The film flow behavior in an oil–gas cyclone separator was experimentally studied to improve the separation efficiency in terms of the effect of the oil film on the cylinder wall. The oil film flow pattern was captured using a high-speed camera, and the cylinder wall was divided into seven regions to analyze according to the different oil film flow patterns. Along the cyclone cylinder height, the central part of the cylinder was the main flow area, in which droplet–wall collisions and oil film splashing were severe. Additionally, the oil film’s distribution characteristics under inlet velocities of 14.0, 16.0, and 18.0 m/s were compared, and the results showed that more splashing oil droplets were generated under higher inlet velocity. Moreover, changing the structure of the central channel and outer cylinder slightly changed the oil film’s area and flow pattern but exhibited a weak effect on the oil film thickness and re-entrainment. Then, an improved structure was proposed by adding a porous cylinder to the outer cyclone to avoid the generation of small splashing droplets from the oil film. The performance of the modified separator was measured in a real oil-injected compressor system, which demonstrated higher separation efficiency with no increase in static pressure loss. The separation efficiency increased by up to 2.7%, while the pressure loss decreased by up to 10%. Thus, the improved structure can improve the performance of oil–gas separators by changing the distribution and thickness of the oil film on the cylinder wall.
The effect of cyclone inlet dimensions on the flow pattern and performance
