Structural Optimization Design and Adaptability Analysis of a Novel Axial-Flow Cyclone

In order to enhance the separation performance of the current dual-barrel gravity separator, a novel axial-flow cyclone separator (AFC) with a secondary separation functionality was devised for its inlet segment. The AFC’s flow field distribution was computationally simulated using the Euler–Lagrange method alongside the Reynolds stress model. Employing a Box–Behnken design, a series of 29 experiments were devised. Multiobjective optimization, focusing on total separation efficiency and pressure drop, was executed using response surface methodology and computational fluid dynamics. Utilizing the AFC with optimized structural parameters, adaptability analysis ensued, exploring the impacts of operating pressure, processing capacity, and mixed oil droplets on the AFC’s separation performance. An evaluation of the separation efficiency of the inlet baffle of the current separator was conducted. Compared to the inlet baffle, the AFC demonstrated a 54.9% increase in total separation efficiency, achieving a separation efficiency of 73.1% for 10 μm droplets.