INSTALLATION – OPERATION – MAINTENANCE MANUAL

FOR

EMPRESA MINERA MANQUIRI S.A.

PROYECTO SAN BARTOLOME
O/C A2AV-4-A2AV-001/A2AV100019

MANIFOLD SYSTEM
M735-SAN 10 MOD gMAX15-3117

CYCLONE W/SUPPORT FRAME

SK1905-SAN 01 MOD gMAX15-3272

Krebs Engineers Chile S.A

Av. Americo Vespucio 2760-D, Centro de Empresas El Cortijo, Conchalí, Santiago, Chile.
Telephone: 56 (02) 463-8300, Fax: 56 (02) 463-8383, e-mail: krebschile@krebs.com
Our contacts are: Gerald Kelton, Max Wedeles.

1
Table of Contents

GENERAL .......................................................................................................................... 4

CYCLONE IDENTIFICATION............................................................................................. 4

RECEIVING INSTRUCTIONS ............................................................................................ 4

STORAGE REQUIREMENTS ............................................................................................ 4

CYCLONE DESIGN CONSIDERATIONS .......................................................................... 5

INLET ORIFICE .................................................................................................................... 5
VORTEX FINDER ................................................................................................................. 6
APEX ORIFICE .................................................................................................................... 6

INSTALLATION.................................................................................................................. 7
PRESSURE GAUGE ............................................................................................................. 8
SUMP ................................................................................................................................ 8
PUMP .............................................................................................................................. 10
PIPING ............................................................................................................................. 10

OPERATION..................................................................................................................... 12
FEED DILUTION ................................................................................................................ 12
PRESSURE MEASUREMENT ............................................................................................... 12
APEX ASSEMBLIES ............................................................................................................ 13

MAINTENANCE ............................................................................................................... 15
HYDROCYCLONE
PARTS…………………………………………………………………………………………….…………..………15
LINERS…………………………………………………………………………………………………………….… 16
TOOLS
REQUIRED……………………………………………………………………….………………..17

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 CYCLONE
DISASSEMBLY……………………………………………………………….………………………………………1
9
WEAR PATTERNS
REVISION…………………………………………………………………….……………………………………....21
CYCLONE
ASSEMBLY…………………………………………………………………………………………………………..23
TypICAL MAINTENANCE
FAILURES…………………………………………………………………………………………………………….2
4
GENERAL RECOMMENDATIONS FOR ELASTOMER LINERS INSTALLATION ............................. 29
ELASTOMER LINER INSTALLATION INSTRUCTIONS ................................................................ 29
INSTALLATION OF ELASTOMER LINERS ................................................................................ 31
INSTALLATION OF CYLINDER LINERS ................................................................................... 31
INSTALLATION OF INLET HEAD LINER .................................................................................. 33
RECOMMENDED SETUP FOR CONNECTING FLANGES ........................................................... 37

CALCULATING FLOWS, DENSITIES AND TONNAGES ............................................... 39

EXPLANATION OF TABLES AND FORMULAS ............................................................. 42

APPENDIX PRINTS/PART LISTS /CATALOGS............................................................. 44

3
General
This manual has been designed to make you familiar with the easiest and most practical way to install,
operate, and maintain the KREBS Cyclone - keep it handy for future reference. Additional information can be
obtained from the KREBS Engineers offices. Please see our web site at www.krebs.com for the location of
the nearest KREBS office or representative. The cyclone you have purchased cannot operate well without
proper care. To keep the unit at top efficiency, correct procedures for installation and maintenance must be
followed.

Cyclone Identification
KREBS Cyclones are designated by Model Numbers, Serial Numbers, size and style. This information is
stamped on an identification plate.
Permanent records for this cyclone are kept by the serial number; therefore, the serial number must be used
with all correspondence and spare parts orders.

Receiving Instructions
Where possible KREBS equipment is usually shipped in its complete assembled form; consistent with
transportation and handling equipment limits. Component parts such as pipe fittings and spare parts are
frequently placed inside the cone section of the cyclone.
When removing the cyclone from its packing, care should be taken to account for all parts. Individual items
can be checked against the packing slip.
An Inlet Pressure Gauge and Diaphragm Assembly is furnished with many KREBS Cyclones. These are
packed separately and without necessary fluid. Please check the crate carefully for these items.

