Three pilot-scale hydrocyclone testworks were conducted to evaluate hydrocyclone performance and design:
1. Varying overflow diameters, pressure, and feed distributions to evaluate separation efficiency. Quartz particles in water were used.
2. Studying the effect of vortex finder parameters on separating light dispersed phases. Particle size distributions of products were measured.
3. Examining the impact of particle size and shape on classification using different feed slurries and measuring overflow and underflow concentrations and sizes.
The hydrocyclone is very important in the separation industry. It is popular due to its simplicity in design and effective operation. It was required that an investigation into the operation and design of the hydrocyclone was performed. The necessary information that was obtained included the theoretical background of the hydrocyclone as well as to how it should be designed
It is the device that utilize specific configuration of N number of cyclones (diameter equal or greater than 300 mm) to treat higher volume of gas efficiently.
The hydrocyclone is very important in the separation industry. It is popular due to its simplicity in design and effective operation. It was required that an investigation into the operation and design of the hydrocyclone was performed. The necessary information that was obtained included the theoretical background of the hydrocyclone as well as to how it should be designed
It is the device that utilize specific configuration of N number of cyclones (diameter equal or greater than 300 mm) to treat higher volume of gas efficiently.
The seventh lecture in the module Particle Technology, delivered to second year students who have already studied basic fluid mechanics.
Centrifugal Separation covers both sedimenting and filtering centrifuges as well as hydrocyclones. Adaptation of the gravity settling and conventional filtration models, to account for the conceptual centrifugal acceleration, is included. Examples of industrial equipment for centrifugal separation are included.
Dense Medium Separation is Gravity Separation Method in Mineral Processing. It is widely used in coal cleaning technology and Coal preparation and in other ores like lead, zinc, manganese, fluorspar, diamond.
Mineral Processing
Jaw crusher
gyratory Crusher
beneficiaton
roll crusher
screening separation classifier
grinding crushing law dry grinding wet grinding Ned university My-203
Ores are typically sorted to increase the efficiency of other refining processes, by reducing the amount of material to be processed while simultaneously increasing its purity. This module explains the ore separation processes.
The first lecture in the module Particle Technology, delivered to second year students who have already studied basic fluid mechanics. Some applications of Particle Technology are described, in industry and nature, and particle size analysis and means of representing the data. The format for the laboratory classes for the module and their reports are covered.
The seventh lecture in the module Particle Technology, delivered to second year students who have already studied basic fluid mechanics.
Centrifugal Separation covers both sedimenting and filtering centrifuges as well as hydrocyclones. Adaptation of the gravity settling and conventional filtration models, to account for the conceptual centrifugal acceleration, is included. Examples of industrial equipment for centrifugal separation are included.
Dense Medium Separation is Gravity Separation Method in Mineral Processing. It is widely used in coal cleaning technology and Coal preparation and in other ores like lead, zinc, manganese, fluorspar, diamond.
Mineral Processing
Jaw crusher
gyratory Crusher
beneficiaton
roll crusher
screening separation classifier
grinding crushing law dry grinding wet grinding Ned university My-203
Ores are typically sorted to increase the efficiency of other refining processes, by reducing the amount of material to be processed while simultaneously increasing its purity. This module explains the ore separation processes.
The first lecture in the module Particle Technology, delivered to second year students who have already studied basic fluid mechanics. Some applications of Particle Technology are described, in industry and nature, and particle size analysis and means of representing the data. The format for the laboratory classes for the module and their reports are covered.
Effect of Geometric Configuration on Performance of Uniflow CycloneIJERD Editor
Reverse flow cyclones find wide applications in many industries however, they require a high
expenditure of energy and large pressure drops, which can be better overcome by uniflow cyclones. A
laboratory unit of Uniflow Cyclone has been developed with 45 mm inlet diameter. The performance
parameters pressure drop and total efficiency were studied for the effect of geometric configuration. The present
study includes the effect of 4 different geometric parameters on performance of uniflow cyclone. The geometric
variation of test cyclones includes the Inlet velocity, Vane angles, Outlet to inlet diameter ratio and Separation
lengths. The overall experimental results yield and investigated the optimal conditions for uniflow cyclone
performance is 450 vane angle, 0.5 outlet to inlet diameter ratio, 3D separation length and 9-10 m/s inlet
velocity. The experimental pressure drop values are validated with the model equations available in literature
and well matched for Ramachandran model.
various dust and gaseous pollutant separation techniques and devices. description of the devices such as their working, particle sizes removed, removal efficiency, mechanism involved etc.
A REVIEW STUDY ON GAS-SOLID CYCLONE SEPARATOR USING LAPPLE MODEL | J4RV4I1001Journal For Research
Cyclone is the most commonly used device to separate dust particles from gas and dust flow. The performance of cyclone separator can be measured in terms of collection efficiency and pressure drop. Parameters like Inlet Flow velocity, the particle size distribution in feed, dimensions of inlet and outlet ducts and cyclone affects the performance of cyclone significantly. Various Mathematical models used for calculation of cut off diameter of separator, flow rate, target efficiency and no. of vortex inside the cyclone to design and study to check the performance of existing cyclone separator. Also new dimensions can be design with help of models. Here, in this study the efficiency achieved with Lapple model cumulatively 86.47%.
This work deals with the application of Computational Fluid Dynamics (CFD) for cyclone modeling on three-dimensional unstructured mesh using the Reynolds Stress turbulence model, a standard k-ε or a k-É model and Large Eddy simulation. Large-eddy simulations (LES) is performed on the gas flow in a cyclone at Re = 280,000. Numerical analysis of flow characteristics and separation efficiency in a high-efficiency cyclone is carried out. The model is only estimated the cyclone's performance under the limited environments; it is difficult to obtain a general model for all the types of cyclones. The purpose of this study is to find out the flow characteristics and separation efficiency numerically using ANSYS Fluent software. The Reynolds stress model (RSM), standard k-ε model and Large Eddy simulations are used in this work to know the flow separation characteristics. The models represent the 3-D, time-dependent flow analysis. CFD velocity profiles, and pressure drops for all the time-dependent flows are compared and discussed. Some details of the flow in the relatively small region in the vicinity of the inlet have strong influence on the separation process is checked with the simulations. The cyclone flow field pattern is simulated and analyzed with the aid of velocity components and static pressure contour plots.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research(IJCER) is an intentional online Journal in English monthly publishing journal. This Journal publish original research work that contributes significantly to further the scientific knowledge in engineering and Technology
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Design and simulation of microfluidic passive mixer with geometric variationeSAT Journals
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3. A hydrocyclone is a size classifier used to
process slurries.
The separation mechanism is based on
enhanced gravity and takes advantage of
particle size and density.[5]
INTRODUCTION
3
Recovery of water to overflow is
generally high (around 90%). It follows
that the coarser particles exit through
the