This study examines the influence of particle sphericity on the aerodynamic behavior and separation efficiency of gas–solid cyclone separators using computational fluid dynamics, focusing on particles in the PM₁₀ range and smaller. A steady-state Reynolds Stress Model (RSM) was applied to resolve anisotropic turbulence and capture the swirling flow inside the cyclone. Simulations were performed under one-way and two-way coupling across particle densities of 700–3320 kg/m3 and sphericity values of 0.5–1.0, representing components from light organic aerosols to dense mineral dusts.
Results show that sphericity markedly impacts particle–flow interactions. Spherical particles promote tighter vortex cores and more predictable centrifugal motion, whereas non-spherical particles increase turbulence and re-entrainment. Pressure drop was influenced more by flow distortion and wall interactions than particle shape alone. Separation efficiency decreased by up to 4.8 % when particle shape was considered, especially at higher densities and near-spherical forms. Accounting for sphericity also reduced the overestimation of pressure drop common in spherical approximations by 4.5–7.3 %.
The RSM framework provided consistent predictions of mean flow fields and particle dynamics, confirming its suitability for cyclone design with lower computational cost. By explicitly considering particle shape, this study offers new insights for optimizing cyclone performance in particulate matter (PM) control, particularly for fine particles within the PM₁₀ threshold. These findings support the design of more energy-efficient and effective separation systems for environmental, industrial, and filtration applications.
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