CFD model of a Hydrocyclone

Peng Xu and Arun S Mujumdar

Minerals, Metals and Materials Technology Centre (M3TC), Faculty of Engineering,
National University of Singapore, Singapore 117576

Abstract
The hydrocyclone is an industrial apparatus used commonly to separate by centrifugal
action dispersed solid particles from a liquid suspension. It is widely used in the mineral
and chemical processing industries because of its simplicity in design and operation, high
capacity, low maintenance and operating costs as well as its small physical size. The
computational fluid dynamic (CFD) technique is used for design and optimization as it
provides a good means of predicting equipment performance of the hydrocyclone under a
wide range of geometric and operating conditions with lower cost. The objective of this
study is to numerically investigate the properties of hydrocyclone and explore several
innovative designs which offer high separation efficiency at low energy cost as well as
reduced erosion-induced wear.
In this study several turbulence models are tested and compared with experimental
results. Also, the effect of the hydrocyclone geometry e.g. inlet duct shape on the erosion
rate within the hydrocyclone is calculated and the hot spots of wear are indicated.
Additionally, several new designs are presented and studied numerically for their erosion
characteristics, pumping power requirements and collection efficiency.

Email: mpev6@nus.edu.sg, Tel. +65-65168870.

1. Introduction
The hydrocyclone is a mechanical separation device to separate dispersed solid
particles from a liquid suspension fed to it by centrifugal action, it is broadly used in
industry because of its simplicity in design and operation, high capacity, low maintenance
and operating costs as well as its small physical size [1]. Experimental investigation using
the LDA technique [2] is a relatively difficult technique and very expensive as well while
empirical models can be used only within the limits of the experimental data from which
the empirical parameters are determined. In view of these shortcomings, mathematical
models based on the basic fluid mechanics are highly desirable to intensify innovation.
The computational fluid dynamic (CFD) technique is gaining popularity in process
design and optimization, it provides a good means of predicting equipment performance
of the hydrocyclone under a wide range of geometric and operating conditions, and also
offers an effective way to design and optimize the hydrocyclones [3-17].
Erosion of parts of the internal wall of the hydrocyclone is a critical issue in mineral
processing both from both safety and economic considerations. The injected solid
particles, such as sand and ore particles, impinge at high vellocity on the inside surfaces
of the components of the hydrocyclone, causing mechanical wear and eventual failure of
the devices. Therefore, the erosion-induced wear should be taken into account together
with separation efficiency and energy cost for optimizing and designing hydrocyclones.
As testing for erosion of industrial devices generally requires special equipment and
methodology, further modeling effort is needed for advancing our capability in predicting
wear of hydrocyclones.

This work presents results of a CFD model of a hydrocyclone based on Fluent version
6.3. First, results using different turbulence models viz. k-, RSM and LES, are compared
with published experimental results for a 75mm standard hydrocyclone [18]. The air core
formation and geometry will be predicted with CFD model. Then, in order to study the
effect of the fed inlet on erosion rate, four designs of a 75mm hydrocyclone fitted with
different inlets are compared.

2. Model description
2.1 Turbulence Model
The turbulence model is the key component in the description of the fluid dynamics of
the hydrocyclone. The free surface, air core and presence of solid particles make the
swirling turbulent flow highly anisotropic, which adds to the difficulty for modeling
hydrocyclones using CFD. Three kinds of turbulence models, k- model, RSM and LES,
are often adopted for modeling the turbulent flow in hydrocyclones.
In mineral processing, the fluid suspensions processed are generally dilute (<10%), thus
the incompressible Navier-Stokes equations supplemented by a suitable turbulence model
are appropriate for modeling the flow in hydrocyclones. The k- model is a semiempirical model with the assumption that the flow in fully turbulent and the effects of
molecular viscosity are negligible. Comparing with standard k- model, the RNG k-
model is more responsive to the effects of rapid strain and streamline curvature and
presents superior performance for the highly swirling flow in a hydrocyclone. While, the
Reynolds stress model (RSM) closes the Reynolds-averaged Navier-Stokes equations
(RANS) by solving transport equations for the individual Reynolds stresses without

