Methods The maximum load（ upper operating limit） of the unit or the maximum gas flow rate of the cyclone separator was determined， which served as the basis for separator design. Then， real-time monitoring of the pressure differences between the inlet and outlet of the separator was conducted using pressure sensors. Utilizing this data， automatic adjustments of the inlet valve or bypass pipeline were triggered to compensate for reductions in process gas volume. Finally， a laboratory simulation system was established to verify the feasibility and effectiveness of the proposed scheme.

Results and Discussion　Two gas replenishment schemes were designed： direct fresh gas replenishment and recycled separator exhaust gas replenishment. An automatic control module was established to regulate gas replenishment. During laboratory simulations， a cyclone separator with a diameter of 300 mm was used. The test results showed that， without gas replenishment， the separation efficiency-gas volume rate curve presented an arch shape， peaking at 94. 7% （measured with talc powder with an average particle size of 12 um） at a gas flow rate of approximately 1 000 m3/h， and the corresponding pressure drop reached 2 100 Pa. The separation efficiency varied greatly with changes in inlet gas volume rate， indicating strong sensitivity to gas volume fluctuations. During gradual decreases in the process gas volume rate from 1 000 m3/h to 300 m3/h， the proposed system automatically replenished gas to maintain the target pressure drop of 2 100 Pa， and the separation efficiency remained stable at 94. 7%. Under replenishment conditions， the relationship curve between separation efficiency and gas volume （gas velocity） transitioned to a nearly horizontal straight line.

Conclusion The automatic gas replenishment at the separator inlet effectively mitigates efficiency loss when the process gas volume decreases， ensuring consistent operation and maintaining maximum efficiency. 2） By coupling a negative feedback control module driven by real-time pressure drop signals， the automatic control and intelligentization of the cyclone separator are enhanced. 3） The proposed scheme is simple and effective， achieving both energy savings and emission reductions.

Keywords：cyclone separator； separation efficiency； automatic air replenishment； intelligentization