Grinding & Classification Circuits

Grinding & Classification Circuits 2017-04-04T06:57:16+00:00
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Hydrocyclone wearlife (4 replies and 3 comments)

8 months ago
Simeon 8 months ago

How long would a hydrocyclone typically last (Barrel, lower cone, mid cone, spigot) before being worn out? It can be rubber lined, Polyurethane whatever material... 

  • When feeding rough like d50 1mm - 4mm ? 
  • High pressure range 90 - 120 kPa 
  • Feed material could be any ore, but have a particular interest in chromite. 
  • Cyclone size: around 200 mm - 300 mm 

Please let me know what you have seen, or would expect a cyclone's wearlife to be? 

Treve Mildren
8 months ago
Treve Mildren 8 months ago

Hi Simeon - It would be normal to use Alumina Ceramic inserts in these heavy wear zones. So you should expect at least 1 year of use before needing to replace these parts. Contact Salter Cyclones.

8 months ago

Thank you so much for the information.

8 months ago
David 8 months ago
1 like by Simeon

Simeon, is this for planning or an actual situation? Do you have any ball-chips in your grinding circuit?

It is recommended that pressure drops, whenever possible, be designed in the 40 to 70 kPa (5 to 10 psi) range to minimize energy requirements as well as reduce wear rates.

It has been found that a pipe size which produces a line velocity of 200 to 300cm/sec (7 to 10 ft/sec) is high enough to prevent particles from settling, even in horizontal sections, but low enough to minimize wear.

When properly designed the central chamber becomes a mixing area and the line velocity should be lowered to approximately 60 to 90 cm/sec (2 to 3 ft/sec). This will help insure that each cyclone is fed with the same slurry concentration as well as the same particle size distribution and also will reduce wear rates.

It is typical that the high mass particles or coarser particles tend to pass the first cyclones and report to the final cyclone. This results in the last cyclone receiving a higher feed concentration of coarser particles, which accelerates the wear of the last cyclone as well as produces a coarser separation due to the higher feed density.

Cyclone Construction varies greatly from one manufacturer to another, but the majority of the designs includes metal housings with replaceable liners with replaceable liners with the most suitable liner material varying from one application to another. It is also common to utilize several different lining materials within the same cyclone to optimize wear characteristics.

Natural gum rubber is the most common material utilized due to its relatively low cost, excellent wear, ease of handling, and it is not fragile. Applications where gum rubber is not suitable are those where the temperatures exceed 60C or there are large amounts of hydrocarbons present in the slurry such as oil or other detrimental chemicals. Ceramic materials have found acceptance as cyclone liners for the apex orifice as well as other areas which exhibit severe abrasion. These include areas such as the lower cone liner and vortex finder. Nihard has also proven to be an acceptable wear material, especially for vortex finders and other areas which require strength as well as abrasion resistance. Other elastomer materials such as neoprene and nitrite are also utilized when hydrocarbons are present or when the temperature exceeds 60 deg C. Urethane has found acceptance, especially in areas where the solids are relatively fine.

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8 months ago

Hey David thank you so much for all the information it will help a lot. We will run an actual test. There will not be ball chips present, but thanks for mentioning that aspect.

We want to run at high pressures (beyond recommendations) to see how this will increase the wear on the cyclone... I would also like to focus on a cyclone with the same lining material throughout. Except for the spigot and vortex finder. Do you think it will be possible to wear a barrel out in 3-4 months?

I will take all your information into account with the further research, thanks for your time.

Alan Carter
8 months ago
Alan Carter 8 months ago

With good ceramic, a life > 3-4 months should be easy.
Krebs/FLSmith also has good cyclone wear materials.

This link here could interest you: Cyclone with in-situ replaceable liner system and method for accomplishing same 

8 months ago

really interesting thank you!

7 months ago
czambrano 7 months ago

Interesting and useful comments. Something to take into consideration specially with high pressure cyclones and coarse material is the underflow launder lining, which finally could shutdown the circuit to have the liner changed with ceramic or a harder material than original rubber.

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