As an efficient solid–liquid separation device, the hydrocyclone is widely applied in various industrial fields such as coal preparation and oil impurity removal, and its classification performance directly determines the efficiency of industrial separation operations., As the core separation zone of the hydrocyclone, the cone segment, its structure and the number of cone angles directly affect the flow field distribution characteristics and particle classification performance of the hydrocyclone. To reveal the regulation mechanism of the combined cone angles on the classification performance of hydrocyclones, numerical analysis and experimental verification methods were adopted to investigate the internal flow field and classification performance of hydrocyclones under different cone angle combinations. The evolution laws of velocity field, pressure field, turbulence characteristics, and particle classification effect under different configurations were systematically explored. The results show that the basic characteristics of the core flow field of the hydrocyclone do not change essentially with the increase in the number of cone segments, but the amplitude, distribution, and stability of flow field parameters are significantly regulated. The three-cone configuration achieves the optimal flow field synergy effect: the amplitude of the high turbulence intensity zone is lower and concentrated near the central axis; the zero-velocity envelope surface is stably maintained at approximately 8 mm in the core separation zone; and the full axial fluctuation of the air core is gentle, which effectively inhibits random particle diffusion and flow pattern mixing. In terms of separation performance, the three-cone configuration exhibits the highest classification efficiency in the core range of sub-coarse particles (10~30 μm), with the cut size (approximately 17.5 μm) in a reasonable range, the steepness index reaching a peak value (approximately 0.55), and the pressure drop (approximately 1.8 × 105 Pa) and split ratio (2.8%) achieving synergistic optimization, balancing separation accuracy and energy consumption control. The single-cone configuration causes flow field disturbance due to the one-time contraction of the flow channel, while the four-cone configuration falls into the dilemma of “high pressure drop–marginal performance gain”, and neither achieves optimal performance. The regulation law of the number of cone segments revealed in this study provides a scientific basis for the structural optimization and engineering application of multi-cone hydrocyclones, and is of great significance for improving the particle classification efficiency in fields such as wastewater treatment and mineral processing.
Cai et al. (Fri,) studied this question.