Storage Requirements
KREBS Cyclones, rubber lined manifold components and auxiliary equipment such as valves, should always
be stored:
out of direct sunlight;
away from heat and;
protected from extreme weather conditions.
The preferred storage area will be a cool, well-ventilated building.
If outside storage is mandatory, the equipment should be totally covered over with heavy, opaque, plastic
weather covering. It is essential that the plastic be opaque so as to cut out direct sunlight. In addition, a light
color opaque material is desirable, to avoid heat build - up under the covering. Flange protectors are usually
supplied with rubber-lined flanges.

4
The covering should be spread over the equipment with allowance for underside ventilation to avoid
excessive heat build-up and moisture condensation. Elevating the equipment a minimum of 2 inches (50
mm) above ground level should ensure adequate ventilation and prevention of moisture condensation.
The natural gum rubber employed in the manufacture of the cyclone liners is adversely affected by heat.
However, if stored exactly as described above, ambient temperatures of less than 120{F (50{C), and
preferably less than 100{F (38{ C) can be maintained.
The equipment will not be damaged by freezing conditions as long as it is kept dry. If sub-zero conditions are
involved, care should be taken when handling to avoid damage to projecting rubber splash skirts and similar
parts as they become brittle at very low temperatures.
Natural gum rubber is damaged by ozone, and hence his equipment should not be stored in close proximity
to possible ozone sources such as high voltage rectifier equipment.
Where auxiliary equipment includes instrumentation, automatic valves, etc., particular care should be taken to
avoid moisture and moisture condensation occurring during storage.

Cyclone Design Considerations

The primary consideration in selecting the proper size and design of cyclone is the classification objective,
and not capacity, as is the case in many other process devices.
KREBS Engineers, for each specific classification objective, calculate the proper relationship between inlet
orifice, vortex finder, and apex orifice size, and all cyclones are engineered for the job prior to shipment.
There is seldom any necessity for changing these orifice sizes unless the classification objectives or plant
operating conditions are altered.

Inlet Orifice
The inlet orifice size governs the entrance velocity of the pulp, but its major function is to provide a smooth
flow-pattern at the point of entry. All KREBS Cyclones are designed with an involute entry that orientates the
particles prior to reaching the tangential point of contact with the cylinder wall.

INLET OPENING

5
This design minimizes turbulence at this point and reduces the possibility of oversize particles being short-
circuited into the vortex finder, due to turbulence or ricochet action.
The involute entry also allows the use of larger vortex finders for equivalent separations than a direct
tangential entry; hence, lower pressure drops, greater unit capacities, and sharper separations are obtained.

Vortex Finder
From the standpoint of its impact on operating results, this is the most critical of all orifices. The vortex finder
size has the greatest effect on pressure drop for a given volume, and generally speaking, the larger the
vortex finder the coarser the cut and the greater the proportion of solids reporting to overflow. Conversely, a
smaller vortex finder normally means a finer cut and lower solids, but too small a size may so reduce volume
and velocity that inferior performance could result.
For any slurry, an optimum balance between permissible dilution, largest vortex finder, and lowest pressure
drop possible for the desired objective should be sought. Since most classification problems involve a fixed
volume, the size of the vortex finder and pressure drop will be interdependent.

Apex Orifice
The function of the apex orifice is to discharge the coarse material in such a form that maximum density and
smoothness of discharge is obtained. Therefore, it should be large enough to allow the tonnage reporting
there to exit with a slight conical cross-sectional shape, but should not be used as a control of separation.
The apex orifice should never be so small that a "roping" condition exists, for this is an indication that a larger
tonnage is reporting to underflow than the apex orifice is allowing to discharge. Therefore, the remainder
must report to overflow, reducing the effectiveness of classification.

6
 INCREASE

VORTEX PRODUCT
CAPACITY PREASSURE
DIAMETER SIZE

D E CREASE

The Underflow dischargen must show a

30 degree cone patter on vertically
mounted cyclone

7
Installation
Each cyclone should be securely mounted on a soundly constructed frame so that stresses on the
overflow/underflow piping are minimized. If the Krebs Cyclone is part of a manifold (battery) of cyclones, is
essential to follow the assembly instructions. The bolts, washers, and nuts are important parts of the overall
design. For this reason, follow the assembly instructions paying close attention to these items. Later, make
the follow-up to assure that all was mounted per the design.

