Based on parametric design of curves using data points, two novel hydrocyclones were designed: Spline-Curved-Cone hydrocyclone (H2) and Expassoc-Curved-Cone hydrocyclone (H3). These designs are improvements on the traditional biconical hydrocyclone (H1). Numerical simulations and experimental validation by PIV measurement were used to investigate the effects of cone section profiles on the flow characteristics and separation efficiency. The results showed both H2 and H3 achieved higher separation efficiency than H1. Specifically, the highest efficiency of H3 increased by 24.71%, and that of H2 increased by 16.22% compared with H1. It was also found the curved design of cone section profile directly affects the tangential velocity distribution and pressure distribution of the flow field inside hydrocyclones. H3 exhibited better flow field stability and highest separation efficiency due to its optimized cone section space and flow structure. This study provides scientific basis and data support for the optimization and industrial application of the cylinder-on-cone hydrocyclones.
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