Effect of Cone Length on Separation Efficiency and Flow Characteristics in a Hydrocyclone

In this work, hydrocyclones with a diameter of 45 mm and cone lengths of 85 mm and 110 mm were employed to investigate the classification behavior of silicon carbide particles. Numerical simulations were carried out using FLUENT based on computational fluid dynamics (CFD). The internal flow characteristics were modeled using the Volume of Fluid (VOF) approach for multiphase flow, coupled with the Large Eddy Simulation (LES) turbulence model. Furthermore, the Discrete Phase Model (DPM) was applied to track particle trajectories and analyze their dynamic behavior within the hydrocyclone. The experimental results showed that, under identical inlet pressure conditions, the hydrocyclone with a cone length of 110 mm achieved superior separation efficiency. Increasing the cone length leads to a reduction in cone angle, which contributes to improved classification performance. However, practical design constraints limit the extent to which the cone length can be increased. To further explore this effect, an extended cone geometry of 150 mm was investigated through numerical simulation. The CFD results indicate that a longer cone structure enhances air core stability, prolongs particle residence time, and decreases the probability of particle misclassification. These findings suggest that optimizing cone length is an effective strategy for improving hydrocyclone performance. The novelty of this study lies in the integration of experimental validation and numerical simulation to systematically evaluate both practical and extended cone designs, thereby providing deeper insights into the relationship between structural parameters and separation efficiency.