Pressure Gauge
Supplied with the KREBS Cyclones is a pressure gauge and diaphragm assembly. The assembly typically has
a 1.25” NPT (nominal 32 mm) connection to be installed in each radial distributor. Please see the attached
assembly drawing.
The Diaphragm Assembly must be installed, and BEFORE installing the Pressure Gauge, the upper chamber
of the diaphragm must be filled with a suitable (light) machine oil.

Sump
The conversion of flow and velocity to kinetic energy in a cyclone is derived from the energy supplied by the
pump. Each adjustment of the cyclone variables will influence the pumping to some degree, and these will be
discussed under operation. Constant volumetric flow to the cyclone is important. Momentary fluctuations are
generally the result of air trapped in the slurry.
Correct design of the pump sump is probably the most important single factor in establishing an efficient
cyclone operation. The liquid level in the sump is by no means an indication that the cyclone is receiving a
constant and uniform volume of feed. This can best be detected by watching the inlet pressure gauge
attached to the cyclone. If the needle of the gauge fluctuates fairly rapidly, it is a definite indication that there
is entrained air in the pump discharge slurry, despite the fact that the pump sump may hold a constant level.
The only way to correct this deficiency is to prevent the entering stream from carrying entrapped air to the
suction of the pump. A simple correction is to mount a horizontal metal plate in the pump sump well below
the normal level of the slurry in the sump. This plate can hang by straps suspended from the top of the sump,
or the plate can be welded at several points around the periphery of the sump to hold it in place. An annular
opening between the plate and the edges of the sump of about one inch around its entire periphery will
generally be sufficient to allow the total volume of slurry to pass from the upper compartment to the lower
section.
It is always difficult to hold the feed volume in any pumping circuit at an exact constant. To safeguard against
this possibility of minor fluctuations in flow, it is always desirable to install a float valve connected to a fresh
water supply in the pump sump. This float can be adjusted in such a fashion that it only functions when the
level in the sump is drawn down to a low level. This will prevent emptying the sump, causing a momentary air
lock and a sudden fluctuation in volume pumped.
In certain de-sliming or de-watering operations, it is permissible to return a portion of the overflow product to
the pump sump to maintain a constant level. It must be remembered that the slime content in any feed slurry
to a cyclone is an inhibiting factor, and the greater the slime content, the more difficult it becomes to make a
given separation for a given set of conditions of dilution and feed pressure.
This is the reason that the use of recirculated overflow product should be handled with caution, as there is
always danger of recirculating an excess quantity and unnecessarily increasing the slime content in the
cyclone feed slurry. Where water is reasonably plentiful or the volume of overflow products is not an
important consideration, it is desirable to add fresh water as a means of volume control in preference to
recirculating the overflow product of the cyclone.
The overflow product should go to atmosphere as near the unit as possible, and facilities should be available
for sampling. If the overflow pipe is carried directly to an elevation substantially below the apex of the
cyclone, it creates a siphon action, which in turn causes coarser particles to be carried into the overflow

8
product. Sometimes one intentionally installs a siphon on an overflow to assist in pulling over coarser sizes
and higher density of overflow products. This procedure must be approached with caution, as it is a strictly
artificial means of controlling the classification potential in a cyclone.
Generally speaking, the use of a larger vortex finder, lower pressure drop, or a combination of both can
accomplish this far more effectively.
The underflow discharge should not be permanently enclosed, as it is most important to be able to observe
the characteristics of this flow. Normally a periodic adjustment of the apex valve will maintain the underflow
as a loose rope or a slight spray discharge, in preference to a so-called "rope" discharge.
A "rope" discharge is an indication that there is excess crowding of solids at the apex orifice, which if carried
too far can cause tramp over-size to be carried into the overflow product. If mesh of separation is relatively
fine, and it is important to hold this separation at a near constant, it is never desirable to attempt to pull a
"rope" discharge at the apex of the cyclone.
The launder handling the underflow should be large enough to permit observation and sampling of the
underflow product, and wide enough to prevent wear on the sides of the launder when the apex is
discharging in a relatively wide spray. It should also be deep enough to avoid splash and excessive wear on
the bottom of the launder.

