Minimum Pressure Drop Research Articles

Novel design and thermal-dynamic analysis on impact-jet nested double-layer microchannel heat sinks with streaming block

In this study, a new design of impact-jet nested double-layer microchannel heat sinks with streaming block is described using 3D printing technologies for improving thermal performance. Both simulation and experiments show that the novel structure arrays improve the thermal characteristics when a streaming block is added to the channel compared with the ones without streaming blocks. The results of five 3D-printed test samples made by Selective Laser Melting method are confirmed by numerical simulations with laminar flow and experimental measurements. Under the same conditions, adding a streaming block to the lower channel significantly increases the thermal performance factor by 7 % on average. Heat transfer enhancement is very pronounced in both the streaming lower block and streaming upper block, as shown by the experimental research and numerical simulation. Additionally, among the five models, the impact-jet nested double-layer microchannel heat sinks with streaming upper block equaling 0.3 mm height shows the best overall thermal performance factor. In the case of Reynolds number equaling 580.4, the overall thermal performance factor of impact-jet nested double-layer microchannel heat sinks with streaming upper block equaling 0.3 mm height is 1.5807. The results indicate that the impact-jet nested double-layer microchannel heat sinks with streaming upper block equaling 0.3 mm height can achieve good heat dissipation with minimal pressure drop loss. The novelty of the work is to combine the advantages of double-layer microchannel, impact-jet nested structure and streaming block to enhance the overall thermal performance for extending the full lifecycle of micro electronic devices.

Enhancing Flow Batteries: Topology Optimization of Electrode Porosity and Shape Optimization of Cell Design

This research focuses on the improvement of porosity distribution within the electrode of an all‐vanadium redox flow battery (VRFB) and on optimizing novel cell designs. A half‐cell model, coupled with topology and shape optimization framework, is introduced. The multiobjective functional in both cases aims to minimize pressure drop while maximizing reaction rate within the cell. Topology optimization results reveal dependencies on initial value, porosity constraint, and flow rate. The distribution with lower porosity is preferred downstream of the inlet manifold. This design enhances active surface area, thus facilitating more effective conversion of incoming educts and improving mass transport of products. Compared to homogeneous electrodes, two‐part design demonstrates superior performance at specific porosity values. For combined porosities of 0.7 and 0.95, optimized distribution results in 81 % reduction in pressure drop, while conversion rate decreases by 7%. As regards various cell designs, optimization suggests a need to reconsider the vertical format of a rectangular cell. Horizontal cells are favored for nearly all porosities and flow rates. Trapezoidal and radial designs characterized by reduced downstream cross sections lead to higher pressure drops and are not preferred. This work provides further valuable insight into optimizing VRFB electrodes and challenges conventional cell design assumptions.

Computational investigation of transportation and thermal characteristics in a bi-modal slurry flow through a horizontally placed pipe bend

In this study, we develop a three-dimensional computational model to explore the transportation and thermal characteristics of a bi-modal slurry flowing through a horizontally placed 90° pipe bend. The slurry comprises silica sand (SS) and fly ash (FA) granular, with varying combinations (65:35, 75:25, 85:15, 95:05, and 100:0). The computational investigation has been carried out for different carrier fluid's characteristics, including Prandtl number, and flow velocity (5 m/s), for efflux concentrations of Cw = 40–60% for each mixture. Validated with experimental data, the computational approach employs a two-phase Eulerian-Eulerian RNG k-ε turbulence model and the kinetic theory of granular flow. Results reveal that the 65:35 combination exhibits minimal pressure drop, and the 100:0 combination shows maximum heat transfer characteristics, particularly with low-viscosity fluid (Pr = 2.88) and high particle efflux concentration (Cw = 60%). The study also examines bend loss coefficients (Kt), concentration distribution, convective heat transfer coefficient (h), and Nusselt number (Nu) across different Prandtl fluids and efflux concentrations.

Hybrid ZOA-SNN technique heat transfer enhancement of the heat exchanger

This paper proposes a hybrid ZOA-SNN technique for Heat Transfer Enhancement of the Heat Exchanger. The proposed hybrid technique is the combined performance of both the Zebra Optimization algorithm (ZOA) and Spiking Neural Network. Commonly it is named as ZOA-SNN method. The proposed method’s main goals are to control temperature and optimize heat transfer (HT). The proposed technique was analyzed using an optimization technique to get a minimal pressure drop and maximum possible heat transfer efficiency for the heat exchanger design. By then, the proposed model is executed on the MATLAB work stage and the performance is calculated using the present procedures. The pressure drop for the proposed strategy is 225 pa. The temperature rise for the proposed method is 3.5 °C. When the temperature drops by 3.5 °C, the heat transfer rate is 4.5 (L/min). Better outcomes are shown by the proposed method in all approaches like Nonprofit Organization (NPO) Obstructive Sleep Apnea (OSA), Global Outstanding Assessment (GOA). From the result, it is concluded that the proposed approach-based temperature is lower and the heat transfer is maximized in contrast to current methods.

