Abstract: Satellite powder is a common defect powder in metal powder preparation by atomization process. Excessive satellite powder defects affect the stability of powder laying and the density of the product. This paper starts from the principle of satellite powder defect formation by atomization process, and uses ANSYS Fluent to conduct numerical simulation in three-dimensional flow field. The influence of two novel atomization tower optimization structures formed by setting a mist protection cover and a supplementary gas device on the macroscopic airflow field in the tower were studied and the control effect of the flow field optimization structure on suppressing the formation of satellite powder was analyzed. The results show that the position and height factors of the mist protection cover affect the isolation effect of powder recirculation directly, and the position factor significant influences the distribution range of the recirculation area at the same time. Placing the mist protection cover structure of 300 mm height at a distance of 200 mm from the center axis and 250 mm from the top of the atomization tower can effectively isolate the direct impact of recirculating particles on the molten droplets in the atomization region. The pressure parameter of the supplementary gas device directly affects the isolation effect of recirculating particles and the intensity of recirculating gas clusters. Placing the supplementary gas device with a pressure parameter of 0.5 MPa at a distance of 200 mm from the center axis can provide good protection for the atomization region. Both of the two novel atomization tower optimization structures can effectively suppress the collision between particles and molten droplets in the atomization region, thus achieving the effect of inhibiting the formation of satellite powder.