Hydro Cyclone Training

HYDROCYCLONES
THEORY AND PRACTICE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
What is a hydrocyclone?
 A classifier of solid particles based on the

mass of the particles. Assuming all solids
have the same specific gravity, cyclones
can be designed for a specific size
classification.
Hydrocyclone
Hydrocyclone
O/F Flange Inlet
Head
Inlet Flange Vortex Finder
Cylinder Apex
Cone Splash Skirt
Metallurgical Cyclone
Sizes:
4” to 33” Nominal Ø
Advantages of Hydrocyclones
1. Equipment is very simple (without moving parts).
2. Very compact (with high capacity).
3. Low cost compared to other technologies.
4. Very versatile as they can be used for classifying,

desliming, or dewatering (thickening).
5. Because they operate with more than one “G”

force, they may work better than other equipment
at separating/classifying high viscosity slurries or
slurries containing flocculants.
6. With spare cyclones installed, can be maintained

without shutting down the system.
What is the Principle of Operation in a
Hydrocyclone?
 Every particle in a cyclone is subjected to two
counteracting forces; centrifugal force (Fc) and
drag force (Fd). The Fc tends to bring particles to
the wall whereas the Fd will tend to drag particles
toward the center.
Fc Then,
If Fc > Fd , the particle will
r
go to the underflow (U/F)
Fd If Fd > Fc , the particle will
go to the overflow (O/F)
Flows within a Hydroyclone
Dc
Vertical velocityl
0.43Dc
0.7Dc
city
o
Ze r
velo
Zones within a Hydrocyclone
A A
C C
D D
A = Unclassified slurry
B = Coarse Particles
B B
C = Fine Particles
D = Slurry in the process
of being classsified
Classification Curves
Cyclones do not make perfect separations so
performance evaluation is based on a set of
separation (recovery) curves
100 Bypass of 100 100

Coarse
50 50 50
Bypass of
Fines
0 d50 0 d50 0 d/d50

Particle Size Particle Size
Actual Corrected Reduced

Recovery Curve Recovery Curve Recovery Curve
Typical Separation (Recovery)
Curve
It is defined with the following parameters: d50, Alpha (α) and Rf
100
α=
4 α=
3
α=
2
50
Rf
0 d50
Variables that Affect the Cut Size in a
Hydrocyclone (d50)
Geometric
Variables
1. Diameter of the cyclone
2. Cone angle(s)
3. Angle of Inclination
4. Inlet Area of Cyclone
5. Diameter of Vortex Finder
6. Diameter of Apex
Diameter of
Cyclone
The diameter of the
cyclone is the inside
diameter of the cylindrical
portion near the top (inside
the liner).
A larger diameter cyclone

produces a coarser d50 cut
size.
d50(Base) = 5.27 x D0.66

D = Diameter of Cyclone (inches)
Cone Angle(s)
Greater cone angles produce coarser separations. This is
true for cyclones with a single cone angle. Traditionally,
cones have been 20° and/or 10° only. Latest generation
gMAX cyclones offer combinations of cones with different
angles (i.e. 30°/10°, 20°/10°, and others) that produce
significantly finer separations.
30°
20°
10°
Standard Cones gMAX Cones

Inclination of Cyclone
The more inclined the cyclone, the coarser the d50.
Except for special applications, inclination less than 25°
from horizontal is not recommended.
∆H
25° Minimum
Open Area of Inlet Open Area (in2)
The open area of the inlet head

liner affects the cut size.
Larger inlet ares result in
coarser cut sizes (d50), but also
increase capacity.
Diameter of the Vortex
Finder
A larger diameter vortex finder
produces a coarser cut size
(d50).
Vortex finder lengths are

standard and optimized for
each cyclone diameter.
Diameter of the Apex
The diameter of the apex is not a
control variable affecting cut size.
Rather, the apex size is selected to
provide an U / F discharge with
high solids content (75% - 80%
typically) but without generating a
"rope” underflow discharge. This
can be verified simply by observing
the discharge angle U / F, which
should be maintained between 20°
and 25°. included⊿ =
20° to 25°
Underflow Discharge Patterns
Transitional Roping
Normal
Flow
Discharge The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Operating
Variables
1. Specific gravity of solids
(application specific)
2. Feed Pressure
3. Feed Slurry Solids Concentration
Specific Gravity of Solids
This variable is not really
controllable, but it does have a
significant effect on the cut size
(d50) in a cyclone.
The higher the solids specific

gravity, the finer the cyclone
product.
1.65
C =
(SG)
s.g.s – s.g.l
s.g.s = specific gravity of solids s.g.l = specific gravity of liquid

