Recently, cyclones have been widely recognized as efficient tools for separating particles from solid-gas mixtures in various sectors. The current research examines how the width and quantity of circular holes in the vortex finder of the Stairmand gas cyclone affect the flow field and overall performance. Sixteen cyclone geometries were numerically investigated at inlet velocities of 8.8 m/s and 17.6 m/s. At 8.8 m/s gas velocity, the 4-hole geometry has a lower cut-off diameter than the other configurations. The no-hole geometry displays a lower cut-off diameter (d50) at a gas velocity of 17.6 m/s. The 12-hole geometry achieves the lowest pressure drop at 17.6 m/s. The pressure drop initially increases with an increase in the number of holes up to 5–6 holes and then decreases. At 8.8 m/s, the no-hole geometry demonstrates lower pressure drops. It is found that although the cut-off diameter has an inverse relationship with the number of holes, the pressure drop is related to the number of holes and size. This study offers important new information for improving the construction and functionality of these separation devices in various industrial contexts.