Self-driven manifold microchannel heat sink for cooling electronics

The advancement of passive, compact, and lightweight thermal management technology for high-power chips is essential for the stable and efficient operation of the next generation of electronic devices. A novel self-driven heat sink based on embedded manifold microchannel heat dissipation technology is proposed, which uses capillary force as the driving force to replace the pump, and minimize pressure drop and thermal resistance between the heat sink and heat source. This design of the embedded self-driven manifold microchannel heat sink allows for the integration and miniaturization of the heat sink and the chip heat source. Through Micro Electromechanical Systems technology, an experimental sink with microchannels with a high aspect ratio was fabricated. A theoretical model is constructed to analyze the influence of the width and depth of the microchannel on the limit heat flux, and the correctness of the model is verified by experiments. The results indicate that the width has a more significant impact on the limit heat flux compared to the depth. An optimal width of 6.5 μm is identified. As the depth increases, the influence of depth on the limit heat flux diminishes. By conducting theoretical calculations on the embedded self-driven manifold microchannel heat sink, it was determined that the device using HFE7100 as the working fluid demonstrates a wider heat load range than ethanol and acetone, and the limit heat flux can reach 41.5W/cm2.

Characteristics of turbulent core–annular flow with water-lubricated high viscosity oil in a horizontal pipe

Direct numerical simulations are performed to investigate the characteristics of a turbulent core–annular flow with water-lubricated high viscosity oil in a horizontal pipe. Six different superficial velocity ratios ( $\,j_w/j_o = 0.057\unicode{x2013}0.41$ ) are examined by changing the water superficial velocity $j_w$ for a fixed oil superficial velocity $j_o$ . The pressure drops in the pipe and the shapes of the phase interface agree well with those from previous experiments. The oil core flow is almost a plug flow, and the gaps between the phase interface and pipe wall are narrow and wide near the upper and lower surfaces of the pipe, respectively, due to the buoyancy. Within a narrow gap, water is confined mostly in a valley region of the wavy phase interface and hardly goes through its crest. On the other hand, water near the phase interface at a wide gap convects downstream almost at the core speed and the flow near the wall is similar to that of single-phase wall-bounded turbulent flow. The annular flow is characterized by three different regimes depending on the clearance Reynolds number ( $Re_c$ ) based on the core velocity and local gap size: laminar Couette flow driven by the core for $Re_c \le 600$ , transitional flow for $600 < Re_c < 2500$ and turbulent flow for $Re_c \ge 2500$ . The minimum pressure drop occurs at $j_w/j_o = 0.11$ in the early transition regime. For all $j_w/j_o$ considered, the negative lift force acting on the core comes from the pressure force which balances the buoyancy.

An approach for topology optimization of heat sinks for two-phase flow boiling: Part 2 – Model calibration and experimental validation

Flow boiling offers increased heat transfer coefficients and effective heat capacity rates that can be leveraged by topology optimization (TO) to generate high-performance microchannel heat sinks. Topology optimization of heat sinks having two-phase flows can be accomplished using the homogenization approach wherein designs are represented as spatially varying distributions of microstructures, as demonstrated in Part 1 of this two-part study. Flow and heat transfer within the microstructures are captured using a two-phase mixture model featuring an effective porous medium formulation. However, closure of these governing equations requires empirical correlations for pressure drop and heat transfer that are specific to the operating conditions, geometry, and surface finish. Therefore, it must be demonstrated these available correlations can be successfully calibrated over a range of microstructural variations present within the homogenization framework, so as to attain the required prediction generality and accuracy needed to ensure the resulting designs achieve Pareto-optimality. This Part 2 of our study successfully demonstrates a comprehensive end-to-end process for two-phase flow model calibration, topology optimized design generation, and experimental validation of optimized performance for flow boiling heat sinks. To this end, a TO algorithm with the homogenization approach and a two-phase mixture model is implemented using available flow boiling correlations for microchannels. A set of uniform pin fin calibration samples are additively manufactured and experimentally tested under flow boiling at various flow rates and heat inputs for model calibration. All of the unknown/free coefficients in the adopted correlations are determined by minimizing the error between the model predictions and the experimental measurements using gradient-based optimization. The calibrated topology optimization algorithm is then used to generate a Pareto-optimal set of heat sinks optimized for minimum pressure drop and thermal resistance during flow boiling. Experimental characterization of these additively manufactured heat sinks, unseen during the model coefficient calibration process, reveals that the measured Pareto optimality curve matches that predicted by the topology optimization algorithm. Lastly, a heat sink design is generated for a design space involving multiple hot spots and background heating to showcase the capability of the experimentally calibrated two-phase topology optimization algorithm at handling complex boundary conditions. The optimized heat sink intelligently distributes an adequate amount of coolant flow to each of the heated regions to avoid local dry-out. This work demonstrates a complete framework for two-phase topology optimization of heat sinks through experimental calibration of flow boiling correlations to the porous medium used by the homogenization approach.

