Skip to main content
SpringerLink
Log in

Numerical study of erosion in dense gas–solid flow in new generation cyclones using two-way and four-way coupling

  • Published:
Computational Particle Mechanics Aims and scope Submit manuscript

Abstract

Cyclones are generally utilized in the industry to separate solid particles from gas streams. A solid–gas taking apart system with a turbulent swirling flow that happens in the cyclone will create erosion on the cyclone wall. The erosion will make a fall in cyclone effectiveness and augment the upholding cost. In this examination, the modeling of erosion produced by solid particles in cyclones of a new design for gas–solid two-phase dense flow along with two-way and four-way coupling effects was done using computational fluid dynamics. The effect of fluid flow velocity parameters, inlet particle diameters, and solid loading at the erosion rate (ER) was discussed. The distribution of pressure contours, axial velocity, and tangential velocity were compared in all couplings. Reynolds stress turbulence model was utilized to solve the flow equation. The DDPM-KTGF technique was used to calculate the particle–particle interactions in the dense discrete phase, and the erosion prediction was assessed by using the Oka model. The outcomes show that the ER rises with the rise in the velocity and diameters of the particles, but the rise in the solid loading ratio in the four-way coupling forecasts the erosion reduction. The cushioning efficacy promoted by inter-particle collisions reduces the ER.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig.4
Fig.5
Fig.6
Fig.7
Fig.8
Fig.9
Fig.10
Fig.11
Fig.12

Similar content being viewed by others

References

  1. Alexander RM (1949) Fundamentals of cyclone design and operation. Proc Aust Inst Min Met 152:203

    Google Scholar 

  2. Stairmand CJ (1951) The design and performance of cyclone separators. Trans Inst Chem Eng 29:356–383

    Google Scholar 

  3. Elsayed K, Lacor C (2011) The effect of cyclone inlet dimensions on the flow pattern and performance. Appl Math Model 3F5(4):1952–1968

    Article  Google Scholar 

  4. Cortes C, Gil A (2007) Modeling the gas and particle flow inside cyclone separators. Prog Energy Combust Sci 33(5):409–452

    Article  Google Scholar 

  5. Avci A, Karagoz I, Surmen A (2013) Development of a new method for evaluating vortex length in reversed flow cyclone separators. Powder Technol 235:460–466

    Article  Google Scholar 

  6. Qian F, Zhang M (2007) Effects of the inlet section angle on the flow field of a cyclone. Chem Eng Technol Ind Chem Plant Equip Process Eng Biotechnol 30(11):1564–1570

    Google Scholar 

  7. Qian F, Wu Y (2009) Effects of the inlet section angle on the separation performance of a cyclone. Chem Eng Res Des 87(12):1567–1572

    Article  Google Scholar 

  8. Erdal FM, Shirazi SA (2006) Effect of the inlet geometry on the flow in a cylindrical cyclone separator. J Energy Res Technol 128(1):62–69

    Article  Google Scholar 

  9. Zhao B, Shen H, Kang Y (2004) Development of a symmetrical spiral inlet to improve cyclone separator performance. Powder Technol 145(1):47–50

    Article  Google Scholar 

  10. Wan G, Sun G, Xue X, Shi M (2008) Solids concentration simulation of different size particles in a cyclone separator. Powder Technol 183(1):94–104

    Article  Google Scholar 

  11. Wang B, Xu DL, Chu KW, Yu AB (2006) Numerical study of gas–solid flow in a cyclone separator. Appl Math Model 30(11):1326–1342

    Article  Google Scholar 

  12. Xiang R, Lee K (2001) Exploratory study on cyclones of modified designs. Part Sci Technol 19(4):327–338

    Article  Google Scholar 

  13. Chuah T, Gimbun J, Choong TS (2006) A CFD study of the effect of cone dimensions on sampling aerocyclones performance and hydrodynamics. Powder Technol 162(2):126–132

    Article  Google Scholar 

  14. Xiang R, Park S, Lee K (2001) Effects of cone dimension on cyclone performance. J Aerosol Sci 32(4):549–561

    Article  Google Scholar 

  15. Yoshida H, Fukui K, Yoshida K, Shinoda E (2001) Particle separation by Iinoya’s type gas cyclone. Powder Technol 118:16–23

    Article  Google Scholar 

  16. Qian F, Zhang J, Zhang M (2006) Effects of the prolonged vertical tube on the separation performance of a cyclone. J Hazard Mater 136:822–829

    Article  Google Scholar 

  17. Kaya F, Karagoz I (2009) Numerical investigation of performance characteristics of a cyclone prolonged with a dipleg. Chem Eng J 151:39–45

    Article  Google Scholar 

  18. Karagoz I, Atakan A, Surmen A, Sendogan O (2013) Design and performance evaluation of a new cyclone separator. J Aerosol Sci 59:57–64

    Article  Google Scholar 

  19. Safikhani H, Mehrabian P (2016) Numerical study of flow field in new cyclone separators. Adv Powder Technol 27:379–387

    Article  Google Scholar 

  20. Safikhani H, Allahdadi S (2020) The effect of magnetic field on the performance of new design cyclone Separators. Adv Powder Technol 31:2541–2554

    Article  Google Scholar 

  21. Safikhani H, Zamani J, Musa M (2018) Numerical study of flow field in new design cyclone separators with one, two and three tangential inlets. Adv Powder Technol 29:611–622

    Article  Google Scholar 

  22. Safikhani H, Esmaeili F, Salehfard S (2020) Numerical study of flow field in new design dynamic cyclone separators. IJE Trans B Appl 33(2):357–365

