Numerical simulation of a square cyclone having different baffle configurations installed inside the inlet manifold

Improving the collection efficiency of square cyclones is vital for industrial applications demanding high particulate separation performance. Despite the installation of baffles in the entrance region of a square cyclone being proposed as a potential solution for enhanced performance, detailed studies on their design and impact are unavailable in the literature. In due course, this study was planned with a focused novelty to address this gap by conducting comprehensive CFD simulations to evaluate the effects of baffle type and configuration on cyclone performance. Two baffle designs, namely: straight and curved, are investigated, along with three vertical distances (d_v = 10 mm, 20 mm, and 30 mm) from the top edge. The Reynolds Stress Turbulence Model (RSM) is used, coupled with the discrete phase model (DPM) for particle tracking. The analysis reveals that baffles significantly increase the total pressure drop but markedly reduce the cut-off diameter (d_cut). Straight baffles outperform curved ones in boosting efficiency, with shorter d_v values further improving performance. The best configuration is that with a straight baffle at d_v = 10 mm, which achieves a remarkable d_cut of 2.2µm, demonstrating superior particle separation. These findings are providing valuable insights for researchers and engineers seeking to optimize baffle-enhanced square cyclones, paving the way for more efficient industrial dust collection systems.