operating manual C516 FIVE INCH HYDROCYCLONE ISSUE 2Pi C516 FIVE INCH HYDROCYCLONE IMPORTANT NOTES TO USERS TIGHTEN FEED WORM-DRIVE CLIP TO A TORQUE OF 150kg-cm (15N-m, 130Ib-in} FEED PRESSURE MUST NOT EXCEED 2.4 barg (240kPag, 35psig) FEED TEMPERATURE MUST NOT EXCEED Red Mouldings: 50°C Yellow Mouldings : 90°C FEED SLURRY MUST BE TRASH SCREENED AT 3mm. FEED SLURRY MUST CONTAIN NO PARTICLES LARGER THAN 3mm & NO MORE THAN 10% BY WEIGHT OF PARTICLES LARGER THAN 0.75mm. STOP FEED BEFORE.WORKING ON UNITc516 FIVE INCH HYDROCYCLONE. OPERATING MANUAL, CONTENTS Page No, Introduction.. 22 General Arrangement : Standard Version... wine With One Body Extension 4 With Two Body Extensions... a 8 Materials of Constructio a sauaeaae .6 Installation... 7 Recommended Overflow Pipework.... 8 Sump Level Controls eae Recommended Trash Screen . 10 Typical Radial Installation... ‘Typical Installation with ‘Wedgo' Distributor... Operation - Principle & Practice. Operation - Parameters & Procedures... 14 Maintenance 15 Parts Replacement... . 16 Volume Split Tabte.. Capacity Curves. Efficiency Curves.INTRODUCTION The Mozley C516 Five Inch hydrocyclone is pour moulded in abrasion resistant polyurethane. For ease of maintenance mouldings are clamped between steel plates fastened by stainless Steel, quick release “swing’ halts. Two grades of polyurethane are available. The standard grade (coloured red) is suitable for Use up to a temperature of 50°C. A ‘high temperature’ grade. (coloured yellow) is suitable for use up to a temperature of 30°C. Four vortex finder/intet caps are available with outlet diameters of 50, 40, 30 and 22mm, ‘onabling the hydracyclone to give ds» cut points in the range 10 to 20 microns (solids SG 2.6|. The 30mm cap is atso available with a large inlet for dutios whore higher throughput with a fine cut point is required and ‘top end’ performance is not critical. Feed and overflow connections ara respectively 65nb (2.5") and 8Onb (3°) threaded sockets. The unit can be supplied fitted with a polyurethane lined, steel iniet adaptor flanged to the clionts raquiromenta. One of two body extensions may be fitted In order to increase throughput and reduce Geo cut point. ‘The spigot cap is to a unique ‘snap fit’ design allowing removal and replacement in seconds. It is fully-interchangeable with the spigot cap used on tho Three and Four Inch hydrocyclone ranges. It is fitted with a removeable insert, available with outlet diameters of 25, 22.6, 20, 17.5, 15, 12.5 and 10mm ellowing close -contral of underflow density. A Fange of spigot inserts is also available in 96% alumina ceramic for use whare severoly abrasive slurries are to be treated, By adjusting vortex finder, body lenath and feed pressure, any throughput within the range 5 to 36 m'/n may be obtained, STANDARD VERSION WITH ONE BODY EXTENSION WITH TWO BODY EXTENSIONS == 2Feed inlet. ————+ ou" ese Threaded Socket) C516 FIVE INCH HYDROCYCLONE ‘Standard Version GENERAL ARRANGEMENT Overflow Outlet (2° 8S? Throsded Socket) Worrn-drive Clip Swing Bot. — (off) Lock Nut | eo ae Mounting Plate View from Top Spigot Retaining Ring Spey ———te Reducer Mounting Plate vortex Finder Cap 203 WEIGHT: 15ko 260 101FIVE INCH HYDRO‘ ICYCLONE With One Body.Extension GENERAL ARRANGEMENT Overtiow Outlot ‘Mounting {3 BSP Threaded Socket) Plate : = te sa | Feed Iolet = Vertex $ #1 Finger Threeded cop Socket) 362 Worm-rive cio o-{— Body Extension ‘Swing! alt ——— 1 (orn 16, — = Lock Nut = Brass Nut — 267 ——+1 v Bottom View from Top Spigot Retaining ing ‘Spray Reducer WEIGHT ; 16.5 ka un 74FIVE INCH HYDROCYCLONE Overfiow Outer Mounting With Two Body Extensions «285? Threaded Socket) __Piato Feed Inlet (2% Be — ~ Threaded Socket) Worm-drive GENERAL ARRANGEMENT Swing Bolt Bon Body Extension Look Nut Brass Nut Bottom Plate Body 267 Spigot ing 1333 Safety wire WEIGHT: 18 ko |-——152 —-| Mounting Piare jew feom Top Spigat Reining ra Spigot ir Can Py Spray re Reducer 5C516 FIVE INCH HYDROCYCLONE MATERIALS OF CONSTRUCTION rena Mounting Plato Tarai Vortex Finder Cop TT / ‘Swingbol’, Locknut, Washer