Cyclone Separator

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Your Leading Shanxi Huazhan Wear-resistant Materials Co., Ltd. Supplier

Shanxi Huazhan Wear-resistant Materials Co., Ltd. is an enterprise specializing in research and development, production, and sales of mineral separator&cyclone, wear-resistant pipes, vibrating screen and crusher based on modern high-performance and many kinds of wear-resistant materials with high-tech methods. At the same time, we also produce ton bags, ordinary woven bags and other related products. Our company can undertake EPC general contracting projects. we have a professional R&D team, design team, construction team, and advanced production equipments to meet the ever-changing needs of customers and provide customers with high-quality products and services.

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Best design

The company has an independent R&D and design team,there are more than 30 engineers.

Quality control

Strict quality management, and formed a strict quality restraint mechanism and a reliable quality assurance operation system.

Rich experience

70% of the front-line employees have 10 years of casting experience.

One-stop solution

With rich experience and one-to-one service,we can help you choose products and answer technical questions.

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Heavy Dielectric Hydrocyclone

Dense medium cyclones are divided into two categories: pressure-feeding and

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3-Product Heavy Dielectric Hydrocyclone

3-Product heavy dielectric hydrocyclone is divided into two categories: pressure-feeding and

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FX Series Cyclone

The basic principle of the FX series cyclone is to separate the liquid-liquid, liquid-solid,

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Heavy Medium Cyclone

Product Details At present, the maximum specification is WTMC1500/1100, and the processing capacity

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Hydrocyclone Sand Separator

As an efficient solid-liquid separation equipment, hydrocyclone sand separator has many advantages,

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Hydrocyclone Separator

The hydrocyclone separator is a common separation and classification equipment based on the

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What Is Cyclone Separator？

Cyclone separator & hydrocyclone is a fluid processing device widely used in fields such as chemical engineering, mining, petroleum, and water treatment. they are suitable for separating solids and liquids whose particles do not mix or do not dissolve in the carrier medium.It achieves separation or mixing of substances through centrifugal force generated by rotational flow.

Benefits of Cyclone Separator

Hydrocyclones do not have moving parts, hence they require low maintenance

High capacity - a 600mm cyclone can handle up to 200t/h of solids

Low capital cost

Low operating cost

Customized thickness of liner inside to meet different application scenarios for separation

High separation efficiency

Cyclones separate at a wide range of sizes for choosing

Simple to install, operate and service.

Types of cyclone separator

FX series cyclone

FX series hydrocyclone is used to increase the concentration of ore pulp and improve the recovery rate of concentrate. It is an ideal equipment for ore pulp concentration and classification.

Three-product Dense Medium cyclone(Pressurized)

Pressurized hydrocyclones are more suitable for industrial applications that require high throughput and high precision, such as coal washing in mineral processing.

Three-product Dense Medium cyclone(Non-Pressurized)

Pressureless hydrocyclones are suitable for applications with low throughput or energy-sensitive applications, such as sewage treatment or some fine chemical processes.

Six Factors Affecting Hydrocyclone Performance

01. Size

The size of a hydrocyclone plays a key role in its performance.
The size of the cyclone affects the amount of centrifugal force that is used for separation. The smaller the cyclone radius, the more the centrifugal force influences a particle – and the stronger that force is in the tug of war. The particles are pulled more toward the shell to create a smaller cut.
The larger the cyclone radius, the less centrifugal force is available to win the tug of war. So, the cut size is larger.

02.Flow rate

Flow rate is another factor that plays a role in hydrocyclone performance. This deals with the pressure of the material being fed to the cyclone.

03.Inlet area

The size of the inlet area determines the capacity of the hydrocyclone. Larger inlet sizes allow for higher throughput without having to change the pressure.
To increase or decrease capacity while operating at the same pressure, look to change the size of the inlet area.

04.Vortex finder diameter

Similar to the inlet area, the vortex finder diameter can affect capacity and the cut point.
The vortex finder, which extends down partially in the center of the feed box, acts as a cutter. A larger-diameter vortex finder allows more material to be pulled into the air core and out the overflow, creating a coarser cut. A smaller vortex finder allows less material to be pulled into the air core and out the overflow, creating a finer separation.

05.Underflow diameter

The underflow diameter of a cyclone’s apex must be matched to the tonnage per hour. If the apex is too small, the air core cannot form properly, and the underflow will rope. This is when the cyclone is operating at its worst.
If the apex is too big, too much air will enter the cyclone along with a lot more water – and, consequently, more fines – will come out the underflow. This affects the cut point.

06.Length of cyclone

The length of the cyclone also affects performance. Longer cyclones allow for finer separations because the material spends more time in the cyclone to decide which way it is going to go. Shorter cyclones make coarser cuts because the material has less time in the cyclone before discharge.
The length of a cyclone is determined by the conical sections – or extended feed boxes – and cone angles. A 10-degree cone angle makes it a longer cyclone while a 40-degree cone angle makes it a shorter cyclone. Adding extended feed boxes increases the length of the cyclone.

