A computational study was carried out to investigate the effects of internal geometry changes on the likelihood of solids buildup within, and the efficiency of, an industrial dust collector. Combustible solids held up in the unit pose a safety risk. The dust collector serves multiple functions, so the design requires a delicate balance. Particles should be separated from the incoming mixture and collected in the bottom of the unit. This particulate material should freely flow into a high-speed ejector (Mach 0.4) underneath. Gas must also flow freely to the top outlet, but sufficient gas must flow down to the ejector so that its motive gas augments the transport of particles back to the reactor (recirculation). Computational design evaluations included: (1) rod spacing, (2) ledge removal, and (3) rod cover plates. Testing on particle size distribution and density was carried out in-house to provide inputs to the computational fluid dynamics (CFD) model. Rod spacing reduction had a mixed effect on flow distribution. Plates were found to induce a negative effect on recirculation and a mixed effect on combustible solids accumulation. Removal of the ledge, however, offered slightly more recirculation along with completely alleviating stagnant solids accumulation. It is shown that, without consideration of detailed fluid physics, general separator design principals might be misguiding. © 2018 American Society of Mechanical Engineers (ASME). All rights reserved.