CFD-based redesign of large industrial-scale cyclones

Cyclones represent a cost-effective solution employed for the separation of particles in gas-solid streams, wherein the enhancement of performance relies on the careful balance between pressure drop and collection efficiency. This study employs Computational Fluid Dynamics (CFD) techniques to numerically assess a large-scale first stage cyclone within a cement kiln cyclone tower. Investigating its reported low collection efficiency, we analyze the impact of geometric modifications aimed at enhancing cyclone performance. The introduction of a dipleg proves to be particularly effective, leading to a substantial increase in collection efficiency and a reduction in pressure drop. The most favorable cyclone configuration demonstrates a remarkable 6 % improvement in collection efficiency and a decrease in pressure drop of approximately 1 mbar. Consequently, particle emissions from the first-stage cyclone are reduced by approximately 30 %, while an increase in clinker production by approximately 100 tons per day is achieved. These findings showcase the potential for significant operational and environmental benefits through optimized cyclone design in cement manufacturing processes.