How to Maintain Cyclone Separator

Maintenance should preferably be done on every maintenance shutdown in order to allow for internal inspection:

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Monitoring the internal condition to determine if there are any abnormal wear patterns forming, or check if any tiles damaged, if it is a ceramic lined cyclone

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Measuring the spigot diameter, since the cyclone efficiency might be affected as the spigot diameter increases

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Looking at the vortex finder leading edge, which means looking from the spigot side into the vortex finder, to determine if the condition is still good. In the event that it is not possible to inspect from the spigot side, the vortex finder length can be measured from the top of the cyclone after the overflow pipe has been removed

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Measuring the vortex finder length and spigot diameter

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Checking for excessive grooves in the cyclone body or vortex finder

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Checking for feed inlet and cone wear, uneven surfaces, and steps

How does Dense Medium Cyclones Work?

Dense medium cyclone is a high-efficiency separation equipment based on centrifugal force field and density difference, which is widely used in mineral processing and environmental protection fields. Its core principle is to mix the material with the weighting medium (such as a suspension of magnetite powder and water) and inject it into the cyclone at high speed, using centrifugal force to form a spiral flow field, so that high-density particles (such as gangue, metal minerals) move to the wall and are discharged from the bottom flow port, and low-density particles (such as clean coal, gangue) gather in the central low-pressure area and separate from the overflow port. This process follows the Archimedean principle, and accurate separation can be achieved by adjusting the medium density (usually 1.3-2.0g/cm³). The equipment is mainly composed of the cyclone body, the weighting medium system and the medium circulation device.

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FAQ

Q: Is it normal for the coarse discharge of a hydrocyclone to experience more rapid wear than other parts of the cyclone?

A: Yes, this is a common issue. It is advisable to upgrade materials in this area to a higher-performing ceramic to address this issue.

Q: What is the best approach to addressing higher wear on the inlet of a dust collection cyclone?

A: A ceramic panel can be designed to address this specific wear zone in the cyclone. This panel features a bolt-in design, ensuring that the inside surface of the cyclone remains smooth and consistent.

Q: What are the different types of cyclones?

A: There are three main types of cyclones, including FX series hydrocyclone, Three-product Dense Medium cyclone(Pressurized), Three-product Dense Medium cyclone(Non-Pressurized).

Q: How do you find the diameter of a cyclone separator?

A: Diameter of cyclone = Dc = 0.063 m. Flow inlet area =0.5Dc*0.2Dc = 4*E-4 m2. Cylindrical length = 1.5 Dc = 0.0945 m. Conical section ht.

Q: How do you size a cyclone?

A: The cyclone size is directly tied to the amount of air going through it. The more air there is, the larger the cyclone required. Without a doubt, this is the most important requirement for sizing a cyclone. The airflow volume is based on the temperature and pressure by the ideal gas law.

Q: How does a sand cyclone work?

A: In a Sand Washing Plant context Hydrocyclones use Fluid Dynamics to separate different types of particles from each other; such as lighter silt and clay from heavier sand particles. Material that is heavier than the cut-point that cannot be overcome by the vacuum are discharged out the bottom as underflow.

Q: What is the difference between a cyclone and a hydrocyclone?

A: General Information. In general, cyclones use centrifugal force to separate particles in a gas or liquid stream. In hydrocyclones, the liquid is the fluid medium. There are two design classifications for cyclones.

Q: What is the minimum particle size for a cyclone separator?

A: Their major limitation is that, unless very small units are used, efficiency is low for particles smaller than five microns. Although cyclones may be used to collect particles larger than 200 microns, gravity-settling chambers or simple inertial separators are usually satisfactory and less subject to abrasion.

Q: How do you calculate the pressure drop of a cyclone separator?

A: The solution of the equation 3 is: P = D* Vt * ln (r) + C (4) This solution gives the pressure distribution in the cyclone flow field. The cyclone pressure drop is a function of the cyclone dimensions and its operating conditions.

Q: What is the difference between a hydrocyclone and a separator?

A: If solids reduce in the feed, Hydrocyclones can flush and will wash the stockpile away, whereas a Separator™ maintains the same density under these conditions, so you maintain the stockpile." Separators™ maintain underflow density under varying feed conditions, which allows them to stockpile material directly.

Q: How efficient is a cyclone separator?

A: Cyclone separators are generally able to remove somewhere between 50-99% of all particulate matter in flue gas. How well the cyclone separators are actually able to remove this matter depends largely on particle size.

Q: Do you need a cyclone separator?

A: Why Use a Cyclone Dust Collector? Cyclone separators can achieve high collection efficiencies, typically separating 99% of the dust particles greater than 10 microns in size from the air stream and depositing them into a collection bin.

Q: What material is cyclone separator?

A: Cyclones are available in various materials such as stainless steel, aluminium, nickel, polystyrene (PS), polyvinylchloride (PVC) and polyvinylidenefluoride (PVDF). “High throughput” cyclones have a diameter greater than 1.5 m and are suitable for separating particles that are 20 µm or larger.

Q: What is the difference between centrifuge and hydrocyclone?

A: The key difference is that hydrocyclones are passive separator packages capable of applying modest amounts of centrifugal force, whereas centrifuges are dynamic separators that are generally able to apply much more centrifugal force than hydrocyclones.

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