The FCB flash calcinerFCB flash calciner is a high-efficiency static calcinerCalciners that uses a gas–solid cyclone combustor for alumina calcinationAlumina calcination. In this setup, preheated air and aluminiumAluminium hydroxide feed enter co-currently from the top, enabling thermal interaction. This study focuses on optimizing particle distribution and heat transferHeat transfer efficiency to reduce specific fuel consumption while maintaining aluminaAlumina qualityQuality, particularly alpha-phasecontent and LOI (Loss on Ignition)Loss On Ignition (LOI). Unlike fluidized bed calcinersCalciners with uniform temperatures, cyclonic systems pose challenges due to vortex-induced gradients, which maycause non-uniform calcinationCalcination. Owing to limited literature on such systems, Computational Fluid Dynamics (CFDComputational Fluid Dynamics (CFD)) tool is used to model gas–solid interactions and combustion behavior. SimulationsSimulation are validatedagainst plant furnace temperature data. The optimized flow profileProfile enhances particle residence time by over 50% and raises near-wall temperatures by approximately 10%. The results offer valuable insights into cyclonic combustor dynamics and provide a pathway for optimizing fuel efficiency while ensuring desired product qualityQuality.