Feed Pressure
Increasing the feed pressure
will result in a finer cut size
(d50)
C (ΔP) = 1.91 x ΔP-0.28
ΔP = Pressure drop in the cyclone, psi
Normal Pressures
Minimum: 5 psig
Coarse Grinds: 5 – 12 psig
Fine Grinds: 12 – 25 psig
Regrind /Tailings: 20 – 25 psig
Solids Concentration
in Feed Slurry
More dilution in the cyclone

feed produces a finer cut size
(d50).
-1.43
53 - V
C (V) =
53
V = % Solids by Volume
Normal Concentrations
Maximum: ~50% solids (by volume)
Primary Grinds: 40–45% solids (by volume)
Calculation of d50c
Calculation of the d50c
If we take the base d50c of a cyclone of a given diameter, we

can then apply the different correction factors to get to the
actual d50c for the specific application, as follows:
d50c (application) = d50c(base) x C1 x C2 x C3 x C4…….
Where C1, C2 C3, C4….. are the factors calculated for each of
the geometric and operating variables of the selected
cyclone.
Capacity Curves of Standard Cyclones
CYCMOD Simulation Program
Basic Information Required for CYCMOD
1. Basic description of the grinding circuit
2. Cyclone feed gradation
3. Solids S.G.
4. % Solids in Feed to Cyclones
5. Circulating Load (%)
6. Minimum Acceptable % Solids in O/F
7. Desired O/F Product Gradation (example: 80% -200 mesh)
Feed Gradation
FEED SIZE DISTRIBUTION D/D50 CORR ACTUAL CORR CORR
#
Microns Mesh WT % CUM % + CYCMOD REC REC U/F O/F
INPUT DATA TABLE
1 300 48 3.6 3.6 4.29 1.000 1.000 5.9 0.0

2 150 100 12.8 16.4 2.14 0.983 0.986 20.6 0.4
3 106 150 12.7 29.1 1.51 0.861 0.889 17.9 2.9
4 88 170 6.8 35.9 1.26 0.715 0.772 8.0 3.2
5 75 200 8.3 44.2 1.07 0.564 0.651 7.7 5.9
6 63 230 6.4 50.6 0.90 0.410 0.528 4.3 6.2
7 53 270 5.4 56.0 0.76 0.291 0.432 2.6 6.3
8 38 325 1.5 57.5 0.54 0.150 0.320 0.4 2.1
9 -38 -325 42.5 100.0 0.19 0.029 0.223 2.0 67.7
TOTAL 100.0 69.4 94.6
Overall Material Balance
INLET VORTEX FINDER APEX PRESSURE
ORIFICES: 15.0 sq.in. 4.0 in. 2.50 in. 10
SPECIFIC GRAVITY: SOLIDS 2.70 LIQUID 1.00
FEED OVERFLOW UNDERFLOW

MTPH SOLIDS 164.0 75.7 88.3
MTPH LIQUID 140 112 28
MTPH PULP 304 188 116
% SOLIDS WT 54.0 40.4 76.0
S.G. PULP 1.515 1.341 1.918
% SOLIDS VOL 30.3 20.1 54.0
U.S. GPM PULP 872 611 261
M3/HR PULP 198 139 59
CYCMOD 56 3.5 70 CIRCULATING LOAD 117%
CYCMOD Results (Output)
KREBS CYCLONE SIMULATION SHEET 1
PASAJE LOS JILGUEROS 108, URB. LIMATAMBO, SURQUILLO, LIMA, PERU DATE 18-Nov-08
TEL: (51-1) 442-8209 FAX: (51-1) 221-7889 Email [email protected] BY PAL
CLIENT ORCOPAMPA
PROBLEM MOLIENDA PRIMARIA - MOLINO BOLAS DOMINION 12' X 16'

164 TPH DE ALIMENTACION Y PRODUCTO DE O/F CON 90% -200M
CYCLONES 2 CICLONES KREBS GMAX15 OPERATIVOS
INLET VORTEX FINDER APEX PRESSURE

ORIFICES: 15.0 sq.in. 4.0 in. 2.50 in. 10
SPECIFIC GRAVITY: SOLIDS 2.70 LIQUID 1.00

MTPH SOLIDS 164.0 75.7 88.3
MTPH LIQUID 140 112 28
MTPH PULP 304 188 116
% SOLIDS WT 54.0 40.4 76.0
S.G. PULP 1.515 1.341 1.918
% SOLIDS VOL 30.3 20.1 54.0
U.S. GPM PULP 872 611 261
M3/HR PULP 198 139 59
CYCMOD 56 3.5 70 CIRCULATING LOAD 117%