Worm-Drive Clip i Body Extension Nut Body Bottom Plate Spigot Ring Safety Wire Spigot Retaining Ring Spigot Insert Spigot Shell Spray Reducer TT} CiSteel, Finish to Mozley Spoc. Polyurethane Stainless Steel Stainless Stoel Polyurethane Polyurethane CSteol, Finish 10 Moziey Spec. Stainless Steet Stainless Steal Polyurethane ‘or Ceramic Polyurethane PolyurethaneINSTALLATION MOUNTING ‘The C516 Five Inch hydrocyciona should be mounted on a suitable rigid frameworkcas shown, allowing easy access to bodly and spigot. FEED PIPEWORS 40nb or 50nb (1.5" of 2") feed pipework should be used with a 40x65 (1.5"x2.5") or 50x65 (2"x2.5") reducing bush fitted in the hydrocyclone inlet. The worm-drive clip provided should be tightened to secure the feed inlet to the reducing bush. A flanged joint ‘and a 0-B0psi pressure gauge should be provided adjacent to the cyclone inlet as shown. OVERFLOW PIPEWORK BOnb (3") threaded elbows may be used for hydrocyclone overflow pipework Care should be taken to avoid siphoning, Alternative ‘mothads ara chown on page 8. LAUNDERS: ‘Tho over‘low launder should be sufficiently farge to handle flowrates up to 30m"/n, The Underflow launder should hava. sufficient ‘fleet’ to enable the discharge of high dansity product. To reduce weer it is adviseable to line launders with rubber or polyurethane. PUMP Normally a rubber lined, centrifugal pump should be used to feed the cyclone. This should be carefully matched to give the required prassure at the cyctone inlet. ‘Operating pressure should not exceed 2.abarg (35psig). Refer to Page 18 to obtain capacity of hydrocyclone, hence pump required PUMP SUMP ‘The sump should include some form of level control 10 avoid ‘surging’ and a 3mm aperture trash screen to reduce the risk of blocking the cyclone. See Pages 9 & 10. MULTIPLE INSTALLATIONS In mulzipie installations a radial or wedge distributor should be used to split the feed aveniy between the cyclones. Typical. examples are shown on Pages 11 & 12. RICHARD MOZLEY LTDis able to supply complete installations designed to meet your exact requirements, INLET ADAPTOR Polyurethane lined inlet adaptors, flanged to any specification, can he supplied on raquest, Please ask for details. sous Onetion under WA Oreftow Product oY p- vaceetton Lascer Undertow Preduet, 7 — Fed Pte takeun Pomp Sump TYPICAL LAYOUT FOR SINGLE FIVE INCH HYDROCYCLONE INSTALLATION,cs16 FIVE INCH HYDROCYCLONE RECOMMENDED OVERFLOW PIPEWORK 80nb (3") MIF Threaded Elbows Air Gap 100nb [4] Pipe \ of Open Launder Hydrocyclone Mounting Plate Breather Pipe 20 (/4" nb x 150 (6") | Continuous PipeworkSUGGESTED METHODS FOR MAINTAINING CORRECT LEVEL IN HYDROCYCLONE FEED PUMP SUMP FEED Hydrocyclone Overtiow Trash Screen usING HYDROCYCLONE OVERFLOW WITH BAFFLE Battle Trash Outler 4 USING HYDROCYCLONE OVERFLOW WITH VALVE Valve Fioat Make-up Water using WATER WITH BALL-COcKTRASH SCREENING SUGGESTED ARRANGEMENT FOR TRASH SCREEN (FIVE INCH HYDROCYCLONE} Plats to deflect flow Feed Screen Framecarefully Feed Lip Stainless Steel Mesh away from Screen edge sealed around edges Aperture: Sin ("/g") Removable Steal _—~ of Wood Frame Perforated Stoo! Support Plate/Sereen Aperture : 25mm (1") ~~ Pump Sump Feed Disuibutor Oversize Material (iscard) TRASH SCREENING OF THE FEED SLURRY 1S ADVISEABLE TO REDUCE if THE POSSIBILITY OF BLOCKAGE OF Rab 85 Puri THE FIVE INCH HYDROCYCLONE INLET OR QUTLETS 10a PETA uss See sea Eat Tees pan Pap one| ae a a a seal SVG BOE SE Km NRO MLA] TYPICAL RADIAL INSTALLATION OF FIVE INCH HYDROCYCLONES «XINO SALLVOIGNI» Geures-u0 enon ews cx) eee a on Fo MOTD “Tse aoTazOM, 1 wo WHIT sas4 wet oN tw cdWITH ‘WEDGE’ DISTRIBUTOR TYPICAL FIVE INCH HYDROCYCLONE INSTALLATIONPRINCIPLE Feed slurry enters the hycroeyclonetangentially under pressure. Asa resultof thehigh centrifugal forces. particles coarser than the ‘cut point’ migrate intoaprimary vortex ad- jacent to the wall and move downwards to discharge witha small volume of water via the spigot. Particles finer than the cut point migrate into a secon- dary upward-moving vortex. along the axis of the