Multi-objective optimization of a Stairmand cyclone separator using response surface methodology and computational fluid dynamics

Abstract The performance of a cyclone is generally assessed using the pressure drop and the collection efficiency of the cyclone. In the present paper, a multi-objective optimization of a classic Stairmand cyclone separator is executed using the response surface methodology (RSM), combined with computational fluid dynamics (CFD) techniques for minimizing the pressure drop and maximizing the collection efficiency. Ten cyclone geometrical factors are considered in this work. Three of them are studied using the RSM according to the results of the preceding screening experiments. The second-order response surface models for each response are successfully carried out using the central composite design (CCD) in the RSM. The desirability function approach is used to optimize the geometrical factors of the cyclone. In comparison to the reference model, the optimal cyclone model decreases the pressure drop by 20.70% and the cut-off size by 75.38%. The accuracies of the response surface models are confirmed and the correctness of the optimal cyclone model is also validated using CFD; the results indicate excellent performance and reliability of the response surface model and the RSM optimization result. According to the analyses of the obtained flow fields, there are several reasons why decreases in the cut-off size with a lower pressure drop are found in the optimal model. The primary reasons for improvements are optimized values of relevant geometrical factors, the production of a distinct, undisturbed downward flow, an increase in the tangential velocity at the near wall region, and a decrease in the peak tangential velocity.

[1]  K. W. Lee,et al.  EXPERIMENTAL STUDY ON SMALL CYCLONES OPERATING AT HIGH FLOWRATES , 1999 .

[2]  Irfan Karagoz,et al.  Effects of Surface Roughness on the Performance of Tangential Inlet Cyclone Separators , 2011 .

[3]  Jianghui Dong,et al.  The gas-solid flow characteristics of cyclones , 2017 .

[4]  S. A. Morsi,et al.  An investigation of particle trajectories in two-phase flow systems , 1972, Journal of Fluid Mechanics.

[5]  Ahmadun Fakhru’l-Razi,et al.  A CFD Study on the Prediction of Cyclone Collection Efficiency , 2005 .

[6]  Sheng-Hsiu Huang,et al.  Effects of the geometric configuration on cyclone performance , 2015 .

[7]  Chris Lacor,et al.  Optimization of the cyclone separator geometry for minimum pressure drop using mathematical models and CFD simulations , 2010 .

[8]  Chris Lacor,et al.  The effect of the dust outlet geometry on the performance and hydrodynamics of gas cyclones , 2012 .

[9]  Lian-ze Wang,et al.  Reducing Pressure Drop in Cyclones by a Stick , 1999 .

[10]  Paul G. Mathews,et al.  Design of Experiments with MINITAB , 2004 .

[11]  K. Elsayed,et al.  The effect of cyclone inlet dimensions on the flow pattern and performance , 2011 .

[12]  H. Safikhani,et al.  Modeling and multi-objective optimization of cyclone separators using CFD and genetic algorithms , 2011, Comput. Chem. Eng..

[13]  G. Derringer,et al.  Simultaneous Optimization of Several Response Variables , 1980 .

[14]  Alex C. Hoffmann,et al.  Flow pattern in reverse-flow centrifugal separators , 2002 .

[15]  F. Boysan,et al.  Advances in Cyclone Modelling Using Unstructured Grids , 2000 .

[16]  Carlo N. Grimaldi,et al.  Separation efficiency and heat exchange optimization in a cyclone , 2017 .

[17]  B. Massey,et al.  Mechanics of Fluids , 2018 .

[18]  Alex C. Hoffmann,et al.  Advantages and risks in increasing cyclone separator length , 2001 .

[19]  G. Box,et al.  On the Experimental Attainment of Optimum Conditions , 1951 .

[20]  S. Bernardo,et al.  3-D computational fluid dynamics for gas and gas-particle flows in a cyclone with different inlet section angles , 2006 .

[21]  A. Yu,et al.  Systematic study of the effect of particle density distribution on the flow and performance of a dense medium cyclone , 2017 .

[22]  Chul-Kyu Kim,et al.  Optimal design of groove shape on passive micromixer using design of experiment technique , 2017 .

[23]  Lian-Ze Wang,et al.  Numerical Study of Gas Phase Flow in Cyclones with the Repds , 2004 .

[24]  M. Bezerra,et al.  Response surface methodology (RSM) as a tool for optimization in analytical chemistry. , 2008, Talanta.

[25]  Arman Raoufi,et al.  Numerical simulation and optimization of fluid flow in cyclone vortex finder , 2008 .

