Article(id=1320037915305030487, tenantId=1146029695717560320, journalId=1316781260334530699, issueId=1320037738695475401, articleNumber=null, orderNo=null, doi=10.3969/j.issn.1005-0329.2026.05.007, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1755446400000, receivedDateStr=2025-08-18, revisedDate=1744214400000, revisedDateStr=2025-04-10, acceptedDate=null, acceptedDateStr=null, onlineDate=1792651164126, onlineDateStr=2026-10-22, pubDate=1780070400000, pubDateStr=2026-05-30, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1792651164126, onlineIssueDateStr=2026-10-22, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1792651164126, creator=13701087609, updateTime=1792651164126, updator=13701087609, issue=Issue{id=1320037738695475401, tenantId=1146029695717560320, journalId=1316781260334530699, year='2026', volume='54', issue='5', pageStart='1', pageEnd='118', issueExtLink='null', onlineDate='null', pubDate='1780070400000', pubDateStr='2026-05-30', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1792651122020, creator='13701087609', updateTime=1792656245721, updator='13701087609', preIssue=null, nextIssue=null, articleTotal=null, ext={EN=IssueExt(id=1320059229113795207, tenantId=1146029695717560320, journalId=1316781260334530699, issueId=1320037738695475401, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1320059229113795208, tenantId=1146029695717560320, journalId=1316781260334530699, issueId=1320037738695475401, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null, downloadFileDto=null}, startPage=56, endPage=63, ext={EN=ArticleExt(id=1320037915472802648, articleId=1320037915305030487, tenantId=1146029695717560320, journalId=1316781260334530699, language=EN, title=Structural optimization of a two‑stage cyclone liquid-solid separator, columnId=null, journalTitle=Fluid Machinery, columnName=null, runingTitle=null, highlight=null, articleAbstract=

To improve the separation performance of a spiral pipe separator,a novel two‑stage cyclone separator using a spiral pipe assembly as the feed channel was developed.The structural parameters of the device were optimized through orthogonal experiments,and the optimal structure was determined as follows:the spiral pipe has one turn,the ratio of the curvature radius to the cyclone body radius is 0.76,and the outlet of the spiral pipe is located one pipe diameter below the interface between the cylindrical and conical sections of the separator.The separation performance before and after optimization was compared using numerical simulation methods,and validation experiments were conducted on the optimized structure.The results show that after optimization,the pressure distribution in the central region of the device becomes more uniform,the negative pressure region shrinks significantly,and the pressure loss is reduced.The swirling velocity increases,the centrifugal force is enhanced,promoting particle movement toward the wall,thereby strengthening liquid-solid separation.With the radial position r/R=0.5 as the boundary,the average solid phase concentration on the side near the wall increases by 5.1%,while the average concentration in the central region of the separator decreases by 28%.The residence time of solid particles inside the cyclone is shortened,and the number of particles escaping from the overflow port is reduced.The optimization of the spiral pipe structural parameters enhances the flow near the wall in the secondary cyclone region while reducing the disturbance to the central fluid,which is beneficial for the liquid-solid separation process in the two‑stage cyclone separator.This study can provide a reference for the engineering design and application of two‑stage cyclone separators.

, authors=Jing ZHANG1, 2, Guangtian LIU1, Bin GONG1, Zhonghao WANG1, Changquan YU1, authorsList=Jing ZHANG, Guangtian LIU, Bin GONG, Zhonghao WANG, Changquan YU, authorCompany=null, correspAuthors=Bin GONG, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, fund=null), CN=ArticleExt(id=1320037917158912875, articleId=1320037915305030487, tenantId=1146029695717560320, journalId=1316781260334530699, language=CN, title=两级旋流液固分离器结构优化, columnId=1317484287230853622, journalTitle=流体机械, columnName=设计计算, runingTitle=null, highlight=null, articleAbstract=

