Numerical study on improving corrugated plate gas–liquid separator performance by integrating baffle and hook designs

Steam-water separators are critical in industrial applications, especially in thermal and nuclear power plants and thermo-chemical hydrogen production. These devices enhance system efficiency by removing water droplets from steam, ensuring dry steam delivery to downstream equipment. The performance of steam-water separators depends on structural design and operating conditions. This study numerically investigates the performance of corrugated plate steam separators with various baffle and hook configurations to optimize separation efficiency and pressure drop. Six designs (Shape-I to Shape-VI) were evaluated using CFD simulations incorporating the k − ϵ turbulence model, the Discrete Phase Model (DPM), and the Discrete Random Walk (DRW) model to capture fluid dynamics and droplet behavior. Velocity distribution, pressure drop, and separation efficiency were analyzed. Results showed that Shape-V (baffles and double hooks) and Shape-VI (staged hooks) offered the highest performance. Shape-VI achieved 99.8% separation efficiency at high inlet velocity but with a higher pressure drop. In contrast, Shape-V achieved slightly lower efficiency with a 48% reduction in pressure drop, making it more suitable when minimizing pressure loss is essential. These findings support the design of more efficient and cost-effective separators, contributing to improved energy system performance and operational reliability. • Novel corrugated plate gas–liquid separator designs proposed for improved performance. • CFD–DPM analysis revealing detailed droplet trajectory mechanisms in complex flow fields. • Performance trade-off analysis: pressure drop vs. efficiency at varying flow. • Practical design insights provided to support optimization of industrial gas–liquid separators.