9
Pump
Pumping to a cyclone, or battery of cyclones, must be carefully engineered to the job both as to size and type
of the pump, and to size and length of the pipe line. Wear results in a much higher pump maintenance cost
than cyclone maintenance cost.
Wear on a pump varies approximately proportionately to the cube of the velocity. In order to minimize the
pump speed and pump maintenance, the cyclone should be as near to the pump as possible. A certain inlet
pressure at the cyclone will be required, so there is also a power saving by having the static and friction head
as low as possible.

Piping
When designing cyclone piping, the most important consideration is to establish a velocity that will prevent
particle segregation in the pipe line, and at the same time hold the velocity to a minimum to reduce wear,
which increases rapidly with increase in velocity.
With a large majority of installations for pumping slurries, the velocity range falls between a low of about 5 f/s
(1.5 m/s) and a high of 15 f/s (4.5 m/s).
Major factors in determining the optimum velocity in a pipeline are:
particle size
angularity of the coarser fractions
specific gravity of solids
slimes content
pulp density
viscosity

10
11
Operation
Numerous factors influence the operation of a cyclone, such as distribution of particle sizes, percent feed solids,
specific gravity of solids and liquid and pulp viscosity.
Following is a brief discussion of some factors influencing cyclone operation, which the operator normally is able
to vary:

Feed Dilution
Feed dilution is the most effective control available. The use of additional dilution water will always result in a
finer and sharper separation.

Pressure Measurement
Pressure drop across a cyclone is the pressure differential between the cyclone inlet and overflow. When the
cyclone discharges to atmosphere, a condition that we always recommend, the inlet pressure (gauge reading)
is, for practical purposes, the pressure drop. In such cases then, the pressure drop and cyclone inlet pressure
are synonymous. Where the cyclone overflow discharges against a head (back pressure against the cyclone
overflow), the terms are not synonymous. Pressure measurement is merely an indication of the energy required
to force a given volume through a cyclone fitted with a certain combination of orifices, and is not an indication of
developed force-pattern or through-put, except as related to that one particular set of operating conditions.
To cite an extreme example, it is entirely possible to operate with an abnormally high pressure drop across a
cyclone fitted with small inlet, vortex, and apex orifice.
The volume throughput could be very slight; whereas, superior performance as well as greatly increased
capacity could result from the same cyclone operating at a lower pressure drop with larger orifices.

WHAT HAPPENS IF THE PRESSURE DROP

INCREASES

INCREASES GETS FINNER

PRESSURE CAPACITY PRODUCT

Excessive pressures result in higher costs for pump operation and maintenance and should be avoided
wherever possible.

Optimization of Apex
The distribution of particle sizes in the underflow product has the greatest influence on underflow percent solids.
For example; a clean, sandy underflow with particles of 2.6 specific gravity and ranging from about 1700 to 230
microns (with a very low percentage of particles less than 230 microns) would produce an underflow product of
65 to 70% solids. A similar underflow with a full-range distribution of sizes from about 1700 to 75 microns could
be discharged at 70 to 76% solids. Many density measurements at various operations have demonstrated that
the difference in pulp density between a moderate spray discharge and a rope discharge is rarely more than
about 2-5% solids.
Various adjustable and fixed apex assemblies are available for KREBS Cyclones. The adjustable series may be
varied as required for plant operation with 0 – 80 psi (0 – 550 kpa) plant air or with hydraulic pressure if plant air
is not available.

CAUTION
Never exceed 100 psi (690 kpm) on the adjustable valve assembly. To do so will result in
distortion of the apex orifice shape and may rupture or dislodge the liner, any of which will
result in poor cyclone performance.

Fixed apex assemblies are usually fitted to cyclones in closed-circuit grinding applications where the highly
abrasion resistant ceramic apex inserts provide extremely long life and minimum apex maintenance costs. The
fixed apex is also used to similar advantage in other applications when apex adjustability is not required.

Variables Controlled by the Operator

The following are the basic variables that the operator can easily control during the operation, this
recommendations specifically directed to reproduce in the field the material balance sheets supplied with the
cyclones. Please find attached to this manual the mentioned material balance sheets.

The variables controlled by the operator are the following:

Feed Percent Solids
Pressure
Underflow Percent Solids
Fresh Feed TMPH
Number of Operating Cyclones
Basically the most important parameter to control is the percent solids in the feed. These values are commonly
controlled by adding or cutting water to the sump.
The pressure drop is a resultant of the volume of pulp being pumped to the cyclones and the number of
cyclones opened.
The operator may need to open cyclones to reduce the pressure to the mentioned value or to close cyclones to
reduce pressure if this increases.