为提高螺旋管分离器的分离性能,研发了一种以螺旋管组作为进料通道的新型两级旋流分离器。采用正交试验对设备的结构参数进行优化设计,确定最优结构:螺旋管圈数为1圈,曲率半径与筒体半径之比为0.76,螺旋管出口位于分离器柱锥分界面以下1倍管径处。通过数值模拟方法对比优化前后的分离性能,并对优化后结构开展验证性试验。结果表明:优化后设备内部中心区域压力分布更加均匀,负压区域大幅收缩,压力损失降低;旋流速度提高,离心力增强,促使颗粒向壁面移动,从而强化液固分离;以径向位置r/R=0.5为界,靠近壁面侧的固相相含率均值提升了5.1%,分离器中心区域的相含率均值下降了28%;固相颗粒在旋流器内部的停留时间缩短,从溢流口逃逸的颗粒数量减少。螺旋管结构参数的优化增强了二级旋流区壁面附近的流动,同时降低了对中心流体的扰动,有利于两级旋流分离器内的液固分离过程。研究可为两级旋流分离器的工程设计与应用提供参考。

, authors=张静1, 2, 刘广田1, 龚斌1, 王忠浩1, 于长泉1, authorsList=张静, 刘广田, 龚斌, 王忠浩, 于长泉, authorCompany=null, correspAuthors=龚斌, authorNote=

张静(1971),女,教授,硕士生导师,研究方向为化工过程强化,E-mail:。

, correspAuthorsNote=
龚斌(1973),男,教授,硕士生导师,研究方向为化工过程强化,通信地址:110142辽宁省沈阳市经济技术开发区11号街沈阳化工大学机械与动力工程学院,E-mail:。
, copyrightStatement=作者向本刊所投稿件一经本刊录用,则该论文的复制权、发行权、信息网络传播权、翻译权、汇编权等权利视为自动转让给本刊。本刊为国内各主要数据库收录期刊,本刊所发表的稿件将同时通过互联网进行网络出版或提供信息服务。, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=OzG/QmnZAbMvCU94GWfsIA==, magXml=qDVlvUwI8GmXQBXP0hYEKQ==, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=kuJMGpCD1xBUNj4UBLy0xg==, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=aQr6PulYvBDwmRiAluAUqg==, mapNumber=null, fund=null)}, authors=[Author(id=1320037919264453491, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1320037915305030487, orderNo=0, firstName=null, middleName=null, lastName=null, nameCn=null, orcid=null, stid=null, country=null, authorPic=null, dead=0, email=2501474185@qq.com, emailSecond=null, emailThird=null, correspondingAuthor=0, authorType=1, ext={EN=AuthorExt(id=1320037919356728182, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1320037915305030487, authorId=1320037919264453491, language=EN, stringName=Jing ZHANG, firstName=Jing, middleName=null, lastName=ZHANG, prefix=null, suffix=null, authorComment=null, nameInitials=null, affiliation=null, department=null, xref=1, 2, address=1School of Mechanical and Power Engineering,Shenyang University of Chemical Technology,Shenyang 110142,China
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张静(1971),女,教授,硕士生导师,研究方向为化工过程强化,E-mail:。

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张静(1971),女,教授,硕士生导师,研究方向为化工过程强化,E-mail:。

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articleId=1320037915305030487, language=CN, label=图9, caption=数值模拟与试验结果对比, figureFileSmall=F7FjhN1CsEco/U9fWBbjIA==, figureFileBig=0K/TXuHTbi5ibqukiYY4vw==, tableContent=null), ArticleFig(id=1320037928735191981, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1320037915305030487, language=EN, label=Tab.1, caption=

Structural parameters of a two‑stage cycloneliquid-solid separator

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参数数值
筒体高度H/mm480
锥段高度H1/mm230
柱段直径D/mm300
柱段半径R/mm150
溢流口直径D1/mm60
底流口直径D2/mm50
螺旋管内径d/mm20
螺距hp/mm100
螺旋管圈数n1.5
螺旋管曲率半径与筒体半径之比Rc/R0.8
螺旋管出口与柱锥分界面无量纲距离L/d1
), ArticleFig(id=1320037928831660974, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1320037915305030487, language=CN, label=表1, caption=