hydrocyclone, and discharge with the majority of the water via the vortox finder. The ‘dso’ cut point may be defined as the size of particle which stands an equal chance of reporting to overflow or underflow, Particles finer than the ‘dee’ cut point size will mainly report to the overflow. Particles coarser than the ‘dso’ cut point size will mainly report to theunderflow. PRACTICE The ‘dso’ cut point size for a given hydrocyclone is governed by many factors, most impor- tant of which are vortex finder diameter, feed pulp density and inlet pressure. To obtain the finest ‘dso’ cut point the hydrocyclone should be operated with the smallest vortex finder, low feed pulpden- sity and high inlet pressure. ‘To obtain the coarsest ‘dso’ cut point the hydrocyclone should be operated with the largest vortex findor, higher feed pulp density and low inlat pressure. Efficiency curves showing “des! cutpoint sizes for various vortex. finders are shown on page 19. It should be notes that the tests from which these curves wore obtained were carried out with fairly low food pulp density (8% solids ww) and maximum inlet pressure (30 psig). The ‘deo’ values shown may be doubled at higher fead pul densities and/or lower inlet pressures. OPERATION ‘OVERFLOW Water plus particles finer than cut point U ‘Tangential Feed Intet |_— Vortex Finder Primary Vortex Secondary Vortex AirCore Spigot UNDERFLOW Particles coarser than cutpoint plus water 13C516 FIVE INCH HYDROCYCLONE OPERATION - PARAMETERS AND PROCEDURES FEED PULP DENSITY For best results feed pulp density should be within the range 5 to 20% solids wiw. At higher densities efficiency of separation decreases. FEED PARTICLE SIZE ‘The Five Inch hydrocyclone is nox normally recommended for treating slurries containing ificant quantities of particles coarser than 750 microns (0.75mm). Slurries containing coarse material sheuld first be treated with. large diameter hydrocyciones or screens 10 remove the coarse:fraction FEED PRESSURE An inlot prossura in.the ranga 8 to 30psi is recommended. For maximum efficiency steady feed pressure must be maintained. It surging oF fluctuation in feed pressure occurs separation efficiency suffers drastically and damage to the hydracyclone may result. ‘Surging is usually a result of Insufficient feed to the pump sump. To overcome this problem ‘one of the methods shown on pago 9 may be used. UNDERFLOW DENSITY Underflow density.has an important infiuence on hydrocyclone performance and can easily be controlled by the operator. It can be increased by fitting a smaller spigot insort or increasing feed pulp donsity, and raducad by fitting a larger spigot insert or reducing feed pulp density, A low density underflow product will form a ‘spray’ or ‘umbrella’ discharge and will contain a relatively high peccentage of ‘misplaced’ slimes. ‘As underflow density is increased the included angle in the ‘spray’ discharge is. reduced until a point is reached at which ‘spray’ discharge is replaced by discharge in e thick, poncillike stream known as ‘rope’ discharge. Under these conditions slimes content in the underflow is at a minimum and pulp density at a maximum. Further reduction in spigot size will lead to loss of coarse solids to the averflow and eventually complete chokage of the spigot. Best operating results are normally achieved with an underfiow density as high as possible, ‘but slightly lower than that required to give a ‘rope’ discharge. 14FIVE INCH HYDROCYCLONE MAINTENANCE: {Also refer to Pages 3 & 16) ENSURE FEED PUMP IS ISOLATED FROM POWER BEFORE STARTING MAINTENANCE ‘The hydrocycione should be dismantied and inspected for wear, or other problems, at ‘regular intervals. The length of interval between inspections will depend on the abra: nature of the feed in each application. As 8 guide, mouldings should be replaced when wear in any area exceeds half the thickness of the moulding in that area. SPIGOT CAP Bomoval 1. Remove spigot retaining ring upwards lit is a push-fit). 2. "Snap off spigot with a sideways twisting action, 3. Pull off spray reducer. 