ALTERNATIVE CONSTRUCTIVE SOLUTIONS FOR REDUCING ENERGY CONSUMPTION IN DUST-SEPARATION SYSTEMS

Abstract

Cyclone and multisyclone collectors dominate industrial dust abatement thanks to their mechanical robustness, yet the fan power needed to overcome pressure drop (ΔP) can account for 25 – 35 % of a plant’s ventilation load. This study critically reviews and quantifies constructive design modifications that trim specific energy consumption (SEC) without sacrificing collection efficiency (η). A PRISMA-based scoping review of Scopus and Web of Science (January 2023 – May 2025) retrieved 47 papers; 12 high-quality studies met pre-defined inclusion criteria. Key aerodynamic variables were re-calculated and normalised to a Stairmand baseline using Euler (Eu) and power (NP) numbers. Complementary CFD metamodels reproduced the reported geometries to cross-verify ΔP trends. Results show that: (i) secondary vortex finders (SVF) and elliptical bodies achieve ΔP cuts of 30–50 %; (ii) axial-flow cyclones reduce Eu by up to 28 % when optimised for blade angle and exhaust depth; (iii) multi-inlet spirals and draft plates offer 15–25 % savings as low-cost retrofits. Overall, judicious redesign alone can lower SEC by 18 – 45 %, with the greatest gains at Re>2×10⁵. Implementation trade-offs—erosion, scale-up, shifting cut-diameters—are discussed, and a step-wise retrofit roadmap prioritising low-capital measures ahead of full-body replacement is proposed. Future work should integrate ΔP sensors, variable-frequency fans and AI controllers to exploit the reduced resistance dynamically.