This study investigates the influence of geometric parameters and inlet velocity on the separation efficiency and pressure drop of an Echeverri cyclone separator using Computational Fluid Dynamics (CFD) simulations. The cyclone separator employs centrifugal force to remove particles from a gas stream, with separation performance strongly affected by inlet velocity and vortex finder dimensions. The Echeverri cyclone model, characterized by enhanced geometrical features such as a longer vortex finder and smooth conical transitions, was simulated with varying vortex finder diameters (100–200 mm) and inlet velocities (6–27 m/s). Turbulent flow was modeled using ANSYS Fluent 2024 R2 with the k–ω SST turbulence model to accurately capture complex swirling flows. Results show that increasing the vortex finder diameter (Dv) reduces tangential velocity and pressure drop but lowers separation efficiency from 98.2% (Dv = 100 mm) to 88.76% (Dv = 200 mm) due to weaker centrifugal forces and reduced particle residence time. Conversely, increasing inlet velocity generally improves separation efficiency up to a critical point (~21 m/s), beyond which efficiency declines due to shorter residence times and flow instability, while pressure drop continuously increases. As for the discrete phase, assumptions include monodisperse spherical particles and neglect of inter-particle collisions. Mesh independence was ensured to balance accuracy and computational cost. These findings highlight the critical trade-off between pressure drop and separation efficiency, emphasizing the importance of optimizing cyclone geometry and operating conditions for enhanced particle separation with minimal energy penalties. The study confirms CFD as a valuable tool for cyclone design optimization in industrial applications.