两级旋流液固分离器结构参数

, figureFileSmall=null, figureFileBig=null, tableContent=
参数数值
筒体高度H/mm480
锥段高度H1/mm230
柱段直径D/mm300
柱段半径R/mm150
溢流口直径D1/mm60
底流口直径D2/mm50
螺旋管内径d/mm20
螺距hp/mm100
螺旋管圈数n1.5
螺旋管曲率半径与筒体半径之比Rc/R0.8
螺旋管出口与柱锥分界面无量纲距离L/d1
), ArticleFig(id=1320037928915547055, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1320037915305030487, language=EN, label=Tab.2, caption=

Test factors and levels

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水平因素
ABC
11.000.761
21.250.800
31.500.84-1
), ArticleFig(id=1320037928982655920, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1320037915305030487, language=CN, label=表2, caption=

试验因素和水平

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水平因素
ABC
11.000.761
21.250.800
31.500.84-1
), ArticleFig(id=1320037929058153393, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1320037915305030487, language=EN, label=Tab.3, caption=

Orthogonal experiment results

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序号因素组合评价指标
ABCη/%f
11.000.761A1B1C179.910.37
21.000.800A1B2C280.380.39
31.000.84-1A1B3C376.571.04
41.250.76-1A2B1C379.650.68
51.250.801A2B2C176.471.07
61.250.840A2B3C265.711.68
71.500.760A3B1C267.541.67
81.500.80-1A3B2C368.551.65
91.500.841A3B3C161.712.62
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正交试验结果

, figureFileSmall=null, figureFileBig=null, tableContent=
序号因素组合评价指标
ABCη/%f
11.000.761A1B1C179.910.37
21.000.800A1B2C280.380.39
31.000.84-1A1B3C376.571.04
41.250.76-1A2B1C379.650.68
51.250.801A2B2C176.471.07
61.250.840A2B3C265.711.68
71.500.760A3B1C267.541.67
81.500.80-1A3B2C368.551.65
91.500.841A3B3C161.712.62
), ArticleFig(id=1320037929230119859, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1320037915305030487, language=EN, label=Tab.4, caption=

Range analysis results

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项目η/%f
ABCABC
k178.9575.7072.700.600.911.35
k273.9475.1371.211.141.041.25
k365.9368.0074.921.981.781.12
Ra13.027.703.711.380.870.23
), ArticleFig(id=1320037929301423028, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1320037915305030487, language=CN, label=表4, caption=

极差分析结果

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项目η/%f
ABCABC
k178.9575.7072.700.600.911.35
k273.9475.1371.211.141.041.25
k365.9368.0074.921.981.781.12
Ra13.027.703.711.380.870.23
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两级旋流液固分离器结构优化
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张静 1, 2 , 刘广田 1 , 龚斌 1 , 王忠浩 1 , 于长泉 1
流体机械 | 设计计算 2026,54(5): 56-63
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流体机械 |设计计算 2026 , 54 (5) : 56 -63
两级旋流液固分离器结构优化
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张静1, 2 , 刘广田1, 龚斌1 , 王忠浩1, 于长泉1
作者信息
  • 1沈阳化工大学 机械与动力工程学院,沈阳 110142
  • 2天津大学 化工学院,天津 300350
通讯作者:
龚斌(1973),男,教授,硕士生导师,研究方向为化工过程强化,通信地址:110142辽宁省沈阳市经济技术开发区11号街沈阳化工大学机械与动力工程学院,E-mail:。
作者简介:

张静(1971),女,教授,硕士生导师,研究方向为化工过程强化,E-mail:。

Structural optimization of a two‑stage cyclone liquid-solid separator
Jing ZHANG1, 2 , Guangtian LIU1, Bin GONG1 , Zhonghao WANG1, Changquan YU1
Affiliations
  • 1School of Mechanical and Power Engineering,Shenyang University of Chemical Technology,Shenyang 110142,China
  • 2School of Chemical Engineering and Technology,Tianjin University,Tianjin 300350,China
出版时间: 2026-05-30 doi: 10.3969/j.issn.1005-0329.2026.05.007
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为提高螺旋管分离器的分离性能,研发了一种以螺旋管组作为进料通道的新型两级旋流分离器。采用正交试验对设备的结构参数进行优化设计,确定最优结构:螺旋管圈数为1圈,曲率半径与筒体半径之比为0.76,螺旋管出口位于分离器柱锥分界面以下1倍管径处。通过数值模拟方法对比优化前后的分离性能,并对优化后结构开展验证性试验。结果表明:优化后设备内部中心区域压力分布更加均匀,负压区域大幅收缩,压力损失降低;旋流速度提高,离心力增强,促使颗粒向壁面移动,从而强化液固分离;以径向位置r/R=0.5为界,靠近壁面侧的固相相含率均值提升了5.1%,分离器中心区域的相含率均值下降了28%;固相颗粒在旋流器内部的停留时间缩短,从溢流口逃逸的颗粒数量减少。螺旋管结构参数的优化增强了二级旋流区壁面附近的流动,同时降低了对中心流体的扰动,有利于两级旋流分离器内的液固分离过程。研究可为两级旋流分离器的工程设计与应用提供参考。

两级旋流  /  液固分离  /  螺旋管  /  正交试验  /  分离效率

To improve the separation performance of a spiral pipe separator,a novel two‑stage cyclone separator using a spiral pipe assembly as the feed channel was developed.The structural parameters of the device were optimized through orthogonal experiments,and the optimal structure was determined as follows:the spiral pipe has one turn,the ratio of the curvature radius to the cyclone body radius is 0.76,and the outlet of the spiral pipe is located one pipe diameter below the interface between the cylindrical and conical sections of the separator.The separation performance before and after optimization was compared using numerical simulation methods,and validation experiments were conducted on the optimized structure.The results show that after optimization,the pressure distribution in the central region of the device becomes more uniform,the negative pressure region shrinks significantly,and the pressure loss is reduced.The swirling velocity increases,the centrifugal force is enhanced,promoting particle movement toward the wall,thereby strengthening liquid-solid separation.With the radial position r/R=0.5 as the boundary,the average solid phase concentration on the side near the wall increases by 5.1%,while the average concentration in the central region of the separator decreases by 28%.The residence time of solid particles inside the cyclone is shortened,and the number of particles escaping from the overflow port is reduced.The optimization of the spiral pipe structural parameters enhances the flow near the wall in the secondary cyclone region while reducing the disturbance to the central fluid,which is beneficial for the liquid-solid separation process in the two‑stage cyclone separator.This study can provide a reference for the engineering design and application of two‑stage cyclone separators.