Case study on thermal management of planar elements with various polymeric heat exchangers: experiment and simulation

A reliable battery thermal management system (BTMS) is essential to ensure proper performance, a long life span and high electric vehicle safety. The primary objective of BTMS is to maintain the cells’ temperature in the range of 15–35 °C while limiting the temperature spread between cells to below 5 °C. Active thermal management with polymeric hollow fibers (PHFs) has been reported in a few articles, but its tremendous flexibility is mainly advantageous for cylindrical cells. Extruded polymeric cold plate heat exchangers with rounded rectangle channels (RRCs) are proposed as a more elegant solution for planar batteries. Heat exchangers using PHFs and RRCs were experimentally compared, with a strong focus on minimizing the maximum temperature and temperature spread of the experimental setup while simultaneously achieving minimal pressure drops. The system behavior with different parameters, including materials, geometry and thermophysical properties, was further studied using properly validated CFD models.

The underground performance analysis of compressed air energy storage in aquifers through field testing

Compressed air energy storage in aquifers (CAESA) has been considered a potential large-scale energy storage technology. However, due to the lack of actual field tests, research on the underground processes is still in the stage of theoretical analysis and requires further understanding. In this study, the first kilometer depth compressed air injection-production field test with multiple flat aquifers is controlled. For all three production rates considered, the minimum pressure drop rate can reach 0.9 MPa/h. An actual wellbore-aquifer-coupled numerical model simulated by T2Well/EOS3 is verified using monitoring data. Due to the limitation imposed by the injection rate, air only flows into the top three sandstone aquifers to build air bubbles. During the production stage, air is first produced from the aquifers and then the air stored in the wellbore is gradually extracted due to the weakened air bubble support effect. Finally, an air-water two-phase occurs and the water level rises in the wellbore. Considering a hypothetical long-term cycle, the designed single aquifer scheme has a better underground performance. A concentrated and larger high air saturation domain can support a stable cycle pressure and above 95% underground efficiency. However, the wellhead pressure drops once water coning happens in the wellbore. With an air bubble replenishment scheme in each cycle, it becomes feasible to maintain stable pressure, ensuring a production pressure difference below 0.94 MPa without water production, over a 100-day cycle in the field. The results provide support for future practical engineering applications.

Fluid flow and heat transfer characteristics of a microstructured microchannel heat sink under flow boiling condition

A microchannel heat sink (MCHS) is known as a heat dissipation device from the miniaturized electronic components and devices due to its capability to dissipate high heat flux from smaller surface area. However, the higher pressure drop and the uneven heat removal along the channel length are the noticeable disadvantages of MCHS. Though there are attempts to address these shortcomings, no existing study has been found to study the effect of positions of microstructures (micro-pin fin and blind holes) and combined effect of micro-pin fins and blind holes under flow boiling condition. Therefore, in the present study, an attempt has been made to logically explain the effect of various arrangements and positions of pin fins and blind holes in the selected twenty-four uniformly distributed stations on the thermohydraulic performance of MCHS through numerically predicted results. The objectives of the study have been attained using the following three analyses, flow boiling, (i) with saturated fluid inlet conditions (inlet Re = 500), (ii) with different inlet subcooling (20, 40, and 60 °C), and (iii) with different heat flux conditions (100, 150, 200 and 250 W/cm2). From the study, it is observed that the pin fin enhances heat transfer in single-phase flow and delays the phase change by disturbing the flow. The blind holes act as nucleation sites and help phase change heat transfer. It is also observed that the ratio of single-phase and two-phase length and arrangement of microstructures in these two regions predominately dominate the heat transfer and fluid flow characteristics of the microchannel heat sink. The optimum performance (maximum heat transfer coefficient and minimum pressure drop) is achieved when twelve pin fins are placed in the upstream half and twelve blind holes are located at the downstream half of the channel. However, design improvement is possible through more computational and experimental analysis.

