Five Kinds of Failures of Hydrocyclones And Solutions

Date: 2021-09-04     From: Longding     Author: admin

The hydrocyclone is effective fine-grain classification equipment in mineral processing equipment. During production, the hydrocyclone will have some failures. If it cannot be resolved in time, production will be affected. The causes and countermeasures of five common faults are listed below.

1. Large fluctuations in feed pressure

The feed pressure will affect the processing capacity and grading particle size of the hydrocyclone. The feed pressure of the hydrocyclone should be kept stable as required, otherwise, it will damage the performance of the equipment and affect its classification effect.

Cause: The drop in the liquid level of the pump tank or insufficient pump feed.

Solution: Increase the liquid level, or close one or two cyclones, or reduce the pump speed.

Cause: The blockage of debris in the pump or worn pump.

Solution: Repair the pump.

2. Hydrocyclone is blocked

It can be judged whether the hydrocyclone is blocked by observing whether the overflow and underflow discharge of the hydrocyclone in operation are unobstructed.

Cause: There are more coarse particles in the overflow, and the overflow and the underflow are reduced.

Solution: The feed port of the hydrocyclone is blocked. The feed valve blocking the hydrocyclone should be closed, removed, and the blockage removed.

Cause: The underflow flow is reduced or cut off.

Solution: The underflow port is blocked. Remove the flange and remove the debris from the underflow port.

3. Abnormal underflow concentration and discharge

The operator should frequently observe the underflow discharge status of the cyclone, and regularly check the underflow concentration and fineness.

Cause: The high underflow concentration may be caused by the large feed slurry concentration or the too small underflow orifice.

Solution: First add an appropriate amount of water to the feed. If the underflow concentration is still large, replace a larger underflow orifice.

Cause: The underflow is discharged in an “umbrella shape” with a low concentration, which may be caused by the low feed concentration.

Solution: Increase the feed concentration.

Cause: The “fine underflow clamp” may be caused by the underflow orifice wear, the underflow orifice is too large, the overflow pipe diameter is too small, and the pressure is too high or too low.

Solution: Adjust the pressure first, then check whether the underflow port is worn or replace a smaller size underflow port, and gradually debug to normal production state.

4. Abnormal overflow concentration and fineness

The operator needs to check the concentration and fineness of the overflow of the cyclone regularly. Increasing overflow concentration or “overflowing roughness” is usually caused by increased ore concentration and clogging of the underflow port.

Cause: Overflow running rough

Solution: Check whether the underflow port is blocked and the feed concentration, and then adjust it according to the specific situation.

Cause: Fine overflow and the small concentration.

Solution: Reduce the pressure or adjust the concentration of the ore, it can also be replaced with a small grit nozzle.

Cause: Coarse overflow and the small concentration.

Solution: Increase the pressure and adjust the concentration of the ore, and can also be replaced with a large grit nozzle.

5. The grit nozzle is spray-like or rope-like

Usually, the sedimentation of the hydrocyclone is discharged in an umbrella shape, and the sedimentation angle is between 10°-20°. And the concentration of about 75% is an ideal working condition.

Cause: The grit nozzle is spray-like, indicating that the size of the grit nozzle is too large.

Solution: Replace with a small grit mouthpiece.

Cause: The rope shape of the grit nozzle is caused by too high ore concentration, too small size of the grit nozzle, or partial blockage of the grit nozzle.

Solution: Increase the size of the grit nozzle, stop the operation of the cyclone, and clear the blockage.