Optimization of a two-stage axial-flow cyclone separator focusing on energy consumption and separation efficiency

Abstract

The miniature two-stage axial flow cyclone separator (AFCS) developed for the gas-liquid separation system in the dry gas seal of large centrifugal compressors faces challenges such as low separation efficiency and high energy consumption. This study addresses these issues by optimizing the AFCS design, focusing on blade angles, exhaust pipe insertion depth, and diameter, using a combination of numerical simulation (RSM and DPM) and experimental methods. Additional measures, such as using anti-backmixing cones and slitting in the cone area of the exhaust pipe, were also explored to evaluate their effects on separation efficiency and energy consumption. The results show that the insertion depth and diameter of the exhaust pipe are optimal when they are 18 mm and 20 mm respectively. The separation efficiency can be increased by 1 ∼ 2 % and the pressure drop can be reduced by 20 kPa by using anti-backmixing cone and slit. Compared with the original two-stage AFCS, the drip stage efficiency of the optimized separator can be increased by 50 %, the separation efficiency can be increased by 10 %, and the pressure drop can be reduced by 20 %, solving the problems of low separation efficiency and high energy consumption of the single-stage separator.