ACTUAL
MESH CUM IND CUM IND CUM IND % REC.
MTPH MTPH MTPH
%+ %+ %+ %+ %+ %+
48 3.6 3.6 5.9 0.0 0.0 0.0 6.7 6.7 5.9 100.0
100 16.4 12.8 21.0 0.4 0.4 0.3 30.1 23.5 20.7 98.6
150 29.1 12.7 20.8 3.4 3.1 2.3 51.1 21.0 18.5 88.9
170 35.9 6.8 11.2 6.8 3.4 2.5 60.9 9.8 8.6 77.2
200 44.2 8.3 13.6 13.1 6.3 4.8 70.9 10.0 8.9 65.1
230 50.6 6.4 10.5 19.6 6.5 5.0 77.2 6.3 5.5 52.8
270 56.0 5.4 8.9 26.3 6.6 5.0 81.5 4.3 3.8 43.2
325 57.5 1.5 2.5 28.5 2.2 1.7 82.4 0.9 0.8 32.0
-325 100.0 42.5 69.7 100.0 71.5 54.2 100.0 17.6 15.5 22.3
TOTAL 164.0 75.7 88.3 53.8
Curves Generated by CYCMOD
C YC LONE R EC OVER Y C UR VES
100. 0
90. 0
80. 0
70. 0
60. 0
50. 0
40. 0
30. 0
20. 0
10. 0
0. 0
10 100 1000
PART I CLE SI ZE (MI CRONS)
FEED OVERFLOW UNDERFLOW REC ACTUAL
Krebs Current State-Of-The-Art Cyclones
Latest Generation Krebs gMAX™
Cyclones
1. They produce a 15-35% cut

finer than traditional
cyclones with a completely
new inlet head, cone(s), and
apex design.
2. They provide wear life 3-4

times higher than other
conventional cyclones,
thanks to the new design
and linings with a minimum
thickness of 1 ".
gMAX™ Cyclones
1. Modified ramp down involute feed entry
reduces turbulence and wear.
2. Liners with 1” minimum thickness for
long life.
3. Cones with varying angles (usually
between 10º - 30º, except for small
cyclones) for sharper, finer separations.
4. Flanged, molded liners to ensure a close
and tight fit in the housings, with proper
internal geometry for good performance.
HYDROCYCLONES
Maintenance
Liners Suitable for All Cyclone Applications
Krebs offers a range of alternative materials for their cyclone

liners from Natural Rubber (BPC) to Neoprene (RN),
Polyurethane (RU), Alumina (CC), Nitride Bonded Silicon Carbide
(CR), Reaction Bonded Silicon Carbide (CX) and Sintered Single
Phase Silicon Carbide (CZ).
Relative Wear Life of Alternative
Materials
20
18
16
14
12
10
8
6
4
2
0
BPC CR CX CZ
MATERIAL DE FORRO
LINER MATERIAL
Mix/Match Liner Materials to Optimize Life
(liners should last between 8 mos. and 1 yr. – sometimes longer)
Natural Rubber (BPC)

For Inlet Head and Cylinder
Nitride Bonded Silicon Carbide(CR)

For the Upper Cones
Reaction Bonded Silicon Carbide (CX)

For the Lower Cones
Sintered Single Phase Silicon Carbide (CZ)

For the Apex
Number 1 Cyclone
Maintenance Goal:
INCREASE CYCLE TIME
Leads To:
Better Cyclone Performance

Lower Material Costs
Less Maintenance Time
Increase Cycle Time By:
1. Increasing the life of the fastest wearing

part.
2. Then repeating this cycle until all liners

last the same amount of time.
3. Mixing of materials required.
Typical Liner Life - Large
Diameter Cyclones (>500
mm)
 Inlet head = 9 mos.
 Cylinder and upper cone liner = 14 mos.
 Lower cone liner = 5 mos.
 Apex = 2 mos.
 Vortex finder, cover plate liner, and inlet adapter = 24 mos.
Many mines
now are
replacing one
larger cone
liner with two
smaller when
wear is
concentrated
in lower 1/3 of
liner
New lower cone
liner as
replaceable
ceramic or rubber
liner
Importance of Maintenance
 Improper joint alignment results in misplaced material &
premature wear.
 Worn or grooved liners result in misplaced material.
 Increased apex diameter results in misplaced fines to U/F,
poor quality C/L.
 Worn inlet head liners result in coarser separation and
decreased pressure drop.
 Worn vortex finder results in misplaced coarse material to
overflow.
Worn
Worn Cyclones
Cyclones
DISASSEMBLE
DISASSEMBLE
•Remove cover plate,
disassemble cone
sections etc.
•Remove the liners
Diagnostics
 Inspect the Unions
 Verify that no negative edges
exist
Diagnostics
 Inspect for Abnormalities
 Flow concentrated areas
 Spiral
Diagnostics
 Verify Diameters
 Inlet, vortex and apex
ASSEMBLE
ASSEMBLE •Installation of new liners
•Replace and repair any