    Google Scholar 

  23. Modabberifar M, Nazaripoor H, Safikhani H (2021) Modeling and numerical simulation of flow field in three types of standard new design cyclone separators. Adv Powder Technol 32(11):4295–4302

    Article  Google Scholar 

  24. Kozolub P, Klimanek A, Bialecki RA, Adamczyk WP (2017) Numerical simulation of a dense solid particle flow inside a cyclone separator using the hybrid Euler–Lagrange approach. Particuology 31:170–180

    Article  Google Scholar 

  25. Hwang IS, Jeong HJ, Hwang J (2019) Numerical simulation of a dense flow cyclone using the kinetic theory of granular flow in a dense discrete phase model. Powder Technol 356:129–138

    Article  Google Scholar 

  26. Finnie I (1960) Erosion of surfaces by solid particles. Wear 3(2):87–103

    Article  Google Scholar 

  27. Oka YI, Okamura K, Yoshida T (2005) Practical estimation of erosion damage caused by solid particle impact: part 1: effects of impact parameters on a predictive equation. Wear 259(1–6):95–101

    Article  Google Scholar 

  28. Oka YI, Yoshida T (2005) Practical estimation of erosion damage caused by solid particle impact: part 2: mechanical properties of materials directly associated with erosion damage. Wear 259(1–6):102–109

    Article  Google Scholar 

  29. Danyluk S, Shack WJ, Park JY (1980) The erosion of a type 310 stainless steel cyclone from a coal gasification pilot plant. Wear 63(1):95–104

    Article  Google Scholar 

  30. Sedrez TA, Decker RK, da Silva MK, Noriler D, Meier HF (2017) Experiments and CFD based erosion modeling for gas-solids flow in cyclone. Powder Technol 311:120–131

    Article  Google Scholar 

  31. Chu KW, Kuang SB, Yu AB, Vince A, Barnett GD, Barnett PJ (2014) Prediction of wear and its effect on the multiphase flow and separation performance of dense medium cyclone. Miner Eng 56:91–101

    Article  Google Scholar 

  32. Tofighian H, Amani E, Saffar-Avval M (2020) A large eddy simulation study of cyclones: the effect of sub-models on efficiency and erosion prediction. Powder Technol 360:1237–1245

    Article  Google Scholar 

  33. Foroozesh J, Parvaz F, Hosseini SH, Ahmadi G, Elsayed K, Babaoğlu NU (2021) Computational fluid dynamics study of the impact of surface roughness on cyclone performance and erosion. Powder Technol 389:339–354

    Article  Google Scholar 

  34. Mansouri A, Arabnejad H, Karimi S, Shirazi SA, McLaury BS (2015) Improved CFD modeling and validation of erosion damage due to fine sand particles. Wear 338:339–350

    Article  Google Scholar 

  35. Duarte CAR, de Souza FJ, dos Santos VF (2016) Mitigating elbow erosion with a vortex chamber. Powder Technol 288:6–25

    Article  Google Scholar 

  36. Farokhipour A, Mansoori Z, Rasteh A, Rasoulian M, Saffar-Avval M, Ahmadi G (2019) Study of erosion prediction of turbulent gas-solid flow in plugged tees via CFD-DEM. Powder Technol 352:236–150

    Article  Google Scholar 

  37. Popoff B, Markus B (2007) A Lagrangian approach to dense particulate flows. In: Int. conf. multiph. flow, Leipzig

  38. Launder BE, Reece GJ, Rodi W (1975) Progress in the development of a Reynolds stress turbulent closure. J Fluid Mech 68:537–538

    Article  MATH  Google Scholar 

  39. Gimbun J, Chuah T, Choong T, Fakhru’l-Razi Y (2005) Prediction of the effects of cone tip diameter on the cyclone performance. Aerosol Sci Technol 36:1056–1065

    Article  Google Scholar 

  40. Syamlal BM, Rogers W, O'Brien TJ (1993) MFIX documentation: volume 1, theory guide, National Technical Information Service. Springfield, VA

  41. Lun CKK, Savage SB, Jeffrey DJ, Chepurniy N (1984) Kinetic theories for granular flow: inelastic particles in Couette flow and slightly inelastic particles in a general flow field. J Fluid Mech 140:223–256

    Article  MATH  Google Scholar 

  42. Schaeffer DG (1987) Instability in the evolution equations describing incompressible granular flow. J Differ Eq 66(1):19–50

    Article  MathSciNet  MATH  Google Scholar 

  43. Wang L (2004) Theoretical study of cyclone design. Ph.D. Thesis, B. Eng., Anhui Institute of Finance and Trade, M.S., Texas A and M University, China

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Engineering, Arak University, Arak, 38156-88349, Iran

    Hamed Safikhani & Hossein Moghadamrad

  2. School of Mechanical Engineering, Arak University of Technology, Arak, 38181-41167, Iran

    Somayeh Davoodabadi Farahani

Authors
  1. Hamed Safikhani
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hossein Moghadamrad
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Somayeh Davoodabadi Farahani
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Somayeh Davoodabadi Farahani.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Safikhani, H., Moghadamrad, H. & Farahani, S.D. Numerical study of erosion in dense gas–solid flow in new generation cyclones using two-way and four-way coupling. Comp. Part. Mech. 10, 1341–1350 (2023). https://doi.org/10.1007/s40571-023-00566-1

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40571-023-00566-1

Keywords

Search

Navigation