A Numerical Study on the Flow Field and Classification Performance of an Industrial-Scale Micron Air Classifier under Various Outlet Mass Airflow Rates

In this study, the gas−particle flow field in a real-size industrial-scale micron air classifier manufactured by Phenikaa Group using 3D transient simulations with the FWC-RSM–DPM (Four-Way Coupling-Reynold Stress Model-Discrete Phase Model) in ANSYS Fluent 2022 R2 and with the assistance of High-Performance Computing (HPC) systems is explored. A comparison among three coupling models is carried out, highlighting the significant influence of the interactions between solid and gas phases on the flow field. The complex two-phase flow, characterized by the formation of multiple vortices with different sizes, positions, and rotation directions, is successfully captured on the real-size model of the classifier. Additionally, analyzing the effects of the vortices on the flow field provides a comprehensive understanding of the gas–solid flow field and the classification mechanism. The effect of the outlet mass airflow rate is also investigated. The classifier’s Key Performance Indicators (KPIs: d50, K, η, ΔP) and the constrained condition of the particle size distribution curve of the final product are used to evaluate the classification efficiency. The contributions of this work are as follows: (i) a simulation analysis of a real-size industrial-scale classifier is conducted that highlights its advantages over a lab-scale one; (ii) a comparison is conducted among three coupling models, showing the advancement of four-way coupling in providing accurate results for simulations of interactions between the gas phase and particles; and (iii) the particle size distribution curve performances of a classified product under different simulation models and outlet airflow rates are addressed, from which optimal parameters can be selected in the design and operation processes to achieve the required efficiency of an air classifier.