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Sizing and Selection of Hydrocyclones PDF
Sizing and Selection of Hydrocyclones PDF
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In designing comminution circuits the depending upon the grinding characteristics
objective is to produce an overflow from the of the ore itself.
cyclone which has a certain size distribution, The separation a cyclone can achieve
normally defined as a given percent passing can be approximated using Equation 2. The
a specified micron size. An empirical D50C (base) for a given diameter cyclone is
relationship shown in Table 1 is used to multiplied times a series of correction factors
relate the overflow size distribution to the designated by C1, C2, and C3.
D50C required to produce the specified
separation. The relationship of this table is (Eq. 2)
for typical or average grinding size
distributions and may vary slightly D50C(application) = D50C(base)xC1xC2xC3
Required Overflow
Size Distribution Multiplier
(Percent Passing) of (To Be Multiplied
Specified Micron Size Times Micron Size)
98.8 0.54
95.0 0.73
90.0 0.91
80.0 1.25
70.0 1.67
60.0 2.08
50.0 2.78
This D50C (base) is the micron size that a Figure 6 and can be calculated using
“standard cyclone” can achieve operating Equation 4. Figure 6 indicates that the level
under the base conditions and is given in of percent solids is extremely important in
Figure 5 or calculated from Equation 3. For determining the proper separation, as the
example, a 25.4 cm (10 in.) diameter higher the concentration the coarser the
cyclone has a base D50C point of 24 separation. It should be pointed out that this
microns. correction is a relative measure of slurry
viscosity and is affected by such things as
0.66
D50C(base) = 2.84 x D (Eq. 3) the size of particles present as well as
particle shape. For example, a feed that
Where D = Cyclone diameter in cm. contains a large amount of clay would tend
to shift this curve to the left and result in a
The first correction (C1) is for the coarser separation, whereas the absence of
influence of the concentration of solids fines would shift the curve to the right and
contained in the feed slurry. The graphical result in a finer separation. Many other
representation of this correction is shown in
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variables such as liquid viscosity also affect liberation of mineral particles at a coarser
this correction. overall separation size.
It has been found that Stoke’s law can be
applied to determine particle diameters
-1.43 which would produce the same terminal
settling velocity for a particle of known
C1 = 53-V (Eq. 4) specific gravity in a liquid of known specific
53 gravity as compared to a particle of 2.65
specific gravity in water. This relationship is
shown in Figure 8 and can be calculated
using Equation 6.
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There are numerous other variables shown that an underflow density of 50% to
which also have an effect of separation; 53% solids by volume is typical for primary
however, these variables are relatively minor grinding circuits, whereas an underflow
and may be neglected for the preliminary density of 40% to 45% solids by volume is
sizing and selection of cyclones. normal for regrind circuits. Therefore, an
underflow density can be assumed which
FLOW RATE establishes the total flow rate that must
report through each cyclone apex. Figure
The second main objective which must be 10 shows the approximate flow rate for a
considered is to provide adequate cyclone given diameter apex orifice.
capacity for the application. The volume of
feed slurry that a given cyclone can handle OPERATIONAL AND DESIGN
is related to the pressure drop across the CONSIDERATIONS
cyclone. The relationship between flow rate
and pressure drop for several different sizes One of the most important considerations
of standard cyclones is shown in Figure 9. is to insure that cyclones are installed
As shown, the flow rate increases as the properly. A detailed list of “Do’s and Don’ts”
pressure drop increases. In order to utilize is given in a later chapter.
