Influence of inlet velocity on the separation performance of a combined hydrocyclone

Hydrocyclone separation exploits centrifugal force to differentiate particles based on their sizes and densities, yet challenges arise when small, dense particles and large, low-density ones settle at similar velocities. To address this, we propose a two-stage combined hydrocyclone for accurate separation. Using numerical simulations, we examine the internal flow field and performance of this system. Our findings reveal that the primary hydrocyclone achieves size-dependent classification, while the secondary one achieves density-dependent sorting. Increasing inlet velocity enhances separation efficiency and accuracy by improving flow field dynamics, albeit at the cost of increased energy consumption and material residence time. Thus, optimizing inlet velocity is vital for maximizing the separation performance and operational efficacy of the combined hydrocyclones.