Effect of Operational and Geometric Variables in Hydrocyclones to Improve Separation Efficiency and Reduce Energy Consumption: A Review and New Insights

Hydrocyclones utilize centrifugal sedimentation to separate dispersed phases from a continuous liquid phase, offering advantages such as the absence of moving parts, ease of operation, and low maintenance costs. They are widely used in the mineral, petrochemical, and biotechnological industries, with their performance being significantly influenced by geometric and operational variables. This review examines the impact of key geometric (e.g. inlet, cone, vortex finder, overflow, outflow, and cylinder) and operational (e.g. particle size, solid concentration, feed flow rate, and pressure drop) parameters on hydrocyclone performance. Recent innovations, new developments, and perspectives to address specific industrial demands are also discussed.