Abstract: In view of the high impurity content, uneven particle size, and powder agglomeration problems existing in the traditional wet process for preparing mica powder, this study optimizes the dispersion process conditions by researching the influence of pH value and dispersant concentration on the Zeta potential value of the powder surface. Based on the relevant principles of solid-liquid separation hydrocyclone field, Flow Simulation was used to analyze the static pressure and velocity distribution of the internal flow field of the hydrocyclone under single-factor conditions, and the structural parameters of the hydrocyclone were optimized to improve sedimentation and classification conditions. Finally, mica powder was trial-produced under the optimized process and equipment conditions and analyzed for verification. The research results show that the mica powder prepared using the improved process and equipment has uniform particle size, with the average particle size reduced by 5.887 μm compared to the traditional process, good classification effect; the flake structure is obvious, the impurity content is reduced, the agglomeration phenomenon is alleviated, and the dispersion effect is improved.