Analysis of swirling flow in hydrocyclones operating under dense regime

There are many circumstances where hydrocyclone performance and dense flow are intertwined, such as for example when feed solids flow exceeds hydrocyclone capacity during continuous operations. The work reported here, which is part of an ongoing research effort to develop a robust CFD model for prediction of hydrocyclone performance, focuses on hydrocyclone operation under high solids concentration. The paper presents the basic physics framework that accounts for solid–liquid and solid–solid interactions under hydrocyclone’s swirling flow. Operating conditions that are past the transition from spray to rope regime are deliberately chosen for this purpose. Model predictions are validated by comparison with solids split and separation curves measured on a 100 mm diameter hydrocyclone. CFD model predictions permit taking an insightful look at the inside of a hydrocyclone under extreme operating conditions, which would be difficult to achieve experimentally. Velocity profiles, G-force distribution and distribution of solids predicted by CFD are bound to lead to a better understanding of the separation that takes place inside a hydrocyclone, which may eventually help improve hydrocyclone design and performance.

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► We examine by means of experiments and CFD the behavior of hydrocyclones.
► We focus on the effect of increasing feed solids content.
► CFD allows understanding the modifications of separation performances.
► Hydrocyclone evolves from classifier to thickener and finally flow splitter.