[26]  Chris Lacor,et al.  Modeling, analysis and optimization of aircyclones using artificial neural network, response surface methodology and CFD simulation approaches , 2011 .

[27]  A. C. Hoffmann,et al.  The effect of the dust collection system on the flowpattern and separation efficiency of a gas cyclone , 1996 .

[28]  Richard J. Munz,et al.  Gas and particle flow patterns in cyclones at room and elevated temperatures , 1996 .

[29]  David Leith,et al.  The Logistic Function and Cyclone Fractional Efficiency , 1990 .

[30]  Chengwen Liu,et al.  Effect of a Stick on the Gas Turbulence Structure in a Cyclone Separator , 2005 .

[31]  H. S. Kim,et al.  Characteristics of the collection efficiency for a cyclone with different vortex finder shapes , 2004 .

[32]  R. Sharma,et al.  The effect of the cyclone length on the performance of Stairmand high-efficiency cyclone , 2015 .

[33]  David Leith,et al.  Cyclone Optimization Based on a New Empirical Model for Pressure Drop , 1991 .

[34]  M. Ray,et al.  Multiobjective Optimization of Cyclone Separators Using Genetic Algorithm , 2000 .

[35]  J. Zhang,et al.  Simulation of Gas Flow Pattern and Separation Efficiency in Cyclone with Conventional Single and Spiral Double Inlet Configuration , 2006 .

[36]  H. Shalaby,et al.  Numerical Calculation of Particle-Laden Cyclone Separator Flow Using Les , 2008 .

[37]  Irfan Karagoz,et al.  Numerical investigation of performance characteristics of a cyclone prolonged with a dipleg , 2009 .

[38]  Ahmadun Fakhru’l-Razi,et al.  The influence of temperature and inlet velocity on cyclone pressure drop: a CFD study , 2004 .

[39]  K. W. Lee,et al.  Effects of cone dimension on cyclone performance , 2001 .

[40]  A. Yu,et al.  Numerical study of gas–solid flow in a cyclone separator , 2006 .

[41]  Bingtao Zhao,et al.  Development of a new method for evaluating cyclone efficiency , 2005 .

[42]  Chris Lacor,et al.  Modeling and Pareto optimization of gas cyclone separator performance using RBF type artificial neural networks and genetic algorithms , 2012 .

[43]  Chris Lacor,et al.  CFD modeling and multi-objective optimization of cyclone geometry using desirability function, artificial neural networks and genetic algorithms , 2013 .

[44]  Douglas C. Montgomery,et al.  Response Surface Methodology: Process and Product Optimization Using Designed Experiments , 1995 .

[45]  Soon-Bark Kwon,et al.  Characteristics of the collection efficiency for a double inlet cyclone with clean air , 2003 .

[46]  Alex C. Hoffmann,et al.  Gas Cyclones and Swirl Tubes: Principles, Design, and Operation , 2007 .

[47]  K. W. Lee,et al.  Experimental Study of Particle Collection by Small Cyclones , 1990 .

[48]  Bingtao Zhao,et al.  Numerical simulation of effect of inlet configuration on square cyclone separator performance , 2011 .

[49]  Lakhbir Singh Brar,et al.  Analysis and optimization of multi-inlet gas cyclones using large eddy simulation and artificial neural network , 2017 .

[50]  D. Misiulia,et al.  Effects of the inlet angle on the collection efficiency of a cyclone with helical-roof inlet , 2017 .

[51]  Joon-Yong Yoon,et al.  Improvement of Hydrodynamic Performance of a Multiphase Pump Using Design of Experiment Techniques , 2015 .

[52]  Henggen Shen,et al.  Development of a symmetrical spiral inlet to improve cyclone separator performance , 2004 .

[53]  K. W. Lee,et al.  Numerical study of flow field in cyclones of different height , 2005 .

[54]  A. Hoekstra,et al.  Gas flow field and collection efficiency of cyclone separators , 2000 .

[55]  Henry França Meier,et al.  Cyclone optimization by COMPLEX method and CFD simulation , 2015 .

[56]  S. Shukla,et al.  Evaluation of numerical schemes using different simulation methods for the continuous phase modeling of cyclone separators , 2011 .

[57]  Chul-Kyu Kim,et al.  Numerical investigation of the effect of surface roughness on the flow coefficient of an eccentric butterfly valve , 2017 .

[58]  T. G. Chuah,et al.  A CFD study of the effect of cone dimensions on sampling aerocyclones performance and hydrodynamics , 2006 .

[59]  Alex C. Hoffmann,et al.  Experimental study of the vortex end in centrifugal separators: The nature of the vortex end , 2005 .