Numerical simulations of gas–liquid two‐phase flow in a recycling cyclone with different structural features

Numerical simulations were employed to investigate the gas–liquid two‐phase flow within a recycling cyclone and the impact of key structural parameters on its separation performance. Using a coupled Reynolds stress model (RSM) for the gas phase and a discrete phase model (DPM) with a discrete random walk (DRW) for liquid droplets, this study analyzed the effects of the recycle line, gap width, baffle plate size, and entrance geometry. Results show that the recycle line significantly enhances separation efficiency, especially at lower inlet velocities. Optimal gap width and baffle plate size are crucial for balancing separation efficiency and operational reliability. While rectangular entrances offer slightly higher separation efficiency than circular ones, they also increase pressure drop. These findings offer valuable guidance for optimizing recycling cyclone design to improve particle separation in industrial settings.