Stairmand's cyclone separators are highly valued in multiple industries for their exceptional effectiveness in separating solid particles from gas streams. Their effectiveness arises from the vortex created within the cyclone, enabling the separation of particles through centrifugal force. Nevertheless, the formation of this strong vortex motion produces a significant drop in pressure throughout the device. Cyclones with lower pressure drops are essential in applications where energy consumption is a major concern. This work explores the use of computational fluid dynamics (CFD) and design of experiments (DoE) to optimise a Stairmand's cyclone separator with the goal of minimising energy consumption.

This study utilises Ansys Fluent as the simulation platform for the CFD simulations. The Reynolds stress turbulence model is employed in conjunction with second-order numerical schemes to improve the accuracy of the simulations. The CFD simulation results for the base case are compared to experimental data obtained by Hoekstra using laser Doppler velocimetry (LDA) and pressure drop measurements. The outcomes of the CFD simulation fall within the expected range of experimental error.

The DoE involve varying several key dimensions of the Stairmand's cyclone separator. The dimensions encompass the overall height of the cyclone, the height of the cylindrical section of the cyclone body, the diameter of the vortex finder, the height of the vortex finder, and the cone tip diameter. A total of 28 simulations are conducted. The dimensions in these simulations are varied using the face-centred central composite design methodology.

The investigation indicates that the diameter of the vortex finder is the most significant factor influencing the pressure drop in a Stairmand's cyclone separator. In contrast, the remaining parameters have a significant smaller impact on the pressure drop. In order to assess the overall impact of the dimensions, a response surface methodology, in conjunction with the screening method, was utilised to determine the most optimal design. As a result, the optimal design succeeds in achieving a 40% decrease in pressure drop compared to the original Stairmand's cyclone separator.

In order to assess the effectiveness of the optimised design, a physical test specimen is manufactured using additive manufacturing and then evaluated on a specialised test rig. The experimental results show a strong correlation between ...