis
In the analysis phase, the CFD modeling and simulation tool solves the partial
differential equations based on the set parameters. The speed of a CFD sim ulation
depends on the computer resources. Today, with parallel and cloud computing
solutions, the time taken to complete a CFD simulation has been reduced from days
to hours.
3.1.5. Optimize design model based on results
After completing the simulation, the data is run through various post-processing
programs to visualize the fluid flow results as contours, streamlines, or streak lines,
per user preference. Based on this information, the component is optimized to suit the
design objectives.

3.2. The steps of solving a problem by computational fluid dynamics or CFD method are
as follows:
1. Pre-processing
2. processing
3. Post-processing

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3.2.1. PRE-PROCESSING
Pre-Processing is the first step in solving CFD analysis. The set of works done before entering
the Fluent software (also other analysis software) and in Computer-Aided Design (CAD)
environments such as design modeler, Space Claim, SolidWorks, CATIA, etc., and Meshing
environments are the pre-processing stage.
In this step, we must do the following set of tasks:
• Create Geometry
• Create Mesh
• Physic Setting
• Select Solver
• Identify Models
• Identify Materials
• Specify Boundary Conditions

3.2.2. PROCESSING
After completing the Pre-Processing stage, we enter the next part, the processing or SOLVE
stage. In this step, we do the following:

• Select Computing Algorithm

• Specify Discretization Method
• Specify Convergence Monitoring Criteria

3.2.3. POST-PROCESSING
Finally, you can view, Extract, and xviiinalyse the generated data and Results Checked, in the
post-processing phase. Another name for this environment is CFD-Post or Result. At this point,
the analyst can double-check the findings and develop conclusions based on them. Static or
animated graphics, graphs, and tables are examples of ways to convey the results.

In summary, problem Identification (Define problem-solving goals, and specify the domain of
the solution); We simulate specifying the geometry in the CFD modeling procedure. Then
discretize the geometry into a computational grid and incorporate into a computational domain
(mesh). Physical, numerical models, beginning, and boundary conditions that characterize
entirely the issue to be addressed must be set up to compute the problem’s solution.
It achieves the answer by executing the numerical method after the simulation setup. Finally,
you extract them in the post-processing step the results.

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Fig. 1 CFD SIMULATION ALGORITHM

Fig. 2 CFD SIMULATION STAGES

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CHAPTER 4

4. CFD SOFTWARE

4.1. SOFTWARE USED CFD SIMULATION & ANALYSIS:

• Simcenter STAR-CCM+ is a computational fluid dynamics (CFD) software used
to simulate products operating under real world conditions.

Simcenter STAR-CCM+ Software is a Computational Aided Engineering (CAE) solution for

solving multidisciplinary problems in both fluid and solid continuum mechanics, within a
single integrated user interface.
Simcenter STAR-CCM+ provides the world's most comprehensive engineering physics
simulation inside a single integrated package. Much more than just a CFD solver, Simcenter
STAR-CCM+ is an entire engineering process for solving problems involving flow (of fluids
or solids), heat transfer, and stress. It provides a suite of integrated components that combine
to produce a powerful package that can address a wide variety of modeling needs.

Fig. 3 CFD SIMULATION PROCEDURE

The Simcenter STAR-CCM+ simulation environment offers all stages required for carrying
out engineering analyses, including:

• Import and creation of geometries

• Mesh generation
• Solution of the governing equations
• Analysis of the results
• Automation of the simulation workflows for design exploration studies
• Connection to other CAE software for co-simulation analysis

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4.2. MODELING GEOMETRY

For many simulations in Simcenter STAR-CCM+, the first step involves preparing the
geometry of the case under investigation. This geometry could come from a model that was
prepared previously in a CAD package, or could be created directly using the 3D-CAD module
within Simcenter STAR-CCM+.
In general, a Simcenter STAR-CCM+ analysis requires one or more geometry parts from
which you define the spatial construction of the regions. Simcenter STAR-CCM+ allows you
to create geometry parts directly using the built-in 3D-CAD modeler, or import geometry from
a wide range of source formats.

