Centrifugal separators have many applications in industry. Comprehensive information based on performance and ‎energy consumption for a detailed comparison between different types of centrifugal separators is essential to allow ‎design optimization and is the focus of this work.‎

Equivalent settling area factor is typically used to compare and scale up centrifuge separators. A performance chart ‎based on this factor is available in the literature that compares the performance of different centrifuge separators ‎including hydrocyclones. However, the available performance chart for centrifuge separators is problematic in terms ‎of over-predicting the hydrocyclone performance and not being updated for the progresses in the centrifuges ‎technologies. ‎

Predicting the equivalent settling area of the ‎hydrocyclones is important for selection and design of the device. It ‎also allows comparison of hydrocyclones to other separators that work using a similar concept. A mathematical ‎model based on the physics of the separation phenomenon in the reverse flow hydrocyclones is developed to ‎predict the equivalent area factor of the hydrocyclone. A framework for comparing performance with an updated ‎performance chart for four types of centrifugal separators and a comparison with a continuous gravity settling tank ‎is described. A model and chart for performance and energy consumption, which makes it possible to compare ‎different separators, is a key result of this work which extends current available handbooks and guidelines.‎ ‎

Studying the effect of using a pump in the underflow on the operating conditions is another focus of this study. This ‎effect can be used for controlling the device as the underflow of the hydrocyclone is usually adjusted to overcome ‎the variable conditions of the feed flow to achieve a desired performance. It is observed that a pump in the ‎underflow through either back pressure or by pump suction allows simulating the function of underflow variable ‎pipe size or valves to control the flow rate. An empirical correlation is developed in this research for the effect of ‎underflow pumping that can be used to predict the pumping influence on the hydrocyclone operating variables and ‎for controlling the hydrocyclone performance.‎