CFD-based optimization and experimental validation of supersonic separator design with angular injection swirler for...

Area of Science:

• Fluid Dynamics
• Thermodynamics
• Chemical Engineering

Background:

• Supersonic separators (SS) offer compact, energy-efficient gas dehydration but their mechanisms are poorly understood.
• Complex interactions between supersonic flow, phase change, and centrifugal forces hinder optimization.

Purpose of the Study:

• To systematically optimize SS geometry and swirler configuration using computational fluid dynamics (CFD).
• To enhance both cooling performance (CP) and collection efficiency (CE) for effective moisture separation.

Main Methods:

• Computational fluid dynamics (CFD) simulations were used for structural optimization of nozzle wall geometry and swirler design.
• Optimization involved wall profile refinement, convergent/divergent length evaluation, and diffuser design.
• Laboratory-scale prototype testing validated CFD predictions under various humidity conditions.

Main Results:

• Optimized Witoszynski convergent profile with a 200 mm convergent length and linear diffuser achieved superior cooling performance (CP < 214 K).
• An angular injection swirler design significantly improved collection efficiency (CE) to 83%, outperforming vane swirlers (79%).
• Experimental results closely matched CFD predictions, validating the optimized design.

Conclusions:

• Optimized SS geometry combined with a passive angular-injection swirler enables efficient condensation and moisture separation.
• The validated model demonstrates practical applicability for industrial gas dehydration solutions.