13
WARNING:

It’s very important to try to maintain this values in the range specified above, if not the performance of the
grinding-clasification circuit could be poor.
Some common changes in the operation that could affect the above variables:
Increases on the Fresh Feed.
Increases on the circulating load.
Increases on the Feed Percent Solids

What to do?
If the fresh feed increases is recommended to administrate this change by opening extra cyclones to control the
feed percent solids, the underflow percent solids to avoid coarse particles by-pass and the pressure drop.
The product to the overflow will get coarser but this is because of the higher tonnage passing through the mill
producing a coarser product to be feed to the hydrocyclone.
If the circulating load increases this could be basically because the ore is harder and the mill is delivering a
coarser material or the apex insert is worn out, this can be checked observing the apex discharge pattern(if the
discharge have an umbrella pattern greater than 30 degree) or measuring the underflow percent solids and
finding this more dilute than normal .
If the feed percent solids increase this may be caused basically because two reasons, an increase on the
circulating load or an increase on the new feed and the way to proceed in this two cases is discussed above.

14
Maintenance
It is necessary to regularly check the cyclone liners for wear. The cyclone liners can only be properly inspected
by disassembling the cyclone. This must be done when the cyclone is not in service.
The life of the liners will depend on the application and the type of liner material being used. It is the
responsibility of the operator to establish a routine for regular inspection after a cyclone has been commissioned
and, from experience, determine the frequency with which the cyclone liners must be inspected and/or changed.

Replacing Cyclone Liners

CAUTION
Before torquing bolts connecting any two housing sections, inspect adjacent liner
alignment for reverse shelving (see images above, and section below). This condition
causes fluid turbulence that may accelerate liner wear, and may also affect cyclone
performance.
A reverse shelf can be corrected during assembly of the cyclone; while the bolts are
still loose. The housing sections can be shifted from side to side until reverse shelf is
eliminated. Torque bolts after proper alignment is achieved.

15
SERVICIO
SERVICIO DE
DE MANTENCION
MANTENCION
DE
DE HIDROCICLONES
HIDROCICLONES

16
 HIDROCICLON
HIDROCICLON
O/F flange Cabezal

Inlet flange Vortex finder

Cilindro Conjunto de Apex

Cono Splash skirt

17
 REVESTIMIENTOS
REVESTIMIENTOS
•GOMAS
–BPC (Blue Pale Crepe)
–Poliu retanos
Poliuretanos
–Neoprenos

•CERAM ICOS
CERAMICOS
–CR (Carburo de Silicio en matriz de Nitruro de Silicio)
–CX (Carburo de Silicio autoligado)
–CZ (Carburo de Silicio Sinterizado y autoligado)

•METALES
–Nihard
–Niquel

18
 EQUIPAMIENTO
EQUIPAMIENTO
•BÁSICO
–2 Operarios
–1 Barreta
–Agua con jabón
–Krebstick y diluyente
–1 Tubo de 1’ por 1,8 mts. de largo
–1 Martillo de bola
–1 Mazo
–Llaves de punta y corona
•AD ICIONAL
ADICIONAL
–Sistema de levante
–Llave de impacto
–Esmeril angular (con copa)

19
HIDROCICLÓN
HIDROCICLÓN USADO
USADO

20
DESARMADO
DESARMADO
•Lavado y limpieza
–Remoción del barro, tierra,
grasa, etc...

•Desapernado
–Extracción de pernos

21
 DIAGNÓSTICO
DIAGNÓSTICO
•Inspección de uniones
–Verificar que no existan resaltos
negativos
–Verificar espaciamiento entre
revestimientos

22
•Desgastes anormales
–Rayaduras
–Concentraciones de flujo
–Anillos y espirales
ales

23
•Verificación de diámetros
Verificación
–Entrada, vórtex y apex

•Retiro de los revestimientos en mal estado

24
ARMADO
ARMADO
•Reemplazo de revestimientos
–Instalación de revestimientos
nuevos
•Vulcanizado de repuestos
–Algunos de los repuestos
vulcanizados en caliente se
pueden recuperar
•Apernado y pintado
–Ensamblado de las distintas
partes del hidrociclón
–Colocación de pernos y pintado
del hidrociclón

