Cyclones/Circuit Operations in a Metallurgical Plant

Cyclones/Circuit Operations in a Metallurgical Plant

© Copyright Orica Australia

Slide 2
Presentation Overview
– Introduction To Classification
– Equipments used in classification

– Components of a Cyclone

– Inclination of a Cyclone
– Principles of Cyclone Operations
• What happens in the Cyclones

– Cluster of Cyclones
 Introduction To Classification
• Classification is the process of separating slurry into overflow (fine particles) and
Underflow (coarse particles) using a Hydrocyclone
• Hydrocyclones are basically a continuous operating classifying device that utilizes
centrifugal forces created within the cyclone body to accelerate the settling rate of
particles.

• A typical hydrocyclone consists of :

• conically shaped vessel, open at its apex, or underflow,
• Joined to a cylindrical section, which has tangential feed inlet.
• The top of the cylindrical section is closed with a plate through which passes an axially
mounted overflow pipe.
• The pipe is extended into the body of the cyclone by a short, removable section known as
the vortex finder.
• The vortex finder prevents short-circuiting of feed directly into the overflow.
 Equipment used in classification
Cyclones

Centrifugal Pumps

Pneumatic valves

Pressure gauges
Components of a Cyclone
• A cyclone has no moving parts
(maintenance cost is relatively
cheaper). It consists of:
• A tangential inlet, which causes the
material to circulate at high speed
around the inside of the cone.
• A cone, which causes the speed of
the circulating material to increase as
the cone tapers down.
• A spigot, which helps determine the
separation characteristics of the
cyclone and provides an outlet for the
underflow discharge.
• A vortex finder, which also helps
determine the separations
characteristics of the cyclone and
provides an outlet for the overflow
discharge.
COMPONENTS OF A
CYCLONE
 COMPONENTS OF A
CYCLONE Tangential
Overflow feed inlet

Vortex Finder

Vortex Finder
Feed Box
Inlet Cylinder Section

Cone Section
Cone

Spigot or Apex

Spigot
Underflow

Slide 9
 Inclination of a Cyclone

• Cyclone inclination significantly affects hydrocyclone performance,

particularly for larger, low pressure cyclones at inclinations of 45 ° to the
vertical or greater. This is an important observation as cyclones are often
mounted in a nearly horizontal position, usually for installation or operational
convenience.

• Cut-point increases and water recovery to underflow decreases with

increasing inclination; there is also some evidence that sharpness of cut may
improve with inclination.

• On balance, inclining the larger hydrocyclones has several process

advantages (Asomah and Napier-Munn, 1996).
 Principles of Cyclone Operations
• Slurry is injected tangentially at pressure of 70 – 120 kPa. It forms a spiral
around the inside wall of the cyclone by centrifugal force.

• Larger, coarser and heavier particles spiral to the side of the inside wall and
exit through the Spigot/Apex as Underflow

• Spiral motion creates a Vortex in the center of the Cyclone, causing the bulk
water and fine particles to flow out to the top through the Vortex Finder as
Overflow

• The underflow gravitates to the scalping screens via splitter box whilst the
overflow to the linear screen
• The overflow has a cut size of 80% passing 106 microns.
Principles of Cyclone Operations
It consists of a conical shaped vessel with an opening at the apex called Spigot.
The cylindrical section is closed off at the top with a pipe protruding into the body
of the cyclone is called the vortex finder.

The feed to the cyclone is introduces at the top through a pipe tangentially to the
side of the cyclone.

This produces a spiral motion to the pulp stream which generates a vortex in the
cyclone with a low pressure zone along the vertical axis of the cyclone.

An air core can develop along the axis, partly produced by dissolved air coming
out of solution under the reduced pressure in that zone, but principally due to
connection with the atmosphere through the cyclone apex opening.
 
