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The purpose of this paper is to propose an effective methodology for the industrial design of tangential inlet cyclone separators that is based on the fully three-dimensional (3D) simulation of the flow field within the cyclone coupled with an effective genetic algorithm.

The proposed fully 3D computational fluid dynamics (CFD) model makes use of the Reynold stress model for the accurate prediction of turbulence, while the particle trajectories are simulated using the one-way coupling discrete phase, which is a model particularly effective in case of low concentration of dust. To validate the CFD model, the numerical predictions are compared with experimental data available in the scientific literature. Eight design parameters were chosen, with the two objectives being the minimization of the pressure drop and the maximization of the collection efficiency.

The optimization procedure allows the determination of the Pareto Front, which represents the set of the best geometries and can be instrumental in taking an optimal decision in the presence of such a trade-off between the two conflicting objectives. The comparison among the individuals belonging to the Pareto Front with a more standard cyclone geometry shows that such a CFD global search is very effective.

The proposed procedure is tested for specific values of the operating conditions; however, it has general validity and can be used in place of typical procedures based on empirical models or engineers’ experience for the industrial design of tangential inlet cyclone separators with low solid loading.

Such an optimization process has never been proposed before for the design of cyclone separators; it has been developed with the aim of being both highly accurate and compatible with the industrial design time.

The purpose of this paper is to present a full 3D Computational Fluid Dynamics (CFD) analysis of the flow field through hydraulic directional proportional valves, in order to accurately predict the flow forces acting on the spool and to overcome the limitations of two-dimensional (2D) and simplified three-dimensional (3D) models.

A full 3D CAD representation is proposed as a general approach to reproduce the geometry of an existing valve in full detail; then, unstructured computational grids, which identify peculiar positions of the spool travel, are generated by means of the mesh generation tool Gambit. The computational grids are imported into the commercial CFD code Fluent, where the flow equations are solved assuming that the flow is steady and incompressible. To validate the proposed computational procedure, the predicted flow rates and flow forces are compared with the corresponding experimental data.

The superposition between numerical and experimental curves demonstrates that the proposed full 3D numerical analysis is more effective than the simplified 3D flow model that was previously proposed by the same authors.

The presented full 3D fluid dynamic analysis can be employed for the fluid-dynamic design optimization of the sliding spool and, more generally, of the internal profiles of the valve, with the objective of reducing the flow forces and thus the required control force.

The paper proposes a new computational strategy that is capable of recognizing all 3D geometrical details of a hydraulic directional proportional valve and that provides a significant improvement with respect to 2D and partially 3D approaches.