damaged housings
•Assemble the housings
Typical
Typical Problems
Problems with
with
Cyclone
Cyclone Liners
Liners
•Liner too long resulting in

deformation in cyclone
interior
•Using worn cones

– Results in negative edges with
new apex
Cyclone
Cyclone Liner
Liner Adjustment
Adjustment
Flow Flow
Flow
Correct Incorrect Correct
Cone Profile / Talon Flange
Problems
Problems Typical
Typical in
in
Liner
Liner Maintenance
Maintenance
(CERAMICS)
(CERAMICS)
•Liners too long and break
upon assembly
•Too much of a gap

between liners
– Results in wear on housing
and undercutting of edge
Maintenance Tips
 Bolts only need to be snug fit
 Many cyclone parts are designed for much higher pressure
than seen in typical grinding circuits and tailings applications
thus some bolts can be left off
 Do not hammer or bang on the cyclones when plugged
 Use of Krebstik adhesive eases installation of liners and
prevents material from moving behind the liner
Installing an Inlet Head Liner
(the hard way)
Titel November 9, 20 57
(the correct way)
STEP 1. STEP 2.
(the correct way - continued)
STEP 3. STEP 4.
STEP 5. STEP 6.
STEP 7. COMPLETE
Kennecott – Tailings - Utah
Tarkwa Gold – Primary Grinding -Ghana
Grand Cote – gMAX33 Cyclones
Mineral Sands - Senegal
(world’s largest cyclone manifold)
FLSmidth KREBS… slurry processing
solutions including cyclones, pumps,
and valves!
Technequip
VALVES
gMAX CYCLONES millMAX PUMPS
Thank You!
November 9, 2024 66

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HYDROCYCLONES

THEORY AND PRACTICE

 A classifier of solid particles based on the

Inlet Flange Vortex Finder

Cone Splash Skirt

2. Very compact (with high capacity).

3. Low cost compared to other technologies.

4. Very versatile as they can be used for classifying,

5. Because they operate with more than one “G”

6. With spare cyclones installed, can be maintained

100 Bypass of 100 100

0 d50 0 d50 0 d/d50

Actual Corrected Reduced

A larger diameter cyclone

d50(Base) = 5.27 x D0.66

Standard Cones gMAX Cones

The open area of the inlet head

Vortex finder lengths are

The higher the solids specific

s.g.s = specific gravity of solids s.g.l = specific gravity of liquid

ΔP = Pressure drop in the cyclone, psi

More dilution in the cyclone

If we take the base d50c of a cyclone of a given diameter, we

d50c (application) = d50c(base) x C1 x C2 x C3 x C4…….

1 300 48 3.6 3.6 4.29 1.000 1.000 5.9 0.0

TOTAL 100.0 69.4 94.6

SPECIFIC GRAVITY: SOLIDS 2.70 LIQUID 1.00

FEED OVERFLOW UNDERFLOW

CYCMOD 56 3.5 70 CIRCULATING LOAD 117%

PROBLEM MOLIENDA PRIMARIA - MOLINO BOLAS DOMINION 12' X 16'

CYCLONES 2 CICLONES KREBS GMAX15 OPERATIVOS

INLET VORTEX FINDER APEX PRESSURE

SPECIFIC GRAVITY: SOLIDS 2.70 LIQUID 1.00

FEED OVERFLOW UNDERFLOW

CYCMOD 56 3.5 70 CIRCULATING LOAD 117%

FEED OVERFLOW UNDERFLOW

PART I CLE SI ZE (MI CRONS)

FEED OVERFLOW UNDERFLOW REC ACTUAL

1. They produce a 15-35% cut

2. They provide wear life 3-4

Krebs offers a range of alternative materials for their cyclone

Natural Rubber (BPC)

Nitride Bonded Silicon Carbide(CR)

Reaction Bonded Silicon Carbide (CX)

Sintered Single Phase Silicon Carbide (CZ)

INCREASE CYCLE TIME

Better Cyclone Performance

1. Increasing the life of the fastest wearing

2. Then repeating this cycle until all liners

3. Mixing of materials required.

•Remove the liners

•Replace and repair any

•Assemble the housings

•Liner too long resulting in

•Using worn cones

Correct Incorrect Correct

•Too much of a gap

gMAX CYCLONES millMAX PUMPS

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