Otimização geométrica de hidrociclones a partir de um histórico em hidrociclonagem na FEQUI/UFU

Abstract

Hydrocyclones are centrifugal separators intended for solid-liquid or liquid-liquid separation where there is a significant difference in density between the phases. They are widely used in the industrial environment and among its advantages it can be listed its compact geometry, simple construction, low maintenance cost and high efficiency. Depending on the purpose of the process (concentration or classification), it is possible to enhance the performance of these separators by optimizing geometric variables. The study of unconventional hydrocyclones has always been a subject of research by FEQUI / UFU. In this context, the aim of this work was to find optimal geometric relations for hydrocyclones in case studies of discrete and "semi-continuous" optimization by data collection and estimation of prediction equations using the Response Surfaces technique to implement them in an optimization algorithm based on genetic algorithm called Differential Evolution Algorithm. Four optimal geometries were generated from the case studies and the equipment were compared experimentally and numerically with geometries from the database that best achieved the specifications of the problem. In addition, a fifth configuration was tested by changing the underflow diameter of one of the optimized hydrocyclones. The geometries were submitted to experimental tests and fluid dynamics simulations. According to the main results, two devices stood out: the optimized geometry to maximize the total efficiency - HGOT1 - and the optimized geometry to minimize the Euler number with the change in the diameter of underflow - HGOT3DU3. HGOT1 reached the same level of total efficiency as the best hydrocyclone in the database, but with a 44.69% reduction in energy expenditure. Although optimized to minimize energy expenditure, HGOT3DU3 was shown to be a more concentrator hydrocyclone than those cataloged in the database, providing a mean underflow-to-throughput ratio 49.73% smaller and a mean volumetric concentration of solids in the underflow stream 52.43% higher than the most concentrator equipment in the researched literature.