4.3. MESHING
A mesh is a discretized representation of a geometric domain. This domain can include real-
world geometry, its content, and its surrounding environment.
Simcenter STAR-CCM+ solvers find solutions to physics equations at the locations defined by
the mesh. For Finite Volume (FV), Simcenter STAR-CCM+ computes values at cell centers;
for Finite Element (FE), Simcenter STAR-CCM+ computes values at element nodes (solid
mechanics) or edges (electromagnetism). Simcenter STAR-CCM+ can generate meshes
suitable for both types of solver.
The physical space that you want to solve within is called the simulation domain. Generating
a mesh typically involves creating a suitable simulation domain. There are two types of flow
that require different approaches when creating the simulation domain: internal flow, such as
a flow in a pipe, and external flow, such as the flow around and through a car.

4.4. POST-PROCESSING
Simcenter STAR-CCM+ allows you to post-process the solution after each iteration or time-
step, (while the simulation is running), as well as when the simulation completes. For this
reason, you generally create post-processing objects before running the simulation. Post-
processing objects are also known as analysis objects.
All simulation data is stored in field functions. Field functions give you access to mesh data,
geometry data, data computed by solvers, and to any data that is derived from solver data.

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CHAPTER 5

5. CYCLONE SEPARATOR

Fig. 4 Schematic Diagram of Cyclone Separator

Cyclones are devices that employ a centrifugal force generated by a spinning gas stream to
separate particles from the carrier gas. Their simple design, low capital cost and nearly
maintenance-free operation make them ideal for use as precleaners for more expensive final
control devices such as bag30 houses or electrostatic precipitators. Cyclones are particularly
well suited for high temperature and pressure conditions because of their rugged design and
flexible component materials
Gas–solid cyclones are frequently used in industrial processes with the primary purpose of
two–phase flow separation, i.e., separation of a high-density phase from a lower-density carrier
phase, using a turbulent swirling flow. The state-of-the-art industrial cyclone designs are able
to operate at elevated temperatures and moderate-to-high loading of solids, while at the same
time meeting the required separation efficiency and having low investment and maintenance
costs. This has led to the frequent use of cyclones as the only/initial stage of separation and
cleaning processes rather than other industrial separators, e.g., bag filters, electrostatic
separators, etc. Examples of cyclone separator applications in demanding industrial process
conditions are high temperature gas–solid heat exchangers, e.g., in the cement industry;
gasification and combustion of solid fuels; coal pyrolysis and gas–solid separation in
circulating fluidized beds (CFBs). With the main purpose of gaining improved insight into the

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flow physics and factors affecting the two important performance parameters of cyclones, i.e.,
pressure drop and separation efficiency, single–phase and gas–solid flows in pilot-scale
cyclones have been extensively studied with the use of experimental methods. Accordingly, a
number of simple semi-empirical/-theoretical models have been proposed to address the flow
field and performance of cyclones and some of them are still being used in cyclone design and
optimization.
In the past two decades, computational fluid dynamics (CFD) has been broadly applied to
predict the separation efficiency and pressure drop of cyclone separators and to optimize
cyclone designs. Compared to the models based on classical cyclone theory, three-dimensional
CFD simulations have the advantage of considering the unsteadiness and asymmetry of cyclone
flow. On the other hand, the presence of strong swirl and anisotropic turbulent flow as well as
adverse pressure gradients in the cyclones has driven the CFD simulation studies to use more
advanced turbulence models, e.g., the Reynolds stress transport model (RSTM) and large eddy
simulation (LES), as well as higher-order discretization techniques, that are capable of
capturing these specific flow physics. These models/techniques, however, are computationally
demanding compared to the more commonly used models, e.g., k–e. Furthermore, with the
addition of extra physics to the CFD simulation of cyclones, e.g., presence of particles at high
loadings and gas–solid heat transfer, additional complications will arise with respect to the
solution’s accuracy and stability. In this paper, a brief introduction to the basic operation
principles of cyclones at ambient and elevated temperatures is initially presented.
Subsequently, the existing CFD simulation studies of cyclones are summarized and discussed
based on the operating temperature, i.e., ambient and elevated temperature, and with a special
focus on the studies with moderate-to-high loading of particles. The paper highlights specific
process parameters that are able to be captured by the CFD simulations at these temperatures.
Furthermore, the important sub-models utilized as well as specific challenges that may be
encountered in such CFD simulations are addressed.
Engineers are generally interested in two parameters in order to carry out an assessment of the
design and performance of a cy- 40 clone. These parameters are the collection efficiency of
particle and pressure drop through the cyclone. An accurate prediction of cyclone efficiency is
very important because an inaccuracy in the efficiency prediction may result in an inefficient
design of the cyclone separator. CFD has a great potential to predict the 45 flow field
characteristics and particle trajectories inside the cyclone as well as the pressure drop [6]. The
complicated swirling turbulent flow in a cyclone places great demands on the numerical

