Computational fluid dynamics modeling and analysis of cyclone separator design for engine air filtration

Abstract Engines operating in dusty mining environments are vulnerable to intake fouling and combustion degradation from high particulate loading. This study evaluates a cyclone separator as a passive pre-filtration device for heavy-duty generator air intakes, using field-derived dust-loading and particle-size-distribution data. A Computational Fluid Dynamics model was developed using the Reynolds Stress Model and an Euler–Lagrange Discrete Phase Model. A practical 60° tilted inlet redesign was assessed under measured dust-loading conditions. The modification increased particle collection efficiency from 53 to 71% by improving axial particle transport toward the conical collection region while preserving centrifugal separation. This gain increased pressure drop from 466.20 Pa to 783.38 Pa and required fan power to 1108.15 W, equal to only 0.13% of the 880 ekW generator rating. Quality Factor analysis showed a slight reduction from 1.6195 kPa −1 to 1.5802 kPa −1 , retaining 97.6% of baseline filtration quality. The results indicate that the 60° inlet modification is a feasible cyclone pre-filtration strategy with improved dust separation and acceptable hydraulic penalty, although secondary cartridge filtration remains necessary for fine particles.