Radiative Thermal Management in Face Masks with a Micro/Nanofibrous Filter.

Micro/nanofiber-based face masks are recommended as personal protective equipment (PPE) against particulate matter (PM), especially PM0.3. Ensuring thermal comfort in daily use face masks is essential in many situations. Here, radiative thermal management is introduced into face masks to elevate the user comfort. An interlayered poly(lactic acid) (PLA) micro/nanofibrous filter effectively captures PM0.3 (99.69%) with minimal pressure drop (49 Pa). Thermal regulation is accomplished by controlling the mid-infrared (MIR) emissivity of the face mask's outer surface. Cooling face masks feature cotton nonwovens with high MIR emissivity (90.7%) for heat dissipation, while warming face masks utilize perforated Al/PE films with minimal MIR emissivity (10.7%) for warmth retention. Skin temperature measurements indicate that the skin covered by the cooling face mask could be 1.1 °C lower than that covered by the 3M face mask, while the skin covered by the warming face mask could be 1.3 °C higher than that covered by the 3M face mask.

Parametric design optimization and thermodynamic analysis of plate fin heat exchanger for helium liquefaction system

The plate-fin heat exchanger is one of the most important components of helium liquefaction system as it recovers cold energy from helium gas in the cold box. Because of larger heat transfer surface area and compact geometrical configuration, plate-fin heat exchangers are widely used. The design of heat exchanger using helium as a cryogenic fluid needs high thermodynamic performance with minimum pressure drop which particularly requires the optimization of dimensional array and its geometrical configurations. In this regard, a parametric investigation was performed to compute the effective geometrical parameters and its effect on thermodynamic (effectiveness and log-mean temperature difference) performance has been discussed in detail. The present study aims to design optimization and thermodynamic performance evaluation of plate-fin type heat exchangers used in helium liquefaction systems. The developed helium liquefaction model has been simulated for the most critical liquefier with and without liquid nitrogen precooling, mixed mode, and refrigeration mode. Each component of the liquefaction model has been technically and thermodynamically analyzed and, in particular, four plate-fin heat exchangers have been considered and designed accurately using Aspen EDR®. Initially, the sensitivity analysis was carried out to characterize the most significant geometrical parameters (fin thickness, height, number and arrangement of layers, frequency, and fin type) and their effect on thermodynamic performance and pressure drop. After that, the artificial intelligence model was used to determine the optimal range of such geometrical variables in which the heat exchanger has maximum effectiveness and log mean temperature difference. Finally, the operating conditions obtained from cycle modeling and optimized geometrical datasets have been applied in commercial simulation software Aspen EDR® for plate-fin heat exchangers design. Finally, a comparative thermodynamic analysis has been carried out to determine the performance of all the designed heat exchangers operating at four different modes (boundary conditions).

Computational Pulsatile Flow and Efficiency Analysis of Biocompatible Microfluidic Artificial Lungs for Different Fiber Configurations.

Average-sized microfluidic artificial lungs consisting of rows and columns of fiber bundles with different column to row aspect ratios (AR) are numerically analyzed for flow characteristics, maximum gas transfer performance, minimum pressure drop, and proper wall shear stress (WSS) values in terms of biocompatibility. The flow is fully laminar and assumed to be incompressible and Newtonian. The transport analysis is performed using a combined convection-diffusion model, and the numerical simulations are carried out with the finite element method. The inlet volumetric flow is modeled as a sinusoidal wave function to simulate the cardiac cycle and its effect on the device performance. The model is first validated with experimental studies in steady-state condition and compared with existing correlations for transient conditions. Then, the validated model is used for a parametric study in both steady and pulsatile flow conditions. The results show that increasing the aspect ratio in fiber configuration leads to converging gas transfer, higher pressure drop, and higher WSS. While determining the optimum configuration, the acceptable shear stress levels play a decisive role to ensure biocompatibility. Also, it is observed that the steady analysis underestimates the gas transfer for higher aspect ratios.