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techniques and the turbulence models employed in the CFD codes when modelling the cyclone
pressure drop.

5.1. Fundamentals of Gas–Solid Cyclone Separators:

The reverse-flow-type gas–solid cyclones are usually equipped with either tangential inlets,
which are the main focus in this study, or axial inlets usually referred to as swirl tubes . A
common configuration of a tangential inlet reverse–flow cyclone is schematically shown in
Figure 1a. In this type of cyclone, the swirling gas flow pattern usually consists of a “double
vortex”: an outer vortex with a downward axial velocity and an upward-moving inner vortex.
The tangential flow pattern, caused by the tangential inlet of the gas to the cyclone system, is
referred to as a “Rankine vortex”, comprised of a near-solid-body rotating flow at the core (i.e.,
tangential velocity is directly proportional to the radius) and a loss-free vortex flow (i.e.,
tangential velocity is inversely proportional to the radius) at the walls. The outer vortex
gradually loses its downward momentum in the bottom regions of the cyclone and changes its
direction, i.e., “vortex end”, to form the inner vortex. The inner vortex is led to the exit pipe,
which is usually extended to the cyclone body to separate the inner vortex from the inlet
velocity field. The axial distance from the “vortex end” location to the vortex finder is termed
the “natural turning length” . The double vortex structure is inherently unstable due to the
presence of a radial pressure gradient imposed by the vortex itself. This phenomenon is referred
to as a precessing vortex core (PVC), which causes the location of the vortex axis to oscillate
with a specific frequency. In some cyclones, in order to stabilize the vortex end position, a
vortex stabilizer is installed either under or above the dust exit location, which leads to
improved separation efficiency and desirable static pressure below the stabilizer.
The static pressure in the cyclone increases monotonically toward the walls to maintain the
equilibrium of the rotating flow pattern. This pressure gradient is also present in the boundary
layer of the cyclone walls, where the tangential velocity is small [19]. This leads to the presence
of a secondary flow, namely inwardly-directed gas flow along the walls, at the cyclone roof,
and the conical section, as depicted in Figure 1c.

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Figure (5): (a) Schematic drawing of a conical reverse-flow cyclone separator illustrating the
basic operating principle and the presence of a double vortex inside the cyclone. (b) Qualitative
patterns of axial, tangential, and radial velocity components of the gas-flow field in cyclones.
(c) The secondary flow pattern caused by the swirl and pressure gradients in the cyclone.

5.2. Performance Parameters of Cyclones:

For the main purpose of gas–solid separation, two important design parameters of reversed-
flow conical cyclones are separation efficiency and pressure drop. These parameters are
affected by the gas–solid flow field inside the cyclone, which in turn is influenced by the
cyclone’s geometrical features as well as the operating conditions. In this section, these
performance parameters are discussed and the influences of operating conditions, e.g., solids
loading and gas temperature, on cyclone performance are explained.

5.2.1. Separation Efficiency

Cyclone separators are suitable for the separation of solid particles with a size range of 2–2000
microns, which are found in many industries, e.g., heavy industrial smoke, coal dust, cement
dust, etc. When solid particles are fed to a cyclone, they are affected by two main forces: the
radially outward-directed centrifugal acceleration force, proportional to the cube of particle
diameter, and the fluid drag force applied to the particles in the opposite direction; whereas the
gravity force is reported to be of minor importance. When the Stokes law applies for the drag
force, which is often valid for solid particles in cyclones, the drag force is proportional to the
particle diameter. This indicates the dominance of the centrifugal acceleration force for larger
particles, leading to their improved separation. The larger particles experience the centrifugal
effect as soon as the gas and solids experience the rotational flow at the inlet, and subsequently,
they are pushed toward the walls and lose their momentum. Once the particles approach the

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wall, they start to move downward due to gravity and the drag force applied to them by the
downward-directed gas flow. Finally, these particles are separated at the bottom of the cyclone.

