Review on the Optimal Design of Cyclone Separator: Theory, Methodology, and Applications

Cyclone separators are highly efficient gas-solid separation that operate on the centrifugal force and play an indispensable role in industries such as chemical engineering, environmental protection, and power generation. They exhibit excellent reliability, particularly under demanding conditions such as high temperatures and elevated particle concentrations. However, a persistent trade-off between separation efficiency and pressure drop has limited further performance improvements. To address this, optimization of cyclone separators has become a major research focus. This article systematically reviews recent advances, first by examining the mechanisms through which key structural parameters, such as inlet geometry, exhaust pipe diameter, and cone angle, influence performance across different industrial applications. Furthermore, the review introduces an integrated optimization framework based on computational fluid dynamics (CFD) simulations, surrogate modelling, and intelligent optimization algorithms to enhance design performance. It critically compares the applicability and limitations of various high-dimensional optimization methods and their integration strategies. The article underscores a paradigm shift from optimizing instantaneous performance toward establishing a lifecycle optimization (LCO) framework that incorporates long-term metrics such as wear and maintenance costs. Evidence shows that coupling CFD with intelligent algorithms enables efficient exploration of multi-objective parameter spaces. Finally, the article discusses current limitations in optimization research and outlines future directions, including multi-physics coupling involving flow, heat, and particle transport, lifecycle optimization, and intelligent decision support systems. In summary, this review establishes a theoretical foundation and provides technical guidance for the energy-efficient, high-performance design and industrial implementation of cyclone separators.