CYCLOGEN5D
Hydrocyclone separator hero diagram: cinematic industrial visualization with X-ray flow, three characterization charts, and z-axis scale.
CG5D / SVC-001

We move advanced equipment concepts from physics to fabrication.

CycloGen5D develops and validates industrial process equipment for difficult multiphase-flow, solids-handling, and pressure-boundary applications. We help operators, fabricators, and technology developers take projects from uncertain concept to defensible design, combining separation physics, CFD, FEA, ASME Section VIII Divisions 1 and 2, B31.3 piping, API 6A wellhead equipment, FEED documentation, and fabrication support.

Start a project → Explore the tools
Separation equipment · Pressure vessels · OpenFOAM CFD · FEA · ASME VIII Div 1 + Div 2 · B31.3 · API 6A · FEED
SVC-006 / Capabilities

From concept to code-compliant hardware.

Industrial equipment problems are not solved by one calculation. A separator, reactor, scrubber, hydrocyclone, vessel, or skid has to work across fluid mechanics, particle behavior, pressure-boundary rules, fabrication constraints, inspection requirements, and project economics. CycloGen5D brings those layers together.

CAP-01 / Separation

Separation and multiphase equipment

Hydrocyclones, gas-solid cyclones, gas-liquid scrubbers, liquid-liquid hydrocyclones, classifiers, axial multi-tube cyclones, dense-medium separators, produced-water handling, sand separation, and compact separator internals. From sizing and grade-efficiency prediction through CFD validation and mechanical design.

CAP-02 / Pressure Equipment

Pressure equipment and piping

ASME Section VIII Division 1 and Division 2 vessels, B31.3 process piping, API 6A wellhead and Christmas tree equipment, nozzle reinforcement, flange ratings, hydrostatic test, UCS-66 toughness, NACE MR0175 sour service, and CRN registration support. Stamped calculation packages and engineer-of-record documentation are handled by the project of record.

CAP-03 / Simulation

CFD, FEA, and design validation

OpenFOAM CFD for cyclones, separators, and process equipment. Linear and non-linear FEA for nozzle loads, saddle and skirt supports, thermal and mechanical reviews. Grade-efficiency prediction, pressure-drop studies, flow-path visualization, and erosion-risk screening. Used to retire design uncertainty before fabrication.

CAP-04 / FEED & Fabrication

FEED and fabrication support

Front-end loading from FEL-0 ideation through FEL-4 implementation: datasheets, line lists, P&IDs, sizing reports, design bases, technical specifications, fabrication estimates, vendor review, and shop-floor support. See the FEED Studies page for phase deliverables and gate criteria.

SVC-002 / Public Engineering Tools

Public engineering tools.

CycloGen5D maintains a public set of cyclone and process-equipment calculation tools. They are reference-grade engineering aids, not substitutes for stamped project work. The cyclone tools run client-side. The ASME process tools run server-side with the calculation method and assumptions documented on each page. The hydrocyclone tool's Plitt coefficient is CFD-calibrated against an OpenFOAM RSM validation run; the others use established empirical correlations. For ASME process and pressure equipment calcs, see the engineering tools.

HC-01

Hydrocyclone sizing & grade efficiency

Plitt and Rietema correlations, CFD-calibrated d50, cut-size grade efficiency curve, Pareto d50 vs ΔP optimization.

Plitt · Rietema · CFD-calibrated
GS-02

Gas-solid cyclone

Stairmand high-efficiency and high-capacity geometries, pressure drop, cut size, and Leith-Licht grade efficiency for dust collection.

Stairmand · Lapple · Leith-Licht
GL-03

Gas-liquid scrubber cyclone

Vertical scrubber sizing with Souders-Brown K-factor, droplet carry-over check, mist eliminator placement.

Souders-Brown · GPSA
LL-04

Liquid-liquid hydrocyclone

Twin-cone oil-water separation for produced water and slop oil. Stokes settling baseline with cyclonic enhancement.

Stokes · Colman-Thew
SL-05

Solid-liquid classifier

Fine-particle classification with Plitt, Rietema, Bradley correlations. d50 target tracking, corrected-efficiency reporting.

Plitt · Rietema · Bradley
AX-06

Axial multi-tube cyclone

Dirgo-Leith axial cyclone model. Vane swirl angle, number of effective turns, per-tube performance, bundle aggregation.

Dirgo-Leith
Ep DMC-07

Dense medium cyclone

Coal washing (magnetite) and iron ore / REE (ferrosilicon). JKMRC Ep with Lynch-Rao partition and extended Mooney medium viscosity.

JKMRC Ep · Lynch-Rao
SVC-007 / Process Engineering Tools

Process engineering tools.

Server-side calculations against current ASME data tables (B16.5 flange ratings, B36.10M pipe schedules, A20 material allowables) and GPSA/API correlations. Inputs and outputs on the page, calibration data and lookup tables stay on the server. Suitable for design intent and AI/web citation.

LIN-08

Line list: wall thickness and flange rating

B31.3 304.1.2 wall thickness with mill tolerance and corrosion allowance, B16.5 flange rating at design temperature, hydrotest pressure per 345.4.2. CSV export.