5.2.2. Pressure Loss

One of the main parameters considered in the design of industrial cyclone systems is the energy
loss, usually termed the pressure loss. The greater the reduction in the pressure loss of the
cyclone in a process, the cheaper the process cost. The overall pressure loss in a reversed-flow
conical cyclone can be separated into three part:

1. Pressure loss at the inlet;

2. Pressure loss in the separation zone;
3. Pressure loss associated with the vortex finder.
The first contributor to the pressure loss is usually of minor importance. The pressure loss in
the separation zone is mainly due to the frictional losses at the wall of the cyclone body. The
vortex finder pressure loss is due to the dissipation of the swirl dynamic pressure in the vortex
finder, which usually takes place without recovering the dynamic pressure into the static
pressure. This pressure drop is the main contributor to the overall pressure drop for single-
phase flow or dilutely loaded cyclones, and it is proportional to the square of the tangential
velocity magnitude. The vortex finder pressure loss is usually affected by the frictional pressure
loss, e.g., if the frictional pressure increases due to higher wall roughness or other operating
conditions, the vortex will be weakened, leading to the reduction of the vortex finder pressure
loss. This indicates that the contribution of different parts of pressure loss changes once the
operating conditions of the cyclone change, e.g., an increase in the temperature or the solids
loading.

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CHAPTER 6

6. CFD MODEL OF CYCLONE SEPARATOR

6.1. GEOMETRY OF CYCLONE

Fig. 6. Geometry of cyclone.

Table 1. Dimensions of the cyclone

separator
Dimension in mm value
Cyclone diameter, D 210
Vortex finder, De 80
Inlet height, a 90
Inlet width, b 50
Depth of vortex finder(diptube), S 100
Cyclone height, H 925
Cyclone body height, h 775
Dust outlet diameter, B 80

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6.2. CAD MODELING OF CYCLONE SEPARATOR

The actual model of cyclone separator was designed as a CAD model in STAR CCM+ software
as per dimensions provided. In STAR CCM+, the model was designed in part modelling
workbench.

Fig.7. Actual Cyclone Separator Model.

Fig.8. CAD Model Actual Cyclone Separator.

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Fig.9. Front & Top View of Cyclone Separator.

6.3. MESHING CAD MODEL

The mesh settings for the simulation to generate a polyhedral volume mesh. For this simulation,
the polyhedral mesher is used in conjunction with the advancing layer mesher to build a mesh
suitable for predicting the swirling flow inside the cyclone.
In this simulation, in order to resolve the swirling motion of the fluid, you apply a volumetric
mesh refinement through the middle of the cyclone. You also apply refinement on the inlet. All
the bodies were then combined into a multi-body part in order to produce a single mesh that
contains all the bodies of cyclone separator. In order to generate the mesh, meshing parameters
were specified, namely physics preference, solver preference, inflation, sizing and method used
for meshing. Thus, the mesh was generated. The statistics representing number of nodes and
number of elements of the meshed component denotes the quality of mesh.

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Table 2. Mesher selected for mesh operation.

Group Mesher
Surface Mesher Surface Remesher
Core Volume Mesher Polyhedral Mesher
Optional Boundary Layer Mesher Advancing Layer Mesher

Table 3. Properties for meshing operation

NODE PROPERTY SETTING

Base Size Value 0.0105 m

Target Surface Size Percentage of Base 80

Minimum Surface Size Percentage of Base 25

Surface Curvature # Pts/circle 72

Surface Growth Rate User Specified 1.3

Number of Prism Layers Number of Prism Layers 2

Prism Layer Stretching Prism Layer Stretching 1.2

Size Type Absolute
Prism Layer Total Thickness
Absolute Size 0.00105 m
Volume Growth Rate Volume Growth Rate 1.5

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Fig.10 Meshed Model of Cyclone Separator

• Final computational mesh comprised polyhedral cells and two prismatic cells (of total
thickness 5mm) at all wall boundaries.
• Mesh count (trimmer + 2 prism layers on the walls):
Cells: 351021 Faces: 2335851 Vertices: 1987030

Table 4. Mesh count of cyclone & diptube.

