Multi-objective optimization of hydrocyclones inlet configurations for improving separation performance

Novel hydrocyclone inlet designs can improve the specific performance objectives, however, the overall performance improvement, comprehensively considering multiple key objectives, is not clearly investigated yet. This study proposes an integrated optimization approach that combines response surface methodology (RSM) and multi-objective optimization (MOO) to optimize four key performance objectives for a traditional inlet (TI) and two novel designs: the tangent circle inlet (TCI) and the tapered spiral inlet (TSI). The well validated RSM establishes the relationship between inlet variables and objectives. The MOO method generates the Pareto-optimal set to capture the trade-offs among these objectives and identifies the optimal solution for overall separation performance. Results indicate that each inlet type is optimally suitable for different separation scenarios: TSI prioritizes separation performance over energy consumption, TCI maintains moderate separation performance and energy consumption, and TI minimizes energy consumption with compromises in separation performance. This study offers valuable insights into hydrocyclones optimization.