Structural Optimization\nDesign and Adaptability Analysis\nof a Novel Axial-Flow Cyclone

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