Cyclone optimization by COMPLEX method and CFD simulation

• Optimization of cyclones by multi-objective optimization and CFD techniques
• COMPLEX method for geometrical optimization of process equipment
• CFD modeling and simulation with multi-fluid concept on Eulerian framework
• New design of cyclone with high collection efficiency and low pressure-drop
• Prediction of the operational performance of cyclones from computational fluid dynamics analysis

The most important performance parameters in cyclone design are the pressure drop and collection efficiency. In general, the best designs provide relatively high efficiency with a low pressure drop. In this study, the multi-objective optimization of cyclones operating with a low particle loading (15 g/m3) and small particle diameter (5 μm to 15 μm) is performed using the COMPLEX algorithm, a constrained derivative-free optimization method. The objective function is formulated to maximize the collection efficiency with a maximum pressure drop restriction. All objective function evaluations are carried out by CFD simulation with the code CYCLO-EE5 based on the Eulerian multi-fluid concept. An optimized design cyclone is obtained applying the proposed methodology in a feasible time (≈ 15 days of computational effort). Also, in comparison with the Stairmand and Lapple cyclones the collection efficiency was 3.5% and 9.2% higher and the pressure drop was 6.3% and 11.4% lower, respectively. The increase in the collection efficiency with lower pressure drop was due to the displacement of the tangential velocity peak toward the wall and an increase in the tangential velocity near the wall.

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