Thermal enhancement of microchannel heat sink using pin-fin configurations and geometric optimization

The microchannel heat sink (MCHS) is a robust cooling technique that ensures the efficiency and reliability of compact electronic devices by dissipating a large amount of heat because of its high surface area-to-volume ratio. This study proposes a novel modification of the pin-fins geometry in MCHS, and geometric optimization using response surface methodology (RSM) to build a low thermal resistant MCHS with enhanced heat transfer efficiency with low-pressure drop. Three dimensional numerical simulations using ANSYS FLUENT 2021 R2 are performed on three pin-fins configurations, i.e., MC-BW (pins mounted transversely to the bottom wall), MC-SW (pins mounted transversely to the side wall), and MC-Mixed (pins mounted transversely to the bottom and side wall). The thermal and flow characteristics are investigated using a laminar conjugate heat transfer model at Reynolds numbers 100–1000. Results show that introducing pin-fins significantly enhances heat dissipation as it continuously breaks the boundary layer and generates flow separation downstream of the pin-fins, which enhances fluid mixing and increases heat transfer augmentation inside MCHS. Among different configurations, the MC-Mixed gives the highest improvement of 50% in the convective heat transfer coefficient at Re = 1000. The highest thermal enhancement factor of η = 1.4 is obtained for the MC-Mixed configuration at Re = 600. For the base wall pin fin configuration RSM yields optimized values of 2.50 mm, 0.25 mm, and 0.045 mm for transverse pitch, longitudinal pitch, and diameter of pin respectively, and for the mixed pin fin configuration it gives 1.0 mm, 0.150 mm, 0.035 mm and 1.250 mm values for transverse pitch, longitudinal pitch, diameter of pin and pitch of side wall pins respectively for the maximum heat transfer and minimum pressure drop.

Numerical investigation of louver edges effect on the performances of louvered fin compact heat exchanger

The rectangular channel louvered-fin compact heat exchanger (LFCHE) is the most efficient type that has been served in a radiator. However, with this type of heat exchanger, the pressure drop rises by three to four times as the heat transfer increases, which results in decreasing performance. This research is aimed to numerically investigate the louver edges (vertical, inclined, and horizontal) effect on LFCHE performance at different louver angle (θ) with air inlet velocities ranging from 1 to 30 m/s. A total of twelve models are made and simulated. The result revealed that the horizontal edge decreases the pressure drop up to 24.2% with a 1.01% increase in outlet air temperature over the base model (inclined edge). Thus, louver edge has design which results in higher and lower effect on pressure drop and temperature change, respectively. The research investigated the effects of louver edges using different performance evaluation criteria. At 10 m/s (Relp = 972.33) the horizontal edge increases the volume goodness (jf) factor up to 21.49% over the base model. Similarly, the horizontal edged fins resulted in maximum increment of jf-factor by 22% and 25% as compared with inclined edge for louver angles θ of 24 ° (at low Relp) and 20 ° (at high Relp), respectively. Generally, the horizontally edged LFCHE is proven to have higher performance in cooling the coolant with a minimum air side pressure drop.

Optimal shape design of printing nozzles for extrusion-based additive manufacturing

The optimal design seeks the best possible solution(s) for a mechanical structure, device, or system, satisfying a series of requirements and leading to the best performance. In this work, optimized nozzle shapes have been designed for a wide range of polymer melts to be used in extrusion-based additive manufacturing, which aims to minimize pressure drop and allow greater flow control at large extrusion velocities. This is achieved with a twofold approach, combining a global optimization algorithm with computational fluid dynamics for optimizing a contraction geometry for viscoelastic fluids and validating these geometries experimentally. In the optimization process, variable coordinates for the nozzle’s contraction section are defined, the objective function is selected, and the optimization algorithm is guided within manufacturing constraints. Comparisons of flow-type and streamline plots reveal that the nozzle shape significantly influences flow patterns. Depending on the rheological properties, the optimized solution either promotes shear or extensional flow, enhancing the material flow rate. Finally, experimental validation of the nozzle performance assessed the actual printing flow, the extrusion force and the overall print control. It is shown that optimizing the nozzle can significantly reduce backflow-related pressure drop, positively impacting total pressure drop (up to 41 %) and reducing backflow effects. This work has real-world implications for the additive manufacturing industry, offering opportunities for increased printing speeds, enhanced productivity.