4. Push out insert. Replacement Replacement is a reversal of removal procedure. Ensure that spigot rotaining ring is coplaced with the thin edge of the taper painting downwards. BODY (8 Extension{e) if fitted) Body, extension(s} and.vortex finder cap mouldings are clamped to the mounting plate with three quick release ‘swing’ bolts. Fomoval 1. Unscrew the three brass nuts to the ends of the threads (18mm spanner).-Do not remove nuts. 2. Take weight of body/extonsion(s}/bottom plat 3. Swing ‘swing’ bolts out of slots in bottom piate. 4, Lift body/extension(s}/vottom plate away from vortex findar cap. (The above procedure may be carriad out by one person but the help‘of an assistant is to be prefered!) 5. Swing bolts may bo-removed from top plate by lifting 12mm ('/3"), turning 90° and lowering through the slots. Replacement Replacement is a reversal of removal procedure. Ensure that ‘tongue & groove’ joints between components are free of debris and locate together correctly. Tighten brass nuts until locknuts contact top of bottom plate (position of focknuts is set @ during manufacture}. Ensure that cross pins in — Q X ges \ Removal 1, Take weight of vortex finder cap. 2. Remove bolts in flanged joint. 3. Drop vortex findar cap away from mounting plate. 4. Slackon worm drive clip on inlet and unscrew and remove flanged inlot adaptor. Replacement Replacement is a reversal of removal procedure.:Ensure that worm drivo clip is tightoned adequately - a tightening torque of 150kg-cm (15N-m, 130Ib-in) is recommended.C516 FIVE INCH HYDROCYCLONE PARTS REPLACEMENT ireM PART No. — Worm Drive Clip (Intet! €1260-8-100 a + Top Plate c539-M e Vortex Finder Cap 5Omm outlet €801-UA5O 40mm outiet c501-U 30mm outlet €502-U 30mm outlet (Large Inlet) = C502-UZ 22mm outlet c503-U ‘Swing’ Bolt Set (3) For Std. Version C841-8 With One Body Extension C543 With Two Body Extensions 544-5 z + Body Extension c530-U =}. Boy c504-U Bottom Plate c540-M —] NB. SETOFPLATES c617-M COMPRISES TOP PLATE o833-Mt PLUS, BOTTOM PLATE C840 Spigot Fing Safety Wire 546-8 Spigot Retaining Clamp C545-8-2 Spigot Insert Ceramic Polyurethane ‘25mm outlet. C505-Cl_ C505-UI 22.5mm outlet n/a C505-UIA22 20mm outlet. —C506-Cl_ C506-UI | _.. 17.8mm outlet n/a C50G-UIAT8 15mm outlet. C507-Cl_ C507-UL 12,5mm outlet nla C507-UIAI2 omm outst —C508-Cl_ CSOB-UI Spigot Shell cs00-U {| ______- Spray Reducer c510-U-150 For High Temperature polyurethane components add '-4' to art no. shown 16C516 FIVE INCH HYDROCYCLONE VOLUME SPLIT TABLE 30psig STANDARD VERSION TWO BODY EXTENSIONS SPIGOT mm > 25 | 20 | 15 | 10 VORTEX FINDER mm Percentage (by volume) of teed liquid recovered to undertlow. Measurement made using clean water, both products discharging to atmosphere. These figures are correct at 30psig operating prassure; volume split to underflow will increase at lower pressure Where zero volume split to underflow is obtained with water, treatment of a pulp stream will result in particles coarser than the cut point discharging from the spigot with minimum water. erat 7|_FIVE INCH HYDROCYCLONE —c516 CAPACITY CURVES 5 io S = e < a & s 5 a = D 3 2 = = PLUS 2 BODY EXTENSIONS 10 20 30 Inlet Pressure psig STANDARD VERSION -———<—<— PLUS TBODY EXTENSION: —_FIVE INCH HYDROCYCLONE TYPICAL EFFICIENCY CURVES Based on Standard Unit (no body extensions) treating 8% wiw silica flour {SG 2.65) in water at 30psig. With one body extension fitted, curves will move approx. 1 micron to the left, With 2 body extensions fitted, curves will move 1.5 to 2 microns to the left x z ae 5 2 = © a 9; 2 5 10 20 50 100 Particle Size - micronsOperating Manual for Item Code No. ‘The information presented herein is, to the bost of our knowledge, true and accurate However, itis offered as a quide only and no warranty or guarantee, express or implied, is made regarding the capacity, performance or suitability of any product. All our products are sold subject to our conditions of sale, a copy ot which is available on request. REVISION DATE Issue General Revision 18.1.95 12 \ EN 2900130 s001/8S 5750, ‘APPROVED BY BVO! 4 20