this graph, the pressure drop used for
calculating the separation is used to FEED PIPING AND DISTRIBUTION
determine the flow rate for the cyclone
diameter which was also used for A most important consideration for a
determining the separation. The flow rate is given cyclone system is proper delivery of
then divided into the total flow for a specific the slurry to the cyclone or cyclones. It has
application to determine the number of units been found that a pipe size which produces
necessary. a line velocity of 200 to 300cm/sec (7 to 10
Since the flow rate given in Figure 9 is for ft/sec) is high enough to prevent particles
water rather than slurry, it should be from settling, even in horizontal sections, but
mentioned that slurry normally increases the low enough to minimize wear. Normally for
capacity of a cyclone over that shown for a single cyclone installation the inlet pipe
water; however, for preliminary estimates size of the manufacturer’s recommendation
this factor can be neglected. This will result produces a velocity in this area.
in the number of cyclones calculated being If the slurry is to be distributed to a
slightly higher than those actually needed. number of cyclones operating in parallel,
Approximately 20% to 25% standby extreme care should be given to the design
cyclones are recommended for operational of the distribution system, and a radial type
as well as maintenance flexibility. of manifold is recommended. This is a
The vortex finder size and inlet area of a system where the cyclones are fed from a
cyclone also have an effect on the central circular chamber. When properly
volumetric flow rate that a given cyclone can designed the central chamber becomes a
handle. Larger vortex finders or inlet areas mixing area and the line velocity should be
would increase the capacity, whereas lowered to approximately 60 to 90 cm/sec (2
smaller vortex finders or inlet areas would to 3 ft/sec). This will help insure that each
decrease the capacity. The shaded area in cyclone is fed with the same slurry
Figure 9 corresponding to each standard concentration as well as the same particle
cyclone gives the approximate range of size distribution and also will reduce wear
capacity for each cyclone. rates. Using the radial manifold also makes
it easier to install standby cyclones.
APEX SELECTION Should an inline type manifold be utilized,
the cyclones do not receive good
The proper selection of apex size is distribution. It is typical that the high mass
critical to proper cyclone performance. For particles or coarser particles tend to pass
each application a circulating load is the first cyclones and report to the final
normally given which establishes the cyclone. This results in the last cyclone
amount of solids which must pass through receiving a higher feed concentration of
the cyclone underflow. Experience has coarser particles, which accelerates the
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wear of the last cyclone as well as produces recommended, the feed pressure is the
a coarser separation due to the higher feed same as the pressure drop.
density. Also, the last cyclone, once shut Cyclone selection provides the pressure
off, becomes difficult to restart because the drop required, and for pump calculations this
solids will tend to pack into the feed pipe. must be converted to meters of slurry which
For applications where the separation is can then be added to the static and friction
not critical or one in which the feed heads to determine the total dynamic head
concentration is extremely low, an inline for the pump. Equation 7 is used for
manifold is acceptable and is much less conversion of pressure drop to meters of
expensive than the radial type. slurry.
MATERIALS OF CONSTRUCTION
M = DR x 0.102 (Eq. 7)
Cyclone Construction varies greatly from G
one manufacturer to another, but the
majority of the designs includes metal Where M = Meters, slurry.
housings with replaceable liners with DR = Pressure drop, kPa.
replaceable liners with the most suitable G = Sp gr of slurry.
liner material varying from one application to
another. It is also common to utilize several As stated, it is recommended that both
different lining materials within the same the overflow and underflow products be
cyclone to optimize wear characteristics. discharged at atmospheric pressure.
Natural gum rubber is the most common Should the overflow be discharged against a
material utilized due to its relatively low cost, positive head, some of the fluid which
excellent wear, ease of handling, and it is normally reports to the overflow is forced to
not fragile. Applications where gum rubber report to the underflow. This does not have
is not suitable are those where the a major effect on classification but does
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temperatures exceed 60 C or there are increase the amount of bypass solids and
large amounts of hydrocarbons present in reduces underflow density.
the slurry such as oil or other detrimental Should the overflow be discharged at a
chemicals. point lower than the feed entrance, a
Ceramic materials have found possible siphon can be established which
acceptance as cyclone liners for the apex would cause a breakdown in classification
orifice as well as other areas which exhibit and could bring larger particles into the
severe abrasion. These include areas such overflow. A large siphon effect could
as the lower cone liner and vortex finder. actually dislodge a worn liner which in turn
Nihard has also proven to be an would plug the overflow piping. Siphons can
acceptable wear material, especially for be prevented by installing a vent pipe on the
vortex finders and other areas which require overflow piping of each cyclone.