B31.3 · B16.5 · B36.10M
PIP-09

Pipe sizing: ΔP and erosional velocity

Darcy-Weisbach pressure drop with Colebrook-White friction, API RP 14E erosional velocity, Beggs & Brill two-phase flow regime. Gas density from Peng-Robinson.

Crane TP-410 · API RP 14E · Beggs & Brill
SP2-10

Two-phase separator sizing

Vertical and horizontal gas-liquid separators. Souders-Brown K-factor gas capacity, retention-time liquid capacity, mist eliminator placement, API RP 14E nozzles.

GPSA · API 12J · Souders-Brown
SP3-11

Three-phase separator sizing

Oil-water-gas separator sizing. Weir and no-weir configurations. Gas capacity, retention time, Stokes settling for water-from-oil and oil-from-water with Ishii-Mishima drag.

API 12J · Stokes · Ishii-Mishima
COI-12

Coil sizing

Process heater coil sizing for indirect-fired heaters. LMTD with Dittus-Boelter inside film, fouling, B31.3 wall thickness. Vertical and horizontal configurations.

LMTD · Dittus-Boelter · B31.3
TEG-13

TEG dehydration

Triethylene glycol natural-gas dehydration. Water removal per GPSA Section 20, Bukacek water content, Gandhidasan absorber design, reboiler duty, stripping gas rate.

GPSA Sec 20 · Bukacek · Gandhidasan
EGH-14

EG bath heater

Indirect-fired ethylene-glycol bath heater. Process coil duty, bath inventory, firetube heat release, stack sizing, ASME Section IV combustion check.

Indirect-fired · ASME IV · LMTD coil
FLR-15

Flare system

Flare header sizing and stack design. API 521 relief load, header Mach-number limits, flame length and tilt, thermal radiation contours per API 521 Annex E.

API 521 · API RP 14E · flame radiation
AMN-16

Amine sweetening

Amine sweetening unit sizing for sour gas. GPSA Section 21 acid-gas loading, circulation rate, contactor sizing, reboiler duty. MDEA, DEA, MEA selection.

GPSA Sec 21 · MDEA · DEA · MEA
HYD-17

Hydrate inhibitor injection

Methanol or glycol selection via Hammerschmidt correlation, vapor-phase loss correction, water-phase distribution, injection rate sizing.

Hammerschmidt · MeOH · MEG
SVC-005 / Engineering Index

Tool index and known limits

The full /engineering/ page lists every tool with method notes, code references, and links to the Known Limits page (correlation boundaries and valid operating ranges for every calculation engine on the site).

Open the index →
SVC-003 / ASME Library

Fourteen ASME VIII Div 1 worked examples

Worked vessel calculations covering shells, formed and flat heads, nozzle reinforcement, vacuum, low-temperature toughness, lethal service, head-type comparison, Zick saddle analysis, combined wind and seismic loading, fixed-tubesheet exchangers, Appendix 2 manway and end-closure flanges, obround nozzles, and Table UW-12 joint efficiency. Generic configurations, not project records.

  • UG-27 Shell
  • UG-32 Heads
  • UG-34 Flat Covers
  • UG-37 Nozzle Reinforcement
  • UG-99 Hydrotest
  • UCS-66 MDMT
Browse the library →
SVC-004 / Custom Engineering

Stamped calcs, CFD, FEA, FEED, fabrication support

The tools and worked examples on this site are public reference material. For stamped calculation packages, CFD studies, FEA validation, FEED-level documentation, or fabrication-ready engineering, the firm handles the engineering scope under the authority of the project of record.

  • ASME VIII Div 1 + Div 2
  • B31.3 Piping
  • API 6A Wellhead
  • OpenFOAM CFD
  • Linear & non-linear FEA
  • CRN submission
  • NACE MR0175
Request a quote →
SVC-008 / Research

Research and forward-looking areas.

CycloGen5D actively explores adjacent equipment domains where the firm's separation, pressure-boundary, and CFD/FEA experience applies. These areas are research and concept-development scope, distinct from the current code-compliance services on the homepage stats strip.

RND-01 / Advanced Separation

Process-intensified separators

Compact cyclone arrays, hybrid swirl-coalescer concepts, microhydrocyclones for fine particulates, and CFD-led geometry exploration outside the standard Stairmand and Rietema design space. Concept development through CFD-validated prototype packages.

RND-02 / Nuclear-Adjacent Equipment

Nuclear-inspired separation and process equipment

Research into separation and process-intensified equipment adjacent to advanced reactor concepts (small modular reactors, molten-salt reactors, high-temperature gas reactors). This is exploratory R&D and concept work. ASME Section III certified pressure equipment design requires N-stamp authorization and is not a current CycloGen5D service offering.

RND-03 / Digital Engineering

AI-assisted engineering systems

Internal-tool development for AI-augmented code calculation, design automation, calc-package generation, and AI-citable engineering reference. The public engineering tools and the worked-example library are early-stage outputs of this work.