two‑stage cyclone  /  liquid-solid separation  /  spiral pipe  /  orthogonal experiment  /  separation efficiency
张静, 刘广田, 龚斌, 王忠浩, 于长泉. 两级旋流液固分离器结构优化. 流体机械, 2026 , 54 (5) : 56 -63 . DOI: 10.3969/j.issn.1005-0329.2026.05.007
Jing ZHANG, Guangtian LIU, Bin GONG, Zhonghao WANG, Changquan YU. Structural optimization of a two‑stage cyclone liquid-solid separator[J]. Fluid Machinery, 2026 , 54 (5) : 56 -63 . DOI: 10.3969/j.issn.1005-0329.2026.05.007
旋流分离器结构简单、操作灵活、处理量大,被广泛用于液固分离过程,在水处理和固废回收等领域已取得显著成效[1-2]。随着环保要求的提高,对旋流分离器的分离效率和分离精度的要求也越来越高,单级旋流分离器已无法满足工业应用需求。旋流器的改进方案以串联和并联为主,可有效提高分离效率、扩大生产能力,并适用于复杂工艺,其结构优化设计决定了设备的投资成本及工业推广的可行性[3-4]。
多入口并联设计方案对于提升旋流分离过程具有重要意义[5]。ZHANG等[6]指出,周向多入口可以缓解射流入口的局部扰动,降低分离器内壁的冲蚀磨损速率。董思捷等[7]将多个切向入口设置在径向外侧,设备压降降低,短路流量占比减少,更有利于小颗粒分离。李彦熹等[8]设计了一种新型蜗壳式多通道旋流分离器,并对其进行了结构优化,有效解决了单入口引起的空气核偏心现象及振荡问题。HO等[9]提出采用2个对称入口,可以降低涡流强度,与单入口旋流分离器相比,分离效率提高约10%。李美求等[10]研究发现,四入口结构具有更加稳定和对称的流场分布,可获得更好的分离效果。
螺旋导叶结构通常用于提高旋流分离器的分离效率[11]。在传统水力旋流器中加装螺旋导流板,可以降低分离器的压降,并减小可分离的颗粒粒径,有利于非均相介质的分离[12-13]。徐保蕊等[14]设计了一种新型螺旋分离器,在其内部加装螺旋导流结构,流体经过螺旋分离段后,在出口形成稳定的螺旋流场。TANG等[15]在旋流器中增设螺旋导流板,该螺旋-旋流组合在天然气水合物地下开采的分离除砂方面表现出良好的分离性能。YUAN等[16]提出一种在旋风分离器环形空间内增设螺旋导叶的设计方案,有效延长了流体在环形空间内的平均停留时间,减少了因短路流而逃逸的颗粒数量,增强了流动稳定性。HU等[17]提出了一种螺旋导流气液分离器,在其内部增设螺旋分流结构,分离效率比传统的重力式气液分离器提高了5.7%。
现有螺旋导流结构设计中,导流片上易产生物料沉积,同时在溢流管底部物料发生局部混合,单通道流场的偏斜也降低了液固分离的稳定性。为了提高分离效率、降低设备改造成本,本文设计一种两级旋流分离器[18]。该分离器利用螺旋管组实现多入口结构,在液固两相分离过程中,采用重力分离与离心分离相结合的方式,实现非均相混合物的连续稳定分离,从而有效提高分离效率。同时,为探究螺旋管组结构参数对分离效率的影响,采用正交试验法开展结构参数优化研究。通过CFD模拟分析旋流分离器内液固两相流场,得出不同因素对底流分配率及阻力系数的影响程度与规律。利用最优结构参数,在不同流量下对优化后的结构进行试验,以验证数值模拟优化方案的可行性,为旋流非均相分离技术的创新与应用优化提供参考。
模型由筒体和4根螺旋管组成。筒体上半部分为圆柱面,下半部分为圆锥面;螺旋管组盘绕于筒体内部,其出口与筒体内壁相切。螺旋管组采用并联入口结构,与分离器形成两级串联,以实现强化液固分离的目的。为探究一级旋流后二级旋流的分离效果,选取柱锥分界面下方60 mm处作为分析线。物理模型如图1所示,具体结构参数如表1所示。
