Comparative Study of Single Cyclone Validation and Predictive Simulation of Multi-Cyclone Configurations

Cyclone separators are widely used for gas–solid separation due to their robustness and low operating cost. This study focuses on the experimental validation of a single cyclone configuration and the development of a MATLAB-based numerical framework. The model employs a Euler–Lagrange approach to capture centrifugal, drag, and gravitational forces acting on spherical polyethylene particles (D = 5 mm). Laboratory-scale measurements of airflow, pressure drop, and separation efficiency showed strong agreement with the numerical model (deviation < 6%), confirming its reliability for the single cyclone case. Beyond this validated framework, exploratory simulations were carried out for series and parallel cyclone configurations to provide predictive insights into possible design trade-offs. Unlike high-fidelity CFD–DEM models, which are computationally intensive and allow detailed turbulence and particle–particle interactions, the present MATLAB model is simplified but transparent and fast to implement. Its originality lies in demonstrating a low-cost, experimentally calibrated tool that can support preliminary design decisions. The multi-cyclone results should be interpreted as predictive trends, as no direct experimental validation was possible within the present setup. These findings offer preliminary guidance for balancing efficiency, energy demand, and throughput in applied mechanics of multiphase flow systems.