Vakamalla, T R and Mangadody, Narasimha
(2015)
Exploration of hydrocylone designs for improved ultra-fines classification using multiphase CFD model.
In: International Comminution and Classification Congress (ICCC), 12-15 August, 2015, San Luis Potosi, Mexico.
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Abstract
In this paper, a set of efficient hydrocyclones are designed for ultra-fines classification using Computational Fluid Dynamics (CFD) technique. The CFD model uses Volume of Fluid multiphase model coupled with Reynolds Stress turbulence model for two phase flow predictions. Lagrangian particle-tracking method is used to predict the particle classification. Conventional cylindrical-conical design and various novel cyclone designs having a combination of multiple and small cone angles, tapered vortex finder and different body shapes are considered in this study. Simulation results are presented in terms of mean flow field, pressure drop, flow split, air core diameter, and turbulent intensity levels and particle cut diameter. Predictions show that all the tested novel designs inherently have potential for finer cut separation and higher tangential velocity compared with the conventional design. Multiphase simulations are also carried out for multiple cone angles design and standard design for 15 wt% of solids. Simulations adopted the Algebraic Slip Mixture model modified with shear lift forces and slurry rheology corrected with fines fraction. Performance by multiphase simulation shows that multiple cone angles design and modified small cone angle design are the best among the tested designs suitable for high separation efficiency, smaller cut-point and minimum coarse particle misplacement due to resultant low turbulence intensity levels. Best designs are fabricated further and tested the performance. CFD predicted efficiency curves are found in close agreement with experiments.
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