新型两级旋流分离器的强化分离原理如图2所示。液固混合物由物料入口进入并联螺旋管组内,在螺旋管中形成旋流流动。在离心力作用下,密度较大的固相颗粒向螺旋管外侧移动,混合相在螺旋管内实现一级分离。与常规旋流分离器相比,新型两级旋流分离器通过在内部增设螺旋管组,形成两级串联结构。由于螺旋管出口与分离器内表面相切,周向多个切向出口使分离器内近壁面的流动叠加,形成强旋流,从而实现二级分离。物料经螺旋管初次分离后进入分离器锥段进行二次分离,在分离器底部,切向速度周向分布均匀,有效解决了流动偏心问题,提高了旋流分离器的液固分离效率。经过两级旋流分离后,固相颗粒从底流口流出进入沉降池,液相从溢流口排出。
采用四面体非结构化网格对物理模型进行划分。在网格生成过程中,对旋流分离器螺旋管切向出口的局部区域进行细化,以准确捕捉一级至二级分离过程中的流动特性。物料入口及螺旋管区域的网格尺寸设为3 mm,其余部分网格尺寸设为7 mm。对分离器入口和螺旋管内外壁面进行加密,获得网格数量为1 763 148的网格方案。由于固相颗粒主要在螺旋管内及分离器内近壁面区域流动,近壁面网格质量对数值模拟结果有较大影响。对分离器内壁面第1~3层网格进行悬挂节点加密,以提高分离器近壁面的网格质量,满足数值模拟的计算精度要求。由此获得网格数量分别为1 968 733,2 132 204,2 352 403共3种网格方案。选取柱锥分界面下方60 mm处分析线上的无量纲切向速度(ut/uin)进行网格无关性分析,如图3所示。网格数为1 763 148的方案切向速度较低,与其他3种方案的切向速度差距较大;其余3种方案所得的切向速度分布趋于一致。综合考虑计算精度与时间成本,确定采用网格数量为2 132 204的网格方案,其雅可比比率为1,网格平均质量为0.839。
数值模拟选用Realizable k-ε与Mixture模型耦合计算液固两相流体流动[19],以水和CaCO3的混合物为模拟介质。其中,水为连续相,密度为998.2 kg/m3,动力黏度为1.003×10-3 Pa⋅s;CaCO3为离散相,密度2 800 kg/m3,颗粒粒径为50 μm。边界条件设置如下:物料入口定义为速度入口,入口速度为0.3 m/s(对应流量为1.4 m3/h),离散相体积分数为10%;溢流口与底流口均定义为自由流出口,底流口流量为总流量的60%;壁面设置为无滑移壁面。压力-速度耦合方式采用SIMPLEC算法,压力梯度采用Green-Gauss Node-Based方法计算,压力离散采用适合螺旋流的PRESTO!格式[20],体积分数采用QUICK格式,动量、湍流动能和湍流耗散率均采用二阶迎风格式,收敛极限设置为10-5。
为了提高分离效率并降低阻力系数,需对旋流器的结构参数进行优化,这些参数是影响液固两相分离的主要因素。前期研究表明,4个螺旋管出口产生的流动叠加使颗粒向壁面聚集的效果最佳[6],且螺旋管曲率半径对分离效率的影响比螺距更为显著[21]。综合考量多种因素,文中选取结构设计中较为重要的3个参数——n,Rc/R和L/d,并分别设置为因素A,B,C,对旋流分离器进行结构优化。采用正交试验方法,分析影响分离效率的主要因素及各因素对评价指标的影响程度。根据现有旋流分离器结构参数的研究,每个因素设置3个水平,具体参数设置如表2所示。
为了得到优化参数,选择旋流分离器底流分配率η和阻力系数f作为分离性能的评价指标。
η=mDown-outletmInlet
f=pInlet-pDown-outletρmuin2/2
式中,mDown-outlet为底流口的CaCO3质量,kg;mInlet为入口的CaCO3质量,kg;pInlet,pDown-outlet分别为入口和底流口的压力,Pa;ρm为混合相密度,kg/m3;uin为入口流速,m/s。
按照正交试验对不同结构参数组合进行数值模拟,以底流分配率η和阻力系数f为评价指标,并将各结构参数组合及其对应的η和f结果列于正交表中,如表3所示。其中,基于A2B2C1的分离器结构参数与表1一致。
对表3中的正交试验结果进行极差分析,表4列出η和f的极差分析结果(其中,k表示某一因素在不同水平下对应评价指标的平均值;极差Ra定义为各水平下k值的最大值与最小值之差,反映了该因素对评价指标的影响程度)。可以看出,对于η和f,螺旋管圈数(因素A)的影响均最大。当螺旋管圈数n=1时,η最大,f最小,即因素A的最佳水平为A1。当螺旋管曲率半径与筒体半径之比减小时,管内离心力增大,同时管长缩短,因此,因素B的最佳水平为B1。当螺旋管出口位于柱锥分界面下方20 mm(L/d=-1)时,出口与锥面距离最近,颗粒更容易贴附在壁面上移动,因此,因素C的最佳水平为C3。最终得到的最佳设计参数组合为A1B1C3,即n=1,Rc/R=0.76,L/d=-1时,η与f的综合评价效果最优。
