Numerical Analysis and Experimental Study on the Classification of Fine Particles Using a Hydrocyclone with Multiple Vortex Finders

Ultrafine particles, as raw materials for various industries such as construction and environmental protection, are currently obtained through repeated ball milling and multiple classifications, but classification efficiency remains at a low level. Based on the principle of hydrocyclone classification, this paper designs a hydrocyclone with a triple-vortex finder structure that can achieve finer particle size distributions without altering the main structure of the hydrocyclone. The classification performance of the triple-vortex finder hydrocyclone is investigated through numerical analysis and experimental methods, with numerical comparisons made to single-vortex finder and double-vortex finder structures. The results indicate that with an increase in the number of vortex finders, the static pressure and tangential velocity gradually decrease, reducing the likelihood of tangential vortex formation while meeting classification requirements. The axial velocity in the triple-vortex finder structure is significantly reduced, which extends the residence time within the hydrocyclone and facilitates sufficient particle classification. As the number of vortex finders increases, the zero-velocity envelope surface (LZVV) gradually migrates inward, enlarging the external swirling classification space. Through numerical and experimental analyses, it is found that the triple-vortex finder hydrocyclone exhibits the highest classification efficiency, the strongest cutting ability, and the best classification accuracy. Compared to the single-vortex finder structure, the cutting particle size of the triple-vortex finder hydrocyclone decreases by 2.5 µm, and the content of fine particles in the underflow is reduced by 4.36 percentage points, effectively decreasing the fine particle content in the underflow. The quality efficiency improves by 18.85 percentage points compared to the single-vortex finder, while the quantity efficiency shows no significant decline. The obtained data provide a theoretical foundation and data support for the structural design of the new hydrocyclone.