------------------------ Cyclone diptube

Cells 259797 91823

faces 1729659 607845

verts 1469561 517540

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6.4. PHYSICS SETUP

Physics models define the physical variables and phenomena in the simulation. In this study,
the Reynolds stress turbulence model is used to limit the simulation run time.
For the turbulent flow in a cyclone the key to the success of CFD lies with the accurate
description of the turbulent behaviour of the flow. To model the swirling turbulent flow in a
cyclone separator, there are a number of turbulence models available in STAR CCM+. These
range from the standard K-OMEGA model to the more complicated Reynolds stress model
(RSM).
The Reynolds stress model requires the solution of transport equations for each of the Reynolds
stress components as well as for dissipation transport without the necessity to calculate an
isotropic turbulent viscosity field. The Reynolds Stress turbulence model yields an accurate
prediction of swirl flow pattern, axial velocity, tangential velocity and pressure drop on cyclone
simulations.
The finite volume method has been used to discretize the partial differential equations of the
model using the SIMPLE 110 method for pressure-velocity coupling and the Second Order
Upwind scheme to interpolate the variables on the surface of the control volume. The
segregated solution algorithm was selected. The Reynolds stress (RSM) turbulence model was
used in this model due to the anisotropic nature of the turbulence in 115 cyclones. Standard
Fluent wall functions were applied and high order discretization schemes were also used.

Table 5. Physics model setup for simulation

Group Box Model
Space Three-Dimensional (selected automatically)
Material Gas
Flow Segregated Flow
Equation of State Constant Density
Time Steady
Turbulent
Viscous Regime Reynold-Averaged Navier-Stokes (selected
automatically)
Reynolds stress turbulence
Solution Interpolation
Reynolds-Averaged Turbulence
Wall Distance (selected automatically)
All y+ Wall Treatment (selected
automatically)

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6.4.1 GAS–SOLID TWO-PHASE FLOW MODEL

In this study, particle phase volume fraction is less than 10%. To calculate the trajectories of
particles in flow, the Lagrangian approach without considering the particle interactions, which
is called discrete phase model (DPM) was used to track individual particles through the
continuum fluid.

The particle force balance equation in this case in x, y and z directions, respectively, can be
written as:

where v2 p/r0 and upvp/r0 represent centrifugal and Coriolis components of particle
acceleration, respectively. The first term on the right-hand side is the drag force per unit particle
mass and

Here Re is the relative Reynolds number defined as Re = (dp/up − u )/, u is the fluid phase
velocity, uF is the particle velocity, is the dynamic viscosity of the fluid, is the fluid density, p
is the density of the particle, and dp is the particle diameter.

The drag coefficient can be calculated from:

where a1, a2 and a3 are constants that apply to smooth spherical particles over several ranges
of Re given by Morsi and Alexander

The discrete random walk (DRW) model was used to model the turbulent dispersion of
particles. In this model, the fluctuating velocity components are discrete piecewise constant
functions of time. Their random value is kept constant over an interval of time given by the
characteristic lifetime of eddies.

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6.5. BOUNDARY CONDITIONS

• Pressure outlet: - atmospheric pressure

• Rest all boundaries treated as no-slip walls

6.6. OPERATING CONDITIONS

• Mass flow rate: - 0.0424 kg/s

GAS: - AIR

• Density: - 1.18415 kg/m^3

• Dynamic viscosity: - 0.0185 cP

SOLID PARTICLE: - ALUMINIUM

• Density: - 2702.0 kg/m^3

• Particle diameter: - 0.1 µm

6.7. MULTI-PHASE FLOW ANALYSIS

In this analysis, initially material properties of dust particles were specified like density,
particle size, mass fraction etc. In multiphase both air and dust particles were considered.
• VELOCITY CONTOUR OF CYCLONE.

