This research article encompasses development of hydrocyclone simulation methodology through validation with suitably designed experiments at a range of process conditions and further understanding on the parametric design and operating conditions. The salient features of the methodology included Eulerian primary phase flow field generation through steady state simulation using RSM turbulence modeling, and evaluation of particle distribution behavior through discrete phase modeling using particle injection technique. The results are validated with water throughput, split and cyclone cut size while classifying flyash. The results have indicated a reasonable matching between the simulated and the experimental values. The studies revealed that the cyclone cut size increases with an increase in vortex finder diameter, a decrease in the spigot diameter, decrease in the inlet velocity of the fluid, and decrease in the viscosity of the fluid. (C) 2012 Elsevier By. All rights reserved.