Numerical Simulation of a Novel Secondary Separation Cyclone

The low separation efficiency of conventional cyclone separators for sub-10 μm particles remains a critical challenge in Na2S production processes. Previous optimization attempts have failed to reconcile economic feasibility with effective fine particle capture requirements. To address this industrial bottleneck, we propose an innovative secondary separation cyclone design tailored for next-generation Na2S manufacturing systems. Our methodology synergizes computational fluid dynamics (CFD) simulations with experimental validation, achieving cost-effective development while ensuring numerical model reliability. Comparative analyses reveal significant improvements: under varying gas velocities, the novel design demonstrates 5.67–9.77% and 7.03–10.14% enhancements in 1–10 μm particle collection efficiency compared to standard and volute-type cyclones, respectively. Mechanistic investigations through flow field characterization elucidate the relationship between vortex dynamics and separation performance. This work provides a structurally optimized cyclone configuration with industrial applicability, as well as a validated hybrid experimental–computational framework that could inform solutions for fine particle separation across chemical processing industries.