Fig 11. Velocity contour view at different planes of cyclone.

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• PRESSURE CONTOUR OF CYCLONE.

Fig 12. Pressure contour view at different planes of cyclone.

Fig 12. Pressure contour view at different planes of cyclone.
• VELOCITY VECTOR OF CYCLONE.

Fig 13. Velocity Vector view at different planes of cyclone.

Fig 12. Pressure contour view at different planes of cyclone.

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• STREAMLINE FLOW

Fig 14. Streamline Flow of cyclone Separator.

Fig 12. Pressure contour view at different planes of cyclone.
6.8. POST- PROCESSING OF MULTI-PHASE FLOW.
In post-processing the different parameters of cyclone are analysed using STAR-CCM+
software which have inbuild feature of analysing different parameters. Simcenter STAR-
CCM+ allows to post-process the solution after each iteration or time-step, (while the
simulation is running), as well as when the simulation completes.

6.8.1. Axial Velocity of Cyclone Separator.

Axial velocity has a significant influence on the downward transmission and separation of
particles in the cyclone separator; axial velocity can be divided into upward flow (upward
direction) and downward flow (downward direction).
Here axial velocity is defined at a line drawn in cyclone as shown
in fig. below.

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Fig 15. Axial Velocity distribution at line probe of cyclone separator

Fig 12. Pressure contour view at different planes of cyclone.
6.8.2. Tangential Velocity of Cyclone Separator
Tangential velocity of particle and gas flow are equal to each other i.e., no slip between the
particles and gas flow in the tangential direction.
Here axial velocity is defined at a line drawn in cyclone as shown in fig. below.

Fig 16. Tangential Velocity distribution at line probe of cyclone separator

Fig 12. Pressure contour view at different planes of cyclone.

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6.8.3. velocity(magnitude) distribution.

Fig 17. Velocity(magnitude) distribution at line probe of cyclone separator

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CHAPTER 7

7. RESULTS
Two performance parameters were extracted from the CFD calculations, viz. the pressure drop
and the collection efficiency of cyclone separator with respect to different particle size. Also,
the Mass average Velocity and Surface Integral of Pressure at cyclone inlet and diptube outlet
is computed using STAR-CCM+ software.

7.1. Pressure drops.

The pressure drop was estimated from the difference between the total pressure averaged at the
inlet and the outlet plane of the cyclone geometry. Cyclone pressure drop associated with the
operation of the cyclone is a major factor to be considered in the design of a cyclone collection
system.
Difference of Total Pressure: Inlet/Outlet
-------------------------------------------------
Total Pressure Drop -4.144073e+02 (Pa)

7.2. Mass Average Velocity.

Mass-average velocity is the average velocity of all the particles in a moving medium based on
their mass. It is the ratio of the total momentum in the medium to the total mass of the medium.

Mass averaged velocity

Part Value (m/s)
cyclone: inlet 7.138400e+00
diptube: outlet 1.427899e+01
---------------------------------------
Total: 1.092968e+01

7.3. Surface Integral of Pressure.

Surface Integral of Pressure

Part Value (N)
cyclone: inlet 2.585896e+00
diptube: outlet -3.371509e-03
---------------------------------------
Total: 2.582525e+00

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7.4. Collection Efficiency of Cyclone Separator.

The collection efficiency of cyclone separator is defined as the fraction of particles of a given
size collected in the cyclone, compared to those of that size going into the cyclone. The capacity
of the cyclone to collect particles is measured by its efficiency Ș, defined as the fraction of the
inlet flow of solids separated in the cyclone. Since a cyclone typically collects a wide range of
particle sizes, it is common to work also with different efficiencies, each defined for a particular
and limited range of particle sizes.
7.4.1. For aluminium particle having diameter 0.1 µm
Inlet: 3.920000e+02 element
Outlet: 1.300000e+01 element
((${InletReport}-${OutletReport})/${InletReport}) *100 = 9.668367e+01