 Principles of Cyclone Operations

• A particle in the pulp stream is subjected to two opposing forces within the
cyclone.
• Outward centrifugal force, and
• Inward drag forces.
• The centrifugal force accelerates the settling rate of the particles, thereby
separating particles on the basis of size and specific gravity. The larger dense
particles which settle fastest move to the cyclone wall where the velocity is
low and they migrate to the apex opening. The smaller particles which are
slower settling move towards the zone of low pressure along the axis, due to
the influence of the drag forces.
• The particles in the central region are then carried upwards and are extracted
by the vortex finder into the cyclone overflow.
 Principles of Cyclone Operations
85% Fines + 85% Water

Overflow

Feed
(Coarse
+
Fines
+
Water)

Underflow (Coarse +15% Water+15%Fines)

 Principles of Cyclone Operations
• The particles in the flow are therefore subjected to two opposing forces:

• An outward centrifugal force (the centrifugal force is the outwards force applied to an
object in a circular motion).

• An inward drag force

• The size at which a particle has an equal chance of reporting to the overflow or
underflow is known as the ‘cut size’ or ‘cut point’.

• This is where the entrainment or drag forces, and the centrifugal forces acting on the
particle are in balance.

• Particles finer than this cut size are dragged with the bulk of the liquid through the
vortex finder, and particles coarser than the cut size are directed to the spigot. Slide 15
 Principles of Cyclone Operations
• Once separated, the underflow and overflow are directed as follows:

• The underflow (coarse sized particles) gravitates back to the ball mill feed
for grinding
• The overflow (finer sized particles) proceed to the trash screens and then
to the pre-leach thickener.

The pattern of the cyclone discharge is extremely useful in determining the

performance of a cyclone and the amount of wear to the spigot.

Slide 16
 Principles of Cyclone Operations
The diagram below illustrates the different types of patterns that may occur and identifies
the condition that could be causing the pattern type

• Zone A: All parameters are fully

functional (Feed Pressure, Liners, pulp
density)

• Zone B: this is termed “Roping”. This

occurs when the feed density is high
and the pressure is lower than the set
point

• Zone C: this is termed “Spraying”. This

occurs when the feed density is low and
pressure is high.
Cluster of Cyclones / Cyclopac
Cyclones are operated as a single Hydroclone (eg tails dam and gravity plant)
or a cluster of several Hydroclones.
Cluster 1

Cluster 2
Cluster of Cyclones

slurry
Variables Affecting Cyclone Separation
Factors influencing the Capacity of a Cyclone
The capacity or throughput of the cyclone is a function of three main variables:-
• Operating Pressure
• The vortex finder diameter
• The solids content of the pulp
• Cyclone Diameter
• Cyclone Geometry
• Manifold Design
• Feed Percent Solids
• Pressure Drop
• Solids & Liquid Specific Gravity
• Slurry Viscosity
• Particle Shape
Trouble Shooting Guide for Cyclones

There are Three Main

Problems with Classifying Cyclones:

• Coarse Particles in the Overflow

• Excessive "Slimes" in the Underflow

• Too Much Water in the Underflow

Slide 21
Coarse Particles in the Overflow

Pressure Drop is Too Low

• This Condition Produces Insufficient

Centrifugal Force to Settle Particles
to the Wall of the Cyclone.

•Changes Feed Density

• Dumps Slimes to Underflow

Slide 22
Cyclone Feed Pump
 TROUBLESHOOTING-cyclones
Problem Cause Remedy
Cyclone
underflow roping Cyclone
high
feed too Open more cyclones
If no more cyclone to open then reduce the feed rate 
Operating fewer
cyclones
 
Little or no Vortex finders Close some cyclones
overflow worn
  Check for worn vortex finder and replace 
Too many
cyclones opened
Little or no Blocked spigot Put another cyclone on line
underflow  
  Isolate the cyclone with blocked spigot and fix problem
Cyclone feed Cyclone feed Check dilution water flow rate
density low density low
    If valve is in auto mode, ensure that the valve is not
sticking
If valve is in manual mode, adjust flow rate
Check mill discharge density
Cyclone feed Little or no Check dilution water flow rate
density high dilution water
    If valve is in auto mode, ensure that the valve is not
sticking
If valve is in manual mode, adjust flow rate
Check mill discharge density
Cyclone passing Worn cyclone Isolate cyclone for liner inspection
coarse material liner Change liners if found worn or peeled off