参照表1中的结构设计参数,按照A1B1C3对应的参数完成最优方案的模型建立。在操作条件与边界条件相同的前提下,对两级旋流液固分离器的分离性能进行数值模拟分析,得到该组合条件下η为83.37%,f为0.51。
为验证优化设计参数下分离性能的显著提升,对比了优化后结构(A1B1C3)与表1所示结构(A2B2C1)的模拟结果,以说明优化参数条件下液固两相分离的优越性。选取旋流分离器纵剖面上的混合相流场进行分析,并利用分析线上的数据进行量化处理。
利用2p/(ρuin2)对压力进行无量纲化处理。图4示出优化前后旋流分离器纵剖面及分析线上的无量纲压力分布。由图4(a)可以看出,优化后中心区域压力分布更加均匀,负压区域大幅收缩(优化前负压区体积占比60.2%,优化后占比28.5%),降低了颗粒从底流口回流的可能性。同时,优化前后无量纲压力最高值分别为2.92和3.77,优化后2p/(ρuin2)>2.0的区域明显大于优化前,说明优化后设备阻力显著下降。由于优化后Rc/R变小,离心力增强,底流口附近压力梯度沿径向提高,有助于维持底流口排放顺畅,减少颗粒堵塞的风险。对分析线上压力分布的比较〔见图4(b)〕表明,轴线上(r/R=0)的压力优化前为-2.23,优化后为-1.32;同时,优化前后压力平均值分别为-0.70和0.02,优化后压力明显高于优化前。其原因在于,优化后螺旋管圈数减少,且螺旋管出口到底流口的距离缩短,均有效降低了流动阻力。
图5示出优化前后旋流分离器纵剖面及分析线上的无量纲切向速度分布。可以看出,优化后高速区(ut/uin>1.0)向底流口方向偏移;ut/uin的最大值在优化前为1.7,优化后为1.73;同时,优化前后分析线上的切向速度均呈M形分布。经计算,与优化前相比,优化后的旋流器在径向位置r/R<0.4的中心区域切向速度降低了11%,而在r/R>0.4的区域切向速度提高了11.2%。优化后结构有效提升了底流口附近的旋流强度,增强了颗粒所受离心力,促使固相向壁面移动,从而强化了液固分离。
为说明优化后设备内流场对液固分离的强化作用,图6示出优化前后旋流分离器纵剖面及分析线上的相含率分布。由图6(a)可以看出,优化前后最大相含率均出现在旋流器底流口附近,且优化后分离器内部的固相颗粒向筒体壁面聚集更明显。由图6(b)可以看出,从旋流器中心到壁面处,相含率逐渐增加。在r/R>0.5的区域,优化后的相含率比优化前提高了5.1%;在r/R<0.5范围内,优化后的固相相含率明显低于优化前,均值降低了28%。
文中研究表明,由于螺旋管出口处固相颗粒与分离器内壁面发生碰撞,部分颗粒离散分布于旋流器内部。在优化前结构中,螺旋管出口与壁面之间存在一定空间,螺旋管出口射流扩散导致颗粒先分散、后撞壁。而在优化后结构中,螺旋管出口与壁面的距离缩短了44%,有效减少了因射流扩散引起的固相颗粒轨迹分散现象。固相颗粒撞壁后沿锥面螺旋下滑;优化后的结构改变了固相颗粒在分离器内的空间分布,使更多颗粒聚集于靠近壁面侧的底流口,从而使得底流分配率较优化前提高了6.9%。
图7(a)示出优化前后离散颗粒在旋流器内部的停留时间分布。优化后固相颗粒的最大停留时间减少,从溢流口逃逸的颗粒数量少于优化前。优化前,固相颗粒从螺旋管出口排出后撞壁,在连续相作用下于分离器内部螺旋上升,最终从溢流口流出。优化后,分离器内螺旋管出口与壁面接近相切,局部流动阻力减弱;固相颗粒受重力和离心力作用,沿壁面螺旋下降至底流口,几乎所有颗粒均从底流口排出。由于优化后螺旋管出口位置降低,固相颗粒停留时间缩短,能够快速沿壁面向底流口流动,有效提升了分离效率。图7(b)示出对底流分配率的统计分析。优化后结构在40 s时底流口排放颗粒比率趋于稳定,达到83.37%;优化前结构在50 s时逐渐稳定,达到76.47%。在50~60 s的稳定分离时间段内,优化后底流分配率较优化前提高了6.9%,且优化后的曲线更加平稳,更有利于液固分离过程的控制。
由上述分析可知,优化后的结构在二级旋流区中心处的负压区收缩,靠近壁面侧的切向速度提高,有效增强了分离器内部的离心力场,使固相颗粒更容易被甩向壁面,加速颗粒向底流口流动。结合相含率分布结果可以看出,优化后颗粒向壁面聚集的效果显著提升。设备中心区域的颗粒含量下降,有效降低了颗粒从溢流口逃逸的比例。
