Development and performance evaluation of a rotating liquid-cone cyclone separator for enhanced particle collection efficiency

Abstract

Conventional cyclone separators experience reduced collection efficiency over time because particles deposited on the wall increase surface roughness, causing performance degradation and maintenance issues. To overcome this limitation and achieve stable long-term particle collection without efficiency loss or re-entrainment, this study developed a Rotating Liquid-Cone Cyclone Separator (RLCCS). The RLCCS uses an impeller installed at the bottom of a cylindrical vessel to rotate the internal liquid and form a liquid cone analogous to the solid cone in typical cyclones. The effects of impeller rotational speed and inlet flowrate on cutoff size were examined through experiments and numerical simulations using the Reynolds Stress Model and Volume of Fluid model to predict the behavior of the rotating liquid and aerosol. The collection efficiency of the RLCCS was compared with that of a solid cyclone of identical geometry. Increasing the impeller speed decreased the paraboloid angle of the liquid cone and reduced the cutoff size. For inlet flowrates of 200 to 600 L/min, the RLCCS achieved cutoff sizes 0.34 to 0.83 μm lower than those of the solid cyclone. The initial amount of Arizona dust A4 (10 to 30 g) in the liquid had no significant effect on performance, and no particle increase at the outlet confirmed the absence of re-entrainment. These findings demonstrate that the RLCCS can control cutoff size through impeller rotation and maintain consistent collection efficiency by simply replacing the contaminated liquid. The RLCCS therefore offers a high performance, low maintenance liquid cyclone technology suitable for various industrial applications.