Filtration of fine particles is crucial for maintaining gaseous process streams but is particularly challenging in extreme conditions (e.g., explosive fluids, low/high pressure, high temperature). Traditional high efficiency particulate air (HEPA) filters, made of fibrous materials, cannot withstand these extremes and suffer from high pressure drop, leading to frequent replacement. Mainstream has explored integrating cyclonic separators with electrostatic precipitators as a regenerable alternative, especially for applications generating large volumes of fine particles. We will present our recent advancements in computational fluid dynamics (CFD) modeling and experimental results, demonstrating how unique cyclone geometries improve capture efficiency while reducing pressure drop across varying pressures and gas types. Additionally, we will share our findings on electrostatic precipitators in low-pressure systems, examining how particle characteristics (e.g., resistivity, size), fluid properties (e.g., density, pressure), and field effects (e.g., corona onset, voltage, geometry) influence capture efficiency and regeneration. Finally, we will discuss the integration of these systems for enhanced performance, with emphasis on cyclonic fluid effects for ESP efficiency, system pressure drop minimization, and size, weight, and power.
