As a widely used separation device, a cyclone separator is especially important to improve its separation efficiency. In this paper, a new two-stage cyclone separator is designed and modeled by the Reynolds stress model. Under the premise of determining the diameter of the second-stage cyclone (D), the effects of five first-stage cyclone diameters (Du) on the performance of the two-stage cyclone are simulated. The performance of the single-stage cyclone separator is also obtained. The results show that Du has significant effects on the internal pressure field, flow field, and vortex core of the two-stage cyclone. Compared with the single-stage cyclone separator, the separation efficiency of the two-stage cyclone separator is significantly improved. When Du = 6D, the separation efficiency is improved by 15.5% compared with that of the single-stage cyclone. In addition, the two-stage cyclone separator can effectively reduce the Euler number.

The adhesion of dust particles on the surface of the dust collector tends to cause great resistance to the dust collector and affects the operating efficiency. In order to visualize particles in the filtration process and to grasp the mechanism of particle viscosity and sphericity on filtration performance, a numerical simulation study was conducted to investigate the deposition behavior of particles during filtration, employing FLUENT-EDEM coupling technology. By examining the deposition process, the role of particle characteristics on dust behavior within the entire filtration system was elucidated. The effects of varying particle surface energy and particle sphericity on filtration pressure drop and cake porosity were analyzed. The findings reveal that under the force of the air, particles on the surface of the filter membrane experience compaction, leading to a reduction in the porosity of the formed cake layer. The diminution of porosity serves to impede the air, consequently augmenting the pressure drop across the filtration system and hindering the operational efficacy of the dust collector. As the surface energy of the particles increases, the adhesive forces between particles are intensified, leading to an elevation in the porosity of the cake layer and a subsequent decrease in the pressure drop. When the surface energy of the particles is increased from 0.01 J/m² to 0.04 J/m², the porosity experiences a modest increase of only 9.1%, yet the pressure drop is significantly reduced by half, amounting to a decrease of 1594 Pa. Under high particle surface energy, as filtration air velocity increases, particles are compressed, resulting in a decrease in cake porosity and an increase in pressure drop. Concurrently, our findings indicate that as the sphericity of particles increases, their surfaces become increasingly smooth which in turn results in a decreased porosity of the cake layer and, consequently, an elevation in the filtration pressure drop.

For workplaces where the dust cakes have high viscosity, it is difficult to peel the dust cake from the surface of the dust filter cartridge. The problem of poor dust removal restricts the efficient and stable operation of the dust collector. This study proposes a diffuser nozzle to improve the pulsed-jet cleaning performance of cone filter cartridges. Through numerical modeling, the study investigates the improvement of pulsed-jet velocity and pressure by the diffuser nozzle, explores the influence of the diffuser angle (θ) and diffuser distance (D) on the jet field of the cone filter cartridge core, and compares the pulsed-jet intensity and uniformity of the dust removal filter cartridge. The findings show that the diffuser nozzle with appropriate parameters is conducive to enhancing the divergence and entrainment of the jet airflow, reducing the airflow velocity in the filter cartridge opening area and increasing the static pressure, while also increasing the airflow entrainment. The pulsed-jet intensity and uniformity, especially the pulsed-jet intensity in the upper part of the filter cartridge, vary significantly with θ or D, and the action mechanisms of θ or D are obtained. Under the recommended diffuser nozzle parameters (θ = 70° and D = 40 mm), the pulsed-jet intensity is 1086 Pa, which is 5.4% higher than that under the condition of the common round nozzle; the uniformity coefficient is 0.14, which is 60.0% better than that under the condition of the common round nozzle. For the upper part of the filter cartridge, the pulsed-jet intensity is 1.39 times that with the common nozzle. The result is significant as it offers a guide for improving the pulse-jet cleaning of dust removal filter cartridges.

Welding technology, extensively utilized in modern industry, poses significant health risks due to metal dust exposure, which can lead to respiratory discomfort, neurological issues, and an increased risk of lung cancer and pneumoconiosis. Enhancing ventilation within factory buildings has proven to be an economical approach to mitigating these risks. This study employs computational fluid dynamics (CFD) to model the airflow and dust transport within a large welding workshop measuring 300 m in length, 28 m in width, and 21 m in height. The impact of the exhaust-to-supply air ratio (ESR) and the height of the side exhaust port (SEP) on dust removal efficiency is investigated. Comparative analysis of transport dynamics between low-density aluminum alloy welding fume and high-density carbon steel welding fume reveals optimal dust exhaust designs. The study identifies two peaks in workshop air velocity at 0–2 m and 8–12 m above the ground, with the top exhaust port (TEP) outperforming the SEP in dust removal. An increased ESR accelerates the upward migration of welding fume, reducing lateral dispersion. An improperly set SEP height can lead to airflow short-circuiting or excessive lateral dispersion, hindering effective dust removal. Optimal SEP height for aluminum alloy and carbon steel dust are determined to be 5 m and 6 m, respectively.