Horse Herd Optimization and LSTM Configuration for Minimizing Pressure Drop and Predicting Thermal Performance in Shell and U-Tube Heat Exchanger

Horse Herd Optimization and LSTM Configuration for Minimizing Pressure Drop and Predicting Thermal Performance in Shell and U-Tube Heat Exchanger

Design of the Microchannels Heat Sink to Augment the Thermal Performance Using Different Type of Cavity with or without Wavy Channel

The development of innovative micro sinks design stems from the urge to perform efficient cooling at a cost of low pressure drop for more miniaturized electronic equipment. The three-dimensional investigations have been carried out with disruptive structures in rectangular microchannels. Microchannel heat sinks with triangular cavity, trapezoidal cavity, wavy plane channel, wavy triangular cavity, and wavy trapezoidal cavity have been considered. The performance variations are evaluated based on the average Nusselt number, friction factor, and thermal performance within the range of Reynolds numbers from 141 to 498. The highest thermal performance is achieved by wavy trapezoidal cavity among all channels. The parametric geometrical studies have also been carried out by varying relative geometric parameters such as relative amplitude, relative cavity length, and relative cavity width. The highest heat transfer enhancement equal to 2.33, for the same channel has been achieved with the combination of relative amplitude; relative cavity length and relative cavity width is equal to 0.75, 0.055, and 0.75, respectively at Reynolds number equal to 498. The wavy shapes give better mixing by creating of additional vortices or dean vortices to increase heat transfer with minimum pressure drop.

Supercritical CO2 flow and heat transfer through tapered horizontal mini-tubes: Parametric analysis and optimization study

One effective method for enhancing heat transfer in tubular heat exchangers involves gradually altering the cross-section of their tubes. While extensive research has been carried out in typical operating conditions, a significant shortage of studies exists that specifically investigate how changes in tube cross-section affect the heat transfer of fluids under critical and pseudocritical conditions. Additionally, the absence of a comprehensive parametric study considering the effect of all operating conditions and geometric parameters, and providing an optimal model in this field, is keenly felt. This paper offers a finite volume-based numerical simulation of steady-state turbulent flow and heat transfer for supercritical CO2 inside circular horizontal mini-tubes with tapered lateral profiles. It is found that the impact of buoyancy on thermal and hydraulic characteristics is more noticeable in the diverging mini-tube than in the converging mini-tube. The results of the parametric study reveal that under the same geometric parameters, the heat transfer coefficient in the diverging mini-tube is higher than that in the converging mini-tube by 5.2–28.6 %, with a simultaneous reduction in pressure drop ranging from 52.1 % to 68.5 %. However, in the case of a high diameter or diameter ratio, the heat transfer coefficient of the converging mini-tube exceeds that of the diverging mini-tube. Subsequently, an optimization study is conducted using BBD-RSM. To achieve the maximum heat transfer coefficient and the minimum pressure drop, an additional 54 cases are investigated, covering diverse ranges of operating conditions and geometric parameters. The results indicate that the mass flow rate and tube diameter are the most influential parameters on thermal and hydraulic characteristics. Additionally, the impact of the diameter ratio on the pressure drop is more pronounced than on the heat transfer coefficient. This research can serve as a foundation for enhancing the design of heat exchange devices within innovative supercritical CO2 power generation cycles.

Numerical Investigation of Cyclone Separators: Physical Mechanisms and Theoretical Algorithms

AbstractGas‐particle aero‐type cyclones have revolutionized biochemical processes, engineering industries, and environmental pollution protection by effectively separating particles from gas. These devices rely on gravitational energy and centrifugal force to dissipate particle phase energy, but achieving optimal energy efficiency while minimizing pressure drop remains challenging. This has led to the development of various cyclone designs in commercial industries, each with unique energy efficiency characteristics. The intricate gas‐particle flow inside cyclones is a critical issue impacted by cyclone geometry, operating conditions, and media parameters. Advanced numerical simulations have been employed to understand this complex flow pattern better, offering researchers valuable insights into the mechanisms of different cyclone separators. This comprehensive review explores the available numerical methods in the literature on cyclones and their corresponding validations. Computational numerical modeling is a promising technique for predicting cyclone energy efficiency, gas‐particle behavior, and overall performance. This investigation delves into the progress and numerical forms of gas‐particle flow cyclones, examining how different parameters impact cyclone performance and flow patterns within the two‐phase flow. The future developments and challenges that may further promote the development of aero‐type cyclone separators, providing theory and engineering support for future cyclone designs, are also covered. As a result, it can confidently be reported that aero‐type cyclone separators remain a critical component in various industrial sectors, offering energy‐efficient solutions for mitigating environmental pollutants and gas‐particle separation systems. With continued development and research, these devices will undoubtedly shape the future of energy processes and engineering industries, ushering in a new era of sustainability and efficiency.