对优化后的两级旋流分离器进行液固分离试验,试验装置如图8所示,其由循环水箱、水泵、流量计、旋流分离器及附件等组成。
试验采用CaCO3颗粒,利用激光粒度分析仪测定颗粒群的中位粒径为50.2 μm。试验中颗粒的初始加入量占进口连续相体积流量的10%,与模拟中设定的体积分数和颗粒粒径保持一致。通过水泵出口阀门控制旋流分离器的入口流量分别为1.4,1.6,1.8,2.0,2.2 m3/h,同时调节溢流口及底流口阀门,以控制底流分流比。
为计算底流口排出固相颗粒的比率,循环水路中设置2个水箱(底流水箱和溢流水箱),且2个水箱之间用管子连通。底流口与溢流口分别与2个水箱连接,水泵入口与底流水箱连接。每个操作参数下从底流水箱中取样5次,计算底流分配率。入口流量分别为1.4,1.6,1.8,2.0,2.2 m3/h时,旋流分离器试验与模拟底流分配率对比曲线如图9所示。随处理量增加,旋流器的分离效率逐渐降低。旋流器入口面积固定,持续增大入口流量(即增大入口流速),湍流作用增强,致使内部流场紊乱,增加了旋流分离的难度,导致分离效率降低。试验值与模拟值的相对误差为3.47%。试验值略低的原因:每次投入颗粒后,待流动进入稳定状态再进行取样,部分颗粒残留在溢流水箱中,导致试验值略低于模拟值。综合试验结果与模拟结果,优化后结构的底流分配率相较于优化前均有提升,其中在入口流量1.4 m3/h时提升了9.0%,在入口流量2.2 m3/h时提升了1.9%。
(1)螺旋管圈数对底流分配率和阻力系数的影响较大。随着螺旋管圈数的增加,颗粒流动阻力增大,在螺旋管内的停留时间延长,不利于提高分离效率。
(2)通过分析结构参数对底流分配率及阻力系数的影响,确定最佳结构设计参数:螺旋管圈数n=1,螺旋管曲率半径与筒体半径之比Rc/R=0.76,螺旋管出口与柱锥分界面无量纲距离L/d=-1。优化后结构的分离效率为83.37%。
(3)优化后分离器内靠近壁面侧的切向速度提高,有效增强了离心力场,固相颗粒在近壁面处的流动更加稳定,加速了颗粒向底流口的运动,有助于强化液固分离过程。同时,负压区收缩、底流口处径向压力梯度增加,均有利于颗粒从底流口顺利排出。
(4)将入口流量为1.4~2.2 m3/h范围内的试验结果与数值模拟结果进行对比,结果表明,该工况下的试验数据充分验证了数值模拟的可靠性。优化后结构的底流分配率相较于优化前提升了1.9%~9.0%,且在处理量较低时底流分配率更高。

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2026年第54卷第5期
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doi: 10.3969/j.issn.1005-0329.2026.05.007
  • 接收时间:2025-08-18
  • 首发时间:2026-10-22
  • 出版时间:2026-05-30
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  • 收稿日期:2025-08-18
  • 修回日期:2025-04-10
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    1沈阳化工大学 机械与动力工程学院,沈阳 110142
    2天津大学 化工学院,天津 300350

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龚斌(1973),男,教授,硕士生导师,研究方向为化工过程强化,通信地址:110142辽宁省沈阳市经济技术开发区11号街沈阳化工大学机械与动力工程学院,E-mail:。
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2种不同金属材料的力学参数
科
Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)
属
Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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