The response surface methodology has been performed based on the Muschelknautz method of modeling (MM) to optimize the cyclone geometrical ratios. Four geometrical factors have significant effects on the cyclone performance viz., the vortex finder diameter, the inlet width and inlet height, and the cyclone total height. There are strong interactions between the effect of inlet dimensions and vortex finder diameter on the cyclone performance. CFD simulations based on Reynolds stress model are also used in the investigation. A new set of geometrical ratios (design) has been obtained (optimized) to achieve minimum pressure drop. A comparison of numerical simulation of the new design and the Stairmand design confirms the superior performance of the new design compared to the Stairmand design. (C) 2010 Elsevier Ltd. All rights reserved.