In this study, a hydrocyclone was designed and manufactured to achieve an inlet flow rate of 1 L/min in the experiment, which was conducted using soda lime bead with a specific gravity of 2.5. Numerical analysis was performed with FLUENT, utilizing the Reynolds stress turbulence and volume of fluid multiphase flow analysis models. Errors in the experimental and numerical analysis were confirmed to be 5.13%, 1.70%, and 2.79% for the inlet pressure, flow rate at the underflow outlet, and total separation efficiency, respectively. To determine the separation efficiency, a laser diffraction particle size analyzer was used to confirm the distribution of particles; the error in each particle size, caused by a reduction in particle size during the experiment, was found to be about 5%. Results from the numerical analysis were consistent with the experimental ones. It was confirmed that the performance of the hydrocyclone could be accurately predicted using numerical analysis. Using the verified value interpreting model, the performance of the hydrocyclone was compared with inlet flow rates of 0.6-1.2 L/min. Additionally, hydrocyclones achieving 1 L/min inlet flow rate with inlet velocities of 1 and 3 m/s were designed for predicting the performance of hydrocyclones in various sizes. (C) 2020 Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.