The Impression of Roughness on Flow Pattern and Performance of Axial Gas Cyclone Along with Erosion Rate

Document Type : Original Article

Authors
Masoud Dorfeshan 1
Sattar Moghaddam 2
Farzad Parvaz 3
1 Assistant Professor, Department of Mechanical Engineering, Faculty of Engineering, Behbahan Khatam Alanbia University of Technology, P.O. Box 63616-47189, Behbahan, Iran
2 2. M.Sc. Student, Department of Mechanical Engineering, Faculty of Engineering, Behbahan Khatam Alanbia University of Technology, P.O. Box 63616-47189, Behbahan, Iran
3 M.Sc., Department of Mechanical Engineering, Semnan University, P.O. Box 35131-191, Semnan, Iran
20.1001.1/jgt.2025.2057137.1054
Abstract
In this study, the effect of wall roughness on flow pattern, performance, and erosion rate in an axial gas cyclone is investigated. Gas cyclones are widely used in various industries such as food processing, dryers, and the cement industry for separating solid particles from gas flow due to their flexibility, low maintenance costs, and efficiency in air pollution control. Numerical modeling is conducted using turbulence models, surface roughness models, the discrete phase model (DPM), and the erosion model to analyze key parameters such as pressure drop, tangential velocity, axial velocity, separation efficiency, and wall erosion rate. The results indicate that increasing wall roughness reduces tangential velocity, thereby decreasing centrifugal force, which negatively affects particle separation efficiency. On the other hand, increasing wall roughness leads to a reduction in pressure drop, which is considered an advantage in cyclone design. Erosion rate analysis also shows that the highest erosion occurs in the lower conical section of the cyclone, and increasing wall roughness can reduce erosion. Overall, this study reveals that wall roughness has conflicting effects on cyclone performance—reducing pressure drop on one hand while decreasing separation efficiency on the other. Therefore, optimizing surface roughness is essential to achieve a balance between these two factors in the design of axial gas cyclones. The results showed that increasing wall roughness reduced tangential velocity by up to 18%, cyclone collection efficiency dropped by approximately 12% for particles larger than 25 μm, while pressure drop decreased by around 9%, which can be considered beneficial in energy-sensitive applications. The highest erosion rate was observed at the cone tip of the cyclone, and wall roughness helped reduce average erosion by nearly 15%.

Keywords

Subjects

Article Title Persian

تأثیر زبری دیواره بر الگوی جریان و عملکرد سیکلون گازی محوری به همراه نرخ فرسایش

Authors Persian

مسعود درفشان 1
ستار مقدم 2
فرزاد پرواز 3
1 استادیار، گروه مهندسی مکانیک، دانشکده فنی و مهندسی، دانشگاه صنعتی خاتم الانبیا بهبهان، بهبهان، ایران
2 دانشجو کارشناسی ارشد، گروه مهندسی مکانیک، دانشکده فنی و مهندسی، دانشگاه صنعتی خاتم الانبیا بهبهان، بهبهان، ایران
3 کارشناسی ارشد، گروه مهندسی مکانیک، دانشکده فنی و مهندسی، دانشگاه سمنان، سمنان، ایران
Abstract Persian

در این مطالعه، تأثیر زبری دیواره بر الگوی جریان، عملکرد و نرخ فرسایش در یک سیکلون گازی محوری بررسی شده است. سیکلون‌های گازی به دلیل انعطاف‌پذیری، هزینه‌های نگهداری پایین و کارایی در کنترل آلودگی هوا، به‌طور گسترده در صنایع مختلف مانند فرآوری مواد غذایی، خشک‌کن‌ها و صنعت سیمان برای جداسازی ذرات جامد از جریان گاز استفاده می‌شوند. مدل‌سازی عددی با استفاده از مدل‌های آشوبناکی، مدل‌های زبری سطح، مدل فاز گسسته و مدل فرسایش انجام شده است تا پارامترهای کلیدی مانند افت فشار، سرعت مماسی، سرعت محوری، راندمان جداسازی و نرخ فرسایش دیواره تحلیل شوند. نتایج نشان می‌دهد که افزایش زبری دیواره باعث کاهش سرعت مماسی و در نتیجه کاهش نیروی گریز از مرکز می‌شود که این امر تأثیر منفی بر راندمان جداسازی ذرات دارد. از سوی دیگر، افزایش زبری دیواره منجر به کاهش افت فشار می‌شود که در طراحی سیکلون یک مزیت محسوب می‌گردد. تحلیل نرخ فرسایش نیز نشان می‌دهد که بیشترین فرسایش در بخش مخروطی پایین سیکلون رخ می‌دهد و افزایش زبری دیواره می‌تواند فرسایش را کاهش دهد. به‌طور کلی، این مطالعه نشان می‌دهد که زبری دیواره تأثیرات متضادی بر عملکرد سیکلون دارد—از یک سو افت فشار را کاهش می‌دهد و از سوی دیگر راندمان جداسازی را کم می‌کند؛ بنابراین، بهینه‌سازی زبری سطح برای دستیابی به تعادل بین این دو عامل در طراحی سیکلون‌های گازی محوری ضروری است. نتایج نشان داد که افزایش ناهمواری دیوار، سرعت مماسی را تا ۱۸ درصد کاهش داد، بازده جمع‌آوری سیکلون برای ذرات بزرگ‌تر از ۲۵ میکرومتر تقریباً ۱۲ درصد کاهش یافت، در حالی که افت فشار حدود ۹ درصد کاهش یافت که این موضوع در کاربردهای حساس به انرژی مفید محسوب می‌شود. بیشترین نرخ فرسایش در نوک مخروط سیکلون مشاهده شد و ناهمواری دیوار به کاهش میانگین فرسایش تقریباً ۱۵ درصد کمک کرد.

Keywords Persian

سیکلون گازی محوری
زبری دیواره
افت فشار
فرسایش دیواره
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Journal of Gas Technology
Volume 9, Issue 2 - Serial Number 13
December 2024
Pages 70-87