25
 FALLAS TÍPICAS EN LA
MANTENCIÓN (GOMAS)

•Mal ensamble
–Los revestimientos quedan más
largos que la carcaza

•Apriete excesivo de
pernos
–Provoca una deformación del
revestimiento en el interior del
hidrociclón

•Revestimientos usados
–Provoca un resalto negativo en el
interior del hidrociclón

26
 FALLAS TÍPICAS EN LA
MANTENCIÓN

•Apriete excesivo de los

pernos
–Los revestimientos pueden
trizarse o quebrarse

•Revestimientos sueltos
–Pueden provocar resaltos
negativos al interior del
hidrociclón

27
 RESUMEN DEL TRABAJO

•Desarmado
–Lavado y limpieza
–Extracción de pernos

•Diagnóstico
–Inspección de uniones
–Desgastes anormales
–Medición de diámetros

•Armado
–Reemplazo de
revestimientos
–Vulcanizado de repuestos
–Apernado y pintado

28
 HIDROCICLÓN
HIDROCICLÓN
REACONDICIONADO
REACONDICIONADO

29
 TASA
TASA DE
DE DESGASTE
DESGASTE
• Establecer una tasa de desgaste por
pieza, para poder determinar en que
momento cambiar los revestimientos del
hidrociclón.
• Tiene menor costo cambiar un
revestimiento, que una carcaza y
además, el revestimiento.
• Esto hará que su costo efectivo sea
menor.

30
Elastomer Liner Installation Instructions
1. The KREBS Cyclone standard liner material is molded, high density, pure gum rubber, and is
compounded to provide a long wear life. In addition, urethane and other elastomers are
available for all liner sections and can be used in applications where gum rubber is not well
suited. All of the elastomer liners are designed for a firm fit into their corresponding housing.
These liners are designed for a compression fit in the housing to extend wear life; which
sometimes gives the initial impression that the elastomer liner is too large. However, by
following the recommended installation techniques, the liners can be easily installed and provide
a good fit.

2. The compression of liners installed in housings may create elongation to the extent that the liner
projects beyond the metal housing. Plywood boards bolted or weighted to each end of the metal
housing will compress liners to the proper length until the adhesive sets up. This takes one to
two hours.

3. Standard elastomer inlet head liners, cylinder liners, and cone liners must be cemented into their
metal housings to prevent premature failure. Apex liners do not need to be cemented.
Recommended adhesive is KrebStik® liner cement, a compound that we stock especially for this
purpose. This KrebStik adhesive also serves as a lubricant making liners slide in easily.

3a. In several situations, adhesive is not necessary for installation. Adhesive is not
needed for urethane liners, all talon flange liners, all apex liners and all liners used in FRP
housings. Smaller diameter cyclones, 3” (75mm), 4” (100mm), 6” (150 mm), generally do not
require liner adhesive although it is not detrimental to use it.

4. The adhesive contact surfaces of all rubber and elastomer liners must be thoroughly cleaned
prior to applying adhesive. We recommend Toloul, Chevron Socal #3, or other general-purpose
solvent.

5. The liner adhesive should be allowed to set up for one to two hours after liner installation prior to
placing the cyclone in service.

6. Many KREBS Cyclone liners are manufactured with integral soft rubber gaskets that fit between
the matting metals or FRP housing flanges. These integral gaskets seal the joint as well as
prevent slurry from entering between the liner and the housing. All flange bolts should be
tightened just snug enough to prevent leakage. Excessive tightening will distort the liner causing
abnormal wear and inefficient performance.

CAUTION: Excessive tightening of flange bolts will cause distortion

and result in abnormally severe wear and possibly liner dislodgment.
(When using a torque wrench, 20 ft. – lbs. (27 N-m) is sufficient. DO
NOT EXCEED).

7. Periodic inspections of liners should be made until accurate wear records are determined. At
which time a replacement schedule based upon operating time can be established. The liner
wear life varies according to its location in the cyclone and generally it is shortest in the lower
cone section where abrasive action is greatest. All KREBS Cyclone liners are designed with a

31
 slight drop off at each joint by making the I.D. at the bottom of each liner slightly greater than the
I.D. of the liner fitting immediately below it. After assembly, each joint should be inspected to
insure that there is either a flush fit of the liners or a slight drop off, but never a projecting shelf.
Since liner wear is not equal throughout the cyclone, the lower section liners must be replaced
more frequently than the upper liners. However, when any liner has worn to the degree that a
projecting shelf results from the installation of a new liner below it, the upper liner should be
replaced also.

