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Dust cyclones reduce particulate emissions but their operation consumes electrical energy. Response surface methodology was used to compare two strategies to reduce energy costs without increasing emissions. Cyclones of a standard design (1D3D) were operated singly and in series, as was an Experimental cyclone of a novel design. A central composite experimental design was used with loading rates from 3 to 75 g m-3 and velocities from 8 to 18 m s-1. Velocity had little influence on the collection efficiency of Standard cyclones across the tested range. A second cyclone in series reduced emissions but more than doubled energy consumption for a given velocity. The Experimental cyclone had a larger inlet and outlet, slightly less pressure drop at a given entrance velocity but lower collection efficiency than the Standard design.