We performed a comprehensive CFD (Computational Fluid Dynamics) analysis for an industrial cyclone separator used in metallurgical and boiler systems. Using ANSYS Fluent, OpenFOAM, and SOLIDWORKS Flow Simulation, we evaluated high-temperature, particle-laden gas streams, optimising the geometry for maximum separation efficiency and minimum pressure drop.

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Our engineers applied RANS turbulence models (k-e / k-w) and discrete-phase tracking to study swirl, recirculation, and particle trajectories.

 

Through Design-of-Experiments optimisation, we reshaped the vortex finder, cone angle, and inlet scroll, achieving measurable gains in efficiency and reducing fan energy demand. Results were validated and visualised in MATLAB, including pressure-loss maps, flow animations, and a full engineering report for production integration.

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We provide CFD simulation and fluid-flow consulting services for industrial systems across the United States and internationally, ensuring design efficiency and compliance with applicable standards.