Collection Efficiency = 96.68% --------------- for Al particles

For particle diameter = 0.005 µm
Collection Efficiency = 85% --------------- for Al particles
For particle diameter = 0.015 µm
Collection Efficiency = 89.23% --------------- for Al particles
For particle diameter = 0.02 µm
Collection Efficiency = 90.65% --------------- for Al particles
For particle diameter = 0.5 µm
Collection Efficiency = 97.33% --------------- for Al particles
For particle diameter = 1 µm
Collection Efficiency = 99.89% --------------- for Al particles

Collection efficiency

1 µm

0.5 µm

0.02 µm

0.015 µm

0.005 µm

0.1 µm

0.75 0.8 0.85 0.9 0.95 1

0.1 µm 0.005 µm 0.015 µm 0.02 µm 0.5 µm 1 µm

Collection efficiency 0.9668 0.85 0.8923 0.9065 0.9733 0.9989

Fig 18. Variation of collection efficiency based on particle diameter

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CONCLUSION
• Cyclones are reliable devices widely used in industry. There are many parameters
which must be considered when designing a cyclone including geometry of the cyclone,
flow rate and inlet geometry.
• Cyclone separators are used to separate dust particulates from air, gas or liquid stream.
Among all the dust collectors, cyclone separator has proved to be the most efficient
device. The overall performance of cyclone separator depends largely on the inner and
outer vortex formed by air and dust particles respectively. This has necessitated efforts
to concentrate on exploring the basic flow physics in the cyclone separator. The results
indicate that the efficiency of cyclone separator depends upon collection of dust
particles.
• Separation in cyclones is favourable with large particles that would normally be entirely
separate, the fluid, in the output will contain only particles smaller than the critical
diameter.
• The efficiency of the separation process increases with particle size solids involved in
the separation operation, the size of solid particles which will be separated is a very
important factor in choosing the cyclone type.
• If the particle size is larger and the sectional area of entry into cyclone is smaller, the
separation efficiency of the cyclone is higher.
• collection efficiency of cyclone separator increases with increasing particle mean
diameter and density; increasing gas tangential velocity; decreasing cyclone diameter;
increasing cyclone length; extraction of gas along with solids through the cyclone legs.
• Thus, a promising conclusion can be drawn from these research is that CFD analysis
could be used to predict the overall performance of the cyclone separator, as a cost-
effective tool in order to obtain clean air at the outlet of the separator.

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REFERENCES

1. Simcenter STAR-CCM+: User guide, tutorials, knowledge base, and tech support,
https://docs.sw.siemens.com/document...tml/index.html
2. J. Jiao, Y. Zheng, G. Sun, J. Wang, Study of the separation efficiency and the flow field
of a dynamic cyclone, Sep. Purif. Technol. 49 (2006) 157–166.
3. Mehdi Azadi, Mohsen Azadi, Ali Mobebbi, A CFD study of the effect of cyclone size
on its performance parameters October 2010 Journal of Hazardous Materials 182(1-
3):835-41.
4. Prachi k. Ithape, Dr. shivprakash bghawtrao brave, Effect of Geometric Parameters on
the Performance of Cyclone Separator using CFD Article · March 2017.
5. ANALYSIS OF CYCLONE COLLECTION EFFICIENCY Simona Lizica
PARASCHIV+, Spiru PARASCHIV+ + DUNAREA DE JOS UNIVERSITY, Galati,
Romania.
6. Jolius Gimbun University Abdullah Luqman Chuah. Fakhru'l-Razi National Defence
University of Malaysia, A CFD Study on the Prediction of Cyclone Collection
Efficiency Article in International Journal for Computational Methods in Engineering
Science and Mechanics · May 2005 DOI: 10.1080/15502280590923649
7. The effect of particle size and input velocity on cyclone separation process m. Marinuc1
f. Rus1
8. CFD Modeling of Gas–Solid Cyclone Separators at Ambient and Elevated
Temperatures Mohammadhadi Nakhaei 1,2, *, Bona Lu 3,4, Yujie Tian 3,4, Wei Wang
3,4, Kim Dam-Johansen 1 and Hao Wu 1
9. CFD Modeling of Gas–Solid Cyclone Separators at Ambient and Elevated
Temperatures Mohammadhadi Nakhaei 1,2, *, Bona Lu 3,4, Yujie Tian 3,4, Wei Wang
3,4, Kim Dam-Johansen 1 and Hao Wu 1..

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