strength as well as abrasion resistance. The underflow should also be discharged
Other elastomer materials such as at or near atmospheric pressure. Should the
neoprene and nitrite are also utilized when underflow be discharged at a negative
hydrocarbons are present or when the pressure, the effect would be similar to a
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temperature exceeds 60 C. Urethane has positive pressure at the cyclone overflow. If
found acceptance, especially in areas where the underflow is discharged against a
the solids are relatively fine. positive pressure, the amount of flow is
reduced and a larger apex must be selected
in order to insure that the classified solids
PRESSURE DROP CALCULATIONS can discharge freely.
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regarding cyclone applications, the feed microns) at a minimum of 40% solids by
slurry being delivered to a cyclone should be weight. Underflow becomes ball mill feed.
as steady as possible with regard to both Specific gravity of solids is 2.9 and
volumetric flow rate and slurry density. estimated circulating load is 225%.
Unsteady feed conditions such as severe
pump surging or extreme variations in slurry STEP 1. Calculate material balance from
density are very detrimental to good cyclone known information. Overflow must be 250
performance. In general, a sump/pump MTPH at 40% solids.
system for a cyclone application should
have a sump with as much depth as Overflow:
possible and a minimum cross-sectional
area consistent with the pump MTPH solids = 250
manufacturer’s recommended retention MTPH water = 375
time. A sump of this design will normally MTPH slurry = 625
eliminate pump surging by allowing small % solids, wt = 40
variations in sump level well above the Sp gr slurry = 1.355
minimum pump suction level. The small 1/sec slurry = 128 (2030 USGPM)
cross-sectional area will reduce the buildup (1/sec = liters per second)
of solids in the bottom of the sump and help
prevent large sections of the settled solids to Underflow: (based on 2.25 x overflow):
slough into the pump suction and plug either
the cyclone feed line or the cyclone apex. MTPH solids = 562
Therefore, a tall sump with a small cross- MTPH water = 187
sectional area provides much smoother MTPH slurry = 749
operation. % solids, wt = 75 (assumed at
Sp gr slurry = 1.966
APEX DISCHARGE PATTERN 1/sec slurry = 106 (1676 USGPM)
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(from Figure 6) Other design and installation information
C2 = Correction for DR = 1.1 (from Figure 7). such as feed distribution systems, materials
Pressure drop assumed at 50 kPa of construction, pressure drop calculations,
(7 psi) which would be low energy and sump/pump design, and apex pattern were
good maintenance. discussed. An example problem for a
C3 = Correction for sp gr solids = 0.93 primary rod mill/ball mill grinding circuit was
(from Figure 8) also given.
Although the method for determining the
Second, calculate cyclone diameter: proper size and selection of hydrocyclones
in this paper has proven to be quite
D50C (application) = D50C (base) x accurate, the engineer should still be aware
C1xC2xc3 of the fact that variations in ore
(from Equation 2) characteristics have an effect on cyclone
154 = D50C (base) x 4.09xl.lx0.93 performance. In cases where the slurry
D50C (base) = 37 microns characteristics are questionable, pilot plant
information should be used to provide more
Therefore, from Figure 5 use 51 cm accurate cyclone sizing and selection.
cyclones (20 in.).
BIBLIOGRAPHY
STEP 4. Calculate number of units
required. Arterburn, R.A., 1976, “The Sizing of
Hydrocyclones, Krebs Engineers, Menlo
From Figure 9: Park, CA.
STEP 5. Calculate proper apex size. Lynch, A.J. and Rao, T.C., 1968, “The
Operatint Characteristics of Hydrocyclone
Total underflow = 106 1/sec Classifiers, “Ind. J. of Tech., 6.