8. The KrebStik liner cement forms a bond between the liner and housing strong enough to hold
the liner in place during normal operation. However, it is not a permanent bond and worn liners
may be manually peeled away from the housing when a replacement is necessary. The housing
contact surface should be cleaned of dirt and foreign material but adhesive does not need to be
removed. An adhesive other than KrebStik may be more difficult to use and is not
recommended.

9. Liners correctly installed should remain in the proper position under normal operating conditions.
However, if performance of a cyclone falls below standard, liners should be examined for wear,
displacement, or tearing.

10. Rubber liners should always be stored in a cool location and never in direct sunlight. KREBS
maintains an extremely large inventory of parts and takes pride in the fact that almost shipments
can be made within 24 hours from receipt of orders.

If there are any problems in the installation or operation of KREBS Cyclones, please contact
KREBS for assistance. Our staff will be happy to assist you.

Installation of Elastomer Liners

Proper installation of KREBS’ gum rubber and other elastomer liners is essential for maximum
performance and service. Most liners must be cemented into their corresponding metal housing.
Apex liners, urethane liners and talon flange style liners do not require adhesive.

Liners are easily replaced by the following procedure:

Removal of Old Liners

1. Remove old liner by grasping one end and “peeling” away the housing. Larger liners
may require working from both ends to loosen entire liner.

2. Remove all dirt and foreign material from housing. It is not necessary to remove
remaining adhesive material.

3. Clean interior of housing thoroughly using cleaning solvent (Chevron Socal #3,
Toloul, or equal).

32
Installation of Cylinder Liners

Note: (i) It is assumed that interior housing has been thoroughly cleaned with solvent as detailed
under A.

(ii) Please refer to numbered photographs corresponding to numbered instructions.

Although this is for the Model D26B, other KREBS Cyclones are similar.

1. Clean exterior surface of the new cylinder liner with cleaning solvent (Toloul, Chevron Socal
#3, or equal.

2/3. Liberally apply Krebs Engineers’ KrebStik liner cement to contact surfaces of cylinder
housing and liner. Never add thinner to reduce viscosity of KrebStik liner cement.

4. Fold cylinder liner fully one-half and insert into housing as shown. Flatten out bulges and
smooth liner into place with liner flanges correctly positioned.

5. Punch out bolt holes in rubber flanges by emptying a ball-peen hammer as shown.

Installation of Inlet Head Liner

6. Bolt one half (either right-hand or left-hand) inlet head housing to cylinder. Liberally apply
KrebStik liner cement to interior surfaces of housing. Prepare inlet head liner by applying
KrebStik to the outside of the lower half.

7/8. Fold inlet head liner and insert as shown. Flatten out bulges and smooth liner into place
with liner flange correctly positioned with housing flange.

9. Liberally apply KrebStik to the upper half of the inlet head liner and interior surface of the
remaining half of inlet head housing. Install gasket and assemble inlet head.

Installation of Cover Plate Liner

10. Wetting the surface of inlet head liner and cover plate liner with soapy liquid will aid
installation of the snug-fit parts.

11. Because of the snug fit, pressure must be applied to cover plate liner while inserting into inlet
head liner.

12. Install cover plate, making sure cover plate liner is properly seated into inlet head liner.

13. After installing vortex finder, overflow adapter and inlet adapter, invert cyclone so it stands on
the overflow adapter. Proceed with remaining assemble instructions.

33
Installation of Cone Liners

14/15. Prepare cone liner and housings as previously noted. Liberally apply KrebStik to interior
surface of cone and exterior surface of cone liner. Insert liner into housing. Flatten out
bulges and smooth liner into plate with liner flanges correctly positioned with housing
flanges.

16. Punch out bolt holes in rubber flanges by employing a ball-peen hammer as shown.

17/19. Repeat steps 14, 15, and 16 for remaining cone sections.

