Experimental Study of Fine Particle Separation in a Multichannel Cyclone with Curvilinear Design and Theoretical Assessment Under Harsh Microclimatic Conditions

Contaminated gas flows are encountered in most industrial processes and require efficient removal of fine dispersed particles of various types and characteristics. Conventional cyclones are widely used under harsh operating conditions; however, their separation efficiency for fine particulate fractions remains relatively low. In this study, next-generation cyclones with a multichannel design featuring cylindrical and spiral casings are investigated, enabling particle collection efficiencies of approximately 90% for particles with a diameter of 2 µm. Under harsh microclimatic conditions—particularly at high humidity levels of 70% or higher and elevated temperatures of 50 to 200 °C—such technology is prone to clogging, necessitating complex regeneration procedures. Recent research has focused on improved channel geometries incorporating secondary peripheral flows, adapted for gas cleaning in harsh environments. Experimental results demonstrate effective removal of fine-dispersed glass and clay particles up to 20 µm in size at initial concentrations of 0.5–15 g/m3. The theoretical assessment of the influence of harsh gas flow conditions includes analyses of critical flow characteristics and the mechanical forces acting on fine particles under varying temperature and humidity conditions. The results indicate a maximum purification efficiency of up to 87.3% with an aerodynamic pressure drop of 440 Pa. The impact of harsh microclimatic conditions is most pronounced in the magnitudes of the centrifugal and drag forces: with an increase in the gas flow temperature by every 50 °C within the range from 0 to 200 °C, these forces increase by factors of 7.3–32.7 and 4–6.3, respectively.