Experimental and Numerical Investigation of a Side-Filtration Hydrocyclone for Enhanced Particle Separation

This study investigates the separation performance of a novel hydrocyclone design incorporating side filtration flow. Experiments were conducted using black silicon carbide powder in an 18.5 mm diameter hydrocyclone, while computational fluid dynamics (CFD) simulations were performed using FLUENT to analyze the flow behavior. The cylindrical section of the hydrocyclone was modified into a porous filter column, allowing controlled side filtrate discharge. The Volume of Fluid (VOF) multiphase model and Large Eddy Simulation (LES) turbulence model were applied to capture the flow field, while the Discrete Phase Model (DPM) was used to track particle motion and assess classification efficiency. Experimental results showed that when the side filtration flow rate was approximately 1/200 of the feed flow rate, the cumulative particle size distribution at the overflow shifted toward smaller particle sizes, indicating improved separation of fine particles. Simulations further revealed an optimal side flow ratio of 0.004–0.005: higher side flow reduced rotational velocity and classification efficiency, while lower side flow provided insufficient pressure relief. Particle tracking demonstrated that side filtration reduced particle recirculation in the cylindrical region, accelerating underflow discharge. These findings highlight the potential of side filtration for enhancing hydrocyclone classification efficiency, providing quantitative insights for future design optimization.