20. Completely assemble the KREBS Cyclone by bolting the cyclone sections together.

34
35
36
Recommended Setup for Connecting Flanges

Recommended arrangement for cylinder/cone connecting flange

Recommended arrangement for cone/cone connecting flange

37
Calculating Flows, Densities and Tonnages

TONNAGE:
SOLIDS

⎡ GPMpulp xδ pulp x(CP / 100)⎤

MTPHsolids = ⎢ ⎥
⎣ 4.41 ⎦
(
MTPH solids = m3 / h ) pulp x(δ pulp ) x(% solids )

PULP

⎡ MTPH solids ⎤
MTPH pulp = ⎢ ⎥
⎣⎢ (C p / 100) ⎦⎥

GPM = Gallons per minute

1 GPM = 0.227 m3/hr.
MTPH = Metric Tonnes per Hour
δ = Pulp Density
ρ = Solids Specific Gravity
Cp = Solids Percent by Weight
MTPH = (STPH / 1.1023) where STPH = Short tons per hour

2) PERCENT SOLIDS IN PULP:

⎡ 100 xρ solids xρliquid ⎤

δ pulp = ⎢ ⎥
⎢⎣100 xρ solids − (C p / 100) x(ρ solids − ρliquid )⎥⎦

δ = Pulp Density
ρ = Specific Gravity of Solids
Cp = Percent Solids by Weight

3) Percent Solids by Weight:

38
 ⎡ MTPH solids ⎤
%=⎢ ⎥ x100
⎢⎣ MTPH pulp ⎥⎦

MTPH = Metric Tonnes per Hour

4) VOLUMETRIC FLOWRATE:

GALLONS PER MINUTE

⎡ mTPH solids x 4 ⎤
GPM pulp = ⎢ ⎥
⎣⎢ δ pulp x(C p / 100) ⎦⎥

1 GPM = 0.227 m3/hr.

MTPH = Metric Tonnes per Hour
δ = Density
Cp = Percent Solids by Weight

CUBIC METERS PER HOUR, PULP (SLURRY)

⎡ GPM pulp ⎤
m3 / hrpulp = ⎢ ⎥
⎣ 4.4 ⎦

5) PERCENTAGE SOLIDS BY VOLUME

⎡ (C p / 100) xδ pulp ⎤
% Solids by Volume = ⎢ ⎥
⎣ ρ solids ⎦

Cp = Percent Solids by Weight

δ = Pulp Density
ρ = Specific Gravity of Solids

6) TONS AND FLOWRATE RELATIONSHIP

39
 ⎡⎛ GPM ⎞ ⎤
STPH = ⎢⎜ ⎟ x(C p / 100) xδ pulp ⎥
⎣⎝ 4.4 ⎠ ⎦

STPH = Short Tons per Hour

Cp = Percent Solids by Weight
δ = Pulp Density

7) PRESSURE

1 PSI = 6895 Pascal.

1 PSI = 0.069 Bar.
1 PSI = 6.89 Kpa.
1 PSI = 14.22 x (Kg / cm2)

40
Appendix Prints / Parts Lists / Catalogs
U

The following is a set of drawings, parts lists, balance sheet and other
technical information regarding the equipment with which this manual is
supplied.

41
MANIFOLD SYSTEM

M735-SAN

10 MOD gMAX15-3117
 BOLT LIST
CONNECTION DESCRIPTION SIZE LENGTH QTY SPARE TOTAL

15 TO 1 HEX BOLT AND NUT 5/8-11 UNC 2 1/2 4 1 5

1 TO 2 HEX BOLT AND NUT 1-8 UNC 3 1/2 28 3 31

2 TO 13 HEX BOLT AND NUT 7/8-9 UNC 3 1/2 8 1 9

2 TO 12 TO 7 STUD AND NUT 3/4-10 UNC 3 36 4 40

6 TO 19.20 HEX BOLT AND NUT 5/8-11 UNC 2 36 4 40

HARDENER WASHER 72 8 80

3 TO 4,22 HEX BOLT AND NUT 5/8-11 UNC 1 1/2 8 1 9

HARDENER WASHER 16 2 18

2 TO 12TO 7 HEX BOLT AND NUT 3/4-10 UNC 2 1/2 108 10 118

21 TO 1 HEX BOLT AND NUT 5/8-11 UNC 2 1/2 4 1 5

19,20 TO 3 HEX BOLT AND NUT 5/8-11 UNC 2 27 3 30

4 TO 22 HEX BOLT AND NUT 5/8-11 UNC 2 78 8 86

CYCLONE w/ SUPPORT FRAME

SK1905-SAN

01 MOD gMAX15-3272