Abstract: The separation performance of the compound cone hydrocyclone is generally better than that of the single cone design,but the influence mechanism of the combination method of cone sections on separation process has not been fully understood yet,making the structural optimization of composite cone mainly based on production experience. Taking a laboratory ϕ150 mm hydrocyclone as the research object,the influences of the cone angle (10°,15°,20°,and 30°) and combination order of different conical sections on the flow field characteristics and separation performance of dual cone hydrocyclones were investigated using the RSM turbulence model and TFM multiphase flow model,which were also compared with single cone hydrocyclones. The results showed that the influence of cone angle in the dual cone structure is basically the same as that in the single cone,and its separation performance is just between those of two single-cone structures that make up the double-cone design. The partition curve,however, is mainly dependent on the small cone angle. Different conical sections showed distinct effects on separation process. The large cone mainly controls the centrifugal strength and separation sharpness by affecting the pressure drop and tangential velocity,while the small cone mainly determines the cut size,water split,and particle yield to the underflow by affecting the material packing and axial velocity near the spigot. Under the same operating conditions,the separation performance can be significantly improved by reasonably matching different cone sections. Specifically,DC-Ⅰ (30°+10°) has the smallest cut size (d50 = 15. 34 μm),while DC-Ⅳ (10°+30°) gives the highest cut sharpness (α = 7. 34) and lowest energy consumption (P= 67. 09 kPa). These results can provide theoretical guidance for the structural design and optimization
of dual cone hydrocyclones.