Hydrocyclone, as a typical non-thermal physical separation equipment, has the technical advantages of simple structure, high separation efficiency, large processing capacity, low operation, and low maintenance costs, etc. It has been widely used in many fields such as petroleum, chemical industry, environmental protection, and mining. With the development of intensified technology for the hydrocyclone separation process, the accuracy of hydrocyclone separation has also developed from the millimeter level to the micron, nanometer, and even ionic molecular level. Based on the principles and engineering applications of the intensification of the hydrocyclone separation process, the research progress of the new intensification technologies for the hydrocyclone separation process is introduced in this study. The testing methods of continuous phase flow from one-dimensional point to two-dimensional surface, and then to three-dimensional body are systematically summarized. A synchronous high-speed motion analyzer (S-HSMA) system, based on microfluidic and high-speed camera, was developed for the detection of the velocity of fast spirally moving particles. The new phenomenon of high-speed self-rotation of particles in hydrocyclone were detected for the first time. The particle self-rotation in hydrocyclone has achieved a breakthrough from phenomenon discovery to engineering application. The new mechanisms of absorption, extraction, and desorption enhancement by particle self-rotation in hydrocyclone were introduced, as well as the novel intensification methods and equipments for bubble enhanced oil-water separation, particle sequencing enhanced micro-particle removal, self-rotation enhanced oil removal in porous media.