Underflow per unit = 106/6 = 18 1/sec
From Figure 10 each apex should be Lynch, A.J., Rao, T.C. and Prisbrey, 1974,
9.5 cm (3 ¾ in.) “Influence of Hydrocyclone Diameter on
Reduced Efficiency Curves,” International
Journal of Mineral Processing, 1, 173.
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Tarr, D.T., 1965, “Practical Application of
Liquid Cyclones in Mineral Dressing
Problems,” AIME Fall Meeting.
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FIGURE 1
CYCLONE CUTAWAY
Vortex Finder
Cylinder Section
Conical Section
Apex
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Figure II
Involuted Feed vs. Tangential Feed
Involuted Feed
Tangential feed
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Gr a p h I
Pa r t i c l e Di a m et er VS. Pa r t i c l e Rec over y
100
90
80
Ac t ua l
Rec over y
Pa r t i c l e Re c o ve r y (% t o Un d e r fl o w )
70
60
50
D50 Poi n t
40
30
Cor r ec t ed
Rec over y
20
10
12
Graph II
Reduced Recovery
100
90
80
70
60
Particle Recovery (% to underflow)
50
40
30
20
10
0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.5 2 2.5 3 3.5 4 4.5 5
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Gr a p h I I I
Cy c l o n e Di a m e t e r VS. D5 0
(Fo r "Ty p i c a l " Cy c l o n e s )
100
90
80
70
60
50
40
35
30
D50 (M i c r o n s )
25
20
15
10
3
1 2 3 4 5 6 7 8 9 10 15 20 25 30 40 50 60
Cy c l o n e Di a m e t e r (I n c h e s )
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Gr a p h I V
Co r r e c t i o n Fo r Fe e d Co n c e n t r a t i o n
100
90
80
70
60
50
40
30
20
Cor r e c t i o n Fa c t or
15
10
9
8
7
6
5
0
0 5 10 15 20 25 30 35 40 45 50
Fe e d Co n c e n t r a t i o n (% s o l i d s b y v o l u m e )
15
Gr a p h V
C o r r e c t i o n Fo r P r e s s u r e D r o p
3
2 .5
1 .5
Co r r e c t i on Fa c t or
0 .9 5
0 .9
0 .8 5
0 .8
0 .7 5
0 .7
0 .6 5
0 .6
0 .5 5
0 .5
0 .4 5
0 .4
10 0
15
10
20
25
30
40
50
60
80
90
70
3
P r e s s u r e D r o p ( P SI )
16
Gr a p h VI
Co r r e c t i o n f o r So l i d s Sp e c i f i c Gr a v i t y
(i n w a t e r )
10
4 .5
3 .5
Co r r e c t i o n Fa c t o r
2 .5
1.5
0 .9
0 .8
0 .7
0 .6
0 .5
0 .4
1 .5
2.5
3 .5
4.5
5.5
6.5
7.5
8.5
9.5
10
2
9
1
So l i d s Sp e c i f i c Gr a v i t y
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Gr a p h VII
Pr essu r e Dr op VS. Vol u m et r i c Fl ow r a t e
30" Cyc l on e
9 ,0 00
26" Cyc l on e
5 ,0 00
20" Cyc l on e
Vo l u m e t r i c Fl o w r a t e (USGPM )
15" Cyc l on e
1,0 00
80 0 10" Cyc l on e
7 00
600
50 0
40 0
300
6" Cyc l on e
20 0
4" Cyc l on e
100
90
80
70
60
50
40
30
15
100
10
15
20
25
40
50
60
80
90
30
70
3
Pr essur e Dr op (PSI)
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Graph VIII
Apex Capacity
10,000
Diameter VS. Flowrate
700
500
400
300
200
Fl o w Ra t e (GPM )
80
70
60
50
40
30
20
10
1
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 2 3 4 5 6 7 8 9 10
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