isotropic eddy-viscosity hypothesis and together with an equation for the dissipation rate.
The quadratic pressure strain (QPS) model in RSM has been demonstrated to give
superior performance in a range of basic shear flow comparing with standard linear
pressure strain (LPS) model [7]. Large eddy simulation (LES) provides an alternative
approach in which large eddies are explicitly resolved in a time-dependent simulation
using the filtered Navier-Stokes equations. Both of Smagorinsky-Lilly subgrid-scale
model (SLM) [13,14] and renormalization group (RNG) subgrid-scale model [15] have
ever been adopted for simulation of hydrocyclone with better performance. It should be
pointed out that LES model requires highly accurate spatial and temporal discretization,
finer mesh than a comparable RANS simulation, and more compute resources.
Therefore, four turbulence models, RNG k-, QPS RSM, and SLM and RNG LES will
be performed in 75mm standard hydrocyclone. And the numerical results will be
compared with each other and that of experiment.
2.2 Multiphase model
Another striking feature of the flow field is the presence of an air core in the
hydrocyclone. The centrifugal force generated by the tangential acceleration pushes the
fluid to the wall and creates a low pressure in the central axis, which gives the right
conditions to suck air into the device and form an air core.
The VOF model can simulate two or more immiscible fluid phases, in which the
position of the interface between the fluids is of interest. In VOF method, the variable
density equations of motion are solved for the mixture, and an additional transport
equation for the volume fraction of each phase is solved, which can track the interface
between the air core and the liquid in hydrocyclone. The single momentum equation is

solved throughout the domain, and the resulting velocity field is shared among the
phases. Thus, the VOF model can be adopted for modeling the air core in hydrocyclone.
However, for the dense slurry, the more sophisticated Eulerian multiphase model will be
more suitable.
2.3 Particle Tracking
In most mineral processing operations, the solid phase is sufficiently dilute (<10%).
Hence discrete phase model (DPM) can be employed, the fundamental assumption of
which is that the dispersed second phase occupies a low volume fraction can be used to
track solid particle movement. The Lagrangian DPM follows the Euler-Lagrange
approach. The fluid phase is treated as a continuum by solving the time-averaged NavierStokes equations, while the dispersed phase is solved by tracking a large number of
particles through the calculated flow field. The dispersed phase can exchange
momentum, mass, and energy with the fluid phase.
The dispersion of particles can be accounted for with a stochastic tracking model, in
which the turbulent dispersion of particles is predicted by integrating the trajectory
equations for individual particles and using the instantaneous fluid velocity. Also,
unsteady tracking is used, where at the end of each time step the trajectory is updated
with the instantaneous velocity. As for the slurry feed concentrations in excess of 10% by
volume, the DPM is not suitable and Eulerian multiphase model is more appropriate for
tracking particles in hydrocyclone.
2.4 Erosion Model
The impingement of solid particles with hydrocyclone walls can cause considerable
wear, which is an issue of great industrial concern, both from safety and economic

considerations. The damage induced by the erosion can cause equipment failure. Hence,
estimation of potential erosion of the hydrocyclone wall is important to predict the
lifetime of the equipment; it is useful to know how it is affected by geometry and
different operating conditions. Because of experimental difficulties, CFD analysis is an
effective tool to investigate the erosion rate of hydrocyclone.
Particle erosion and accretion rates can be computed at wall boundaries using the
following model equations. The erosion rate is defined as [19]
N

Rerosion =

m&p C (d p ) f ( )vb ( v )

p =1

(1)

where C (d p ) is a function of particle diameter, is the impact angle of the particle path
with the wall face, f ( ) is a function of impact angle, v is the relative velocity, b(v) is

a function of relative particle velocity, and A is the area of the cell face at the wall. The
three functions C, f and b can be defined as boundary conditions at the wall; however the
default values are not updated to reflect the material being used. Therefore, these
parameters have to be updated for different materials. It is known that one of the main
parameters which influence the erosion rate is the particles impingement angle. The
impingement angle function can be used as the following model and defined by a piecelinear profile [20-21]
f ( ) = sin(2 ) 3sin 2 ( )
f ( ) = cos 2 ( ) / 3

for 18.43o

for > 18.43o

(2a)

(2b)

To calculate the erosion rate from Eq. (1), the diameter function and velocity exponent
function are adopted as 1.8E-09 and 1.73.[19,22] The CFD model records the number,
velocity, mass and the impact angle of the various particles for each of the grids that form
6

the internal geometry of the hydrocyclone. Then, the erosion rate of the hydrocyclone
walls is determined using Eqs. (1) and (2).
2.5 Simulation results
In this work, the simulations are conducted using Fluent CFD software package
(version 6.3.26). The geometry of the 75mm standard hydrocyclone is the same as
Hsieh's experiment [18] (figure 1(a)). In the simulation, the velocity inlet boundary
condition and pressure outlet boundary conditions for vortex finder and spigot are
applied. And the inlet flow rate is kept as 1.12 kg/s and the pressure at the two outlets is
1atm. The physical constants of the liquid phase were set to those of water. The solid
particle density is 2700 kg/m3 and its wt fraction is 4.8%, which is injected at the inlet.
The flow problem is simulated with three-dimensional unstructured mesh of hexahedral
cells (figure 1(b)). Trial numerical results indicated that the solution is independent of the
characteristics of the mesh size.

(a)

(b)

Figure. 1. (a) Schematic dimensions of the standard hydrocyclone with stream lines, (b)
Grid representation used in simulation.
7

3. Model Validation

The simulated flow field, air core and separation results are compared with
experimental results to validate the model. In order to explore the inner flow field in
hydrocyclone, three different horizontal planes situated 60, 120 and 170mm from the top
wall of 75mm standard hydrocyclone are selected to give a general description of
velocity field. On each plane, the axial and tangential velocity profiles are compared with
those of the experimental results. The comparison results show that the predicted axial
and tangential velocities of the RNG k- turbulence model are far from the experimental
results while the performances of QPS RSM, SML LES and RNG LES models can
capture the velocity profiles. Comparison between the latter three turbulence models
indicates that the although the QPS RSM and SML LES models perform better near the
center, the RNG LES model can track the turbulent velocities near the wall better.
Furthermore, the absolute error is little for the axial velocity and nearly zero for
tangential velocity near wall. Another point should be noted that the QRS RSM
turbulence model combing with VOF multiphase model can lead to numerical stability,
while the LES model consumes significantly more computing resources and times.
The ability to predict well the development of the air core in the hydrocyclone is a test
of the CFD model. The predicted air core and general mass balances are calculated and
compared with experiments as listed in Table 1. For RNG k- turbulence model, there is
no obvious air core after reaching steady state, while the predicted air core diameters with
QPS RSM, SLM LES and RNG LES are 10.6mm, 11.5mm and 10.45mm respectively,
which are all close to the experimental value 10mm. In all, QPS RSM, SLM LES and
RNG LES can be used for modeling a hydrocyclone.

3.0

(a)

Experiment
RNG k-
QPS RSM
SLM LES
RNG LES

2.0
1.5

Tangential Velocity (m/s)

Axial Velocity (m/s)

2.5

1.0
0.5
0.0
-0.5

Experiment
RNG k-
QPS RSM

SLM LES
RNG LES

5
4
3
2
1

(b)
0

-1.0

-0.04 -0.03 -0.02 -0.01 0.00 0.01

-0.04 -0.03 -0.02 -0.01 0.00 0.01

0.02 0.03 0.04

0.02

0.03 0.04

Radius (m)

Radius (m)

3.0

(c)

1.5

Tangential Velocity (m/s)

Axial Velocity (m/s)

2.0

Experiment
RNG k-
QPS RSM

Experiment
RNG k-
QPS RSM
SLM LES
RNG LES

2.5

1.0
0.5
0.0
-0.5

SLM LES
RNG LES

5
4
3
2
1

(d)

0
-1.0
-0.04

-0.03

-0.02

-0.01

0.00

0.01

0.02

0.03

-0.04

0.04

-0.03

-0.02

-0.01

0.00

0.01

0.02

0.03

0.04

Radius (m)

Radius (m)

3.0

(e)

Experiment
RNG k-
QPS RSM
SLM LES
RNG LES

2.0
1.5

Tangential Velocity (m/s)

Axial Velocity (m/s)

2.5

1.0
0.5
0.0
-0.5
-1.0
-0.03

Experiment
RNG k-
QPS RSM

SLM LES
RNG LES

5
4
3
2
1

(f)

0
-0.02

-0.01

0.00

0.01

0.02

0.03

-0.03

-0.02

-0.01

0.00

0.01

0.02

0.03

Radius (m)

Radius (m)

FIG. 2. Axial and tangential velocity profile- comparison with experimental results at (a)(b) 60mm, (c)-(d) 120mm, and (e)-(f) 170mm from the top wall of 75mm standard
hydrocyclone.

Table 1. General mass balance for four different turbulent models

RNG
QPS
SLM
Experiment
k-
RSM
LES
Feed flow rate (kg/s)
1.117
1.12
1.12
1.12
Overflow flow rate (kg/s)
1.062
0.882 1.072
1.071
Underflow flow rate (kg/s) 0.055
0.238 0.058
0.053
Split ratio (%)
95.1
78.75 95.7
95.6
Pressure drop (kPa)
46.7
38.3
41.13
40.2
Air core diameter (mm)
10.0
0.2
10.6
11.5

RNG
LES
1.12
1.03
0.09
92.0
38.4
10.45

4. Erosion Rate

There are many parameters affecting the erosion rate, such as flow rate, design of the
inlet, geometry and dimensions of the hydrocyclone and slurry properties etc. can affect
the erosion rate, among which the inlet has a very important effect on the wear
characteristics of hydrocyclone. Thus, as a preliminary work, we will calculate erosion
rate for hydrocyclone with four different inlets and discuss the influence of the design of
inlet ducting on wear characteristics of hydrocyclone. . In order to compare the effect of
the inlet geometry on the erosion rate, the same fluid and particle velocity 2.25m/s are
adopted for each case, the flow rate of solid particles is set as 0.05kg/s, particle diameter
is 11.5m. In calculation of the erosion rate of hydrocyclone, the interactions of the solid
particles and the continuous phase need to be taken into account.
Fig. 3 shows the erosion rate of the inner wall of the simulated hydrocyclones fitted
with different inlets. Table 2 lists the maximum and average erosion rates and computed
pressure drop for each case. Although the standard hydrocyclone with tangential inlet
(fig. 3(a)) has been widely used in mineral processes, the erosion rate for it is the highest
compared with the other three designs. Also, obvious wear hot spot can be found at the
bottom of the cone section, where the erosion rate is very high. The maximum and
10

integral erosion rates are 3.72E-4 and 1.87E-6 kg/(m2s), respectively. However, the
pressure drop is the lowest, 32.8 kPa. For the modified tangential inlet (fig. 3(b)), there is
no obvious wear hot spot, but the erosion rate is still high compared with the involute
inlet. The maximum and average erosion rates are 7.61E-7 and 4.72E-8 kg/(m2s),
respectively, and the pressure drop is very high (81.7kPa). For the involute inlet which
can provide a smooth transition from pressure energy to rotational momentum, the
distribution of erosion rate is relatively uniform and the value is low. For the circular
involute inlet, the maximum computed erosion rate is only 4.32E-7 kg/(m2s) and the
average value is 2.91E-8 kg/(m2s) while for the elliptical involute inlet, the maximum and
integral erosion rates are 4.37E-7 and 3.90E-8 kg/(m2s), respectively. Moreover, the
pressure drop of circular involute inlet (45.7kPa) is much smaller than that of elliptical
involute inlet (72.3kPa). It can be seen from fig. 4 that the erosion rate at the inlet is
nearly zero, while the erosion rate for conical section and spigot is much higher than that
of cylindrical section and vortex finder.

(a)

(b)

(c)

(d)

Figure.3. Computed local erosion rates of the inner wall of tested hydrocyclone fitted
with different inlets: (a) standard tangential inlet, (b) modified tangential inlet, (c)
circular involute inlet and (d) elliptical involute inlet.
11

Table 2. Computed Erosion rate for four inlet duct designs

Pressure
Maximum Erosion Face average erosion
Inlet
drop (kPa) rate ( kg/(m2s))
rate ( kg/(m2s))
Standard tangential inlet
32.8
3.72E-4
1.84E-6
Modified tangential inlet
81.7
7.62E-7
4.72E-8
Circular involute inlet
45.7
4.32E-7
2.91E-8
Elliptical involute inlet
72.3
4.37E-7
3.90E-8
5. Conclusions

Four turbulence models, RNG k-, QPS RSM, SLM LES and RNG LES, were used to
predict the aerodynamic performance of a 75mm standard hydrocyclone. The comparison
of numerical and experimental results indicates that the RNG k- turbulence model is not
suitable for modeling the highly swirling flows in hydrocyclones, while QPS RSM, SML
LES and RNG LES models can capture well the velocity profiles and predict the
formation of air core. With a VOF multiphase model, the air core formation was analyzed
in detail and the diameter of steady air core was successfully predicted. The effects of
inlet on the erosion rate were investigated with the RNG LES model. The involute inlet
can eliminate the wear hot spot and lower the level of concentrated wear. This is only a
preliminary study of the design and optimization process concerning erosion rate of a
hydrocyclone. In our future study, other parameters and conditions such as inlet flow
rate, particle characteristics etc. which can affect erosion rate will be investigated as all of
the performance parameters should be taken into account for good design and operation
of the hydrocyclone and to increase its service life.

12

Acknowledgements

This work was supported by M3TC at NUS, partial support of the National Natural
Science Foundation of China through grant number 10572052, as well as the Foundation
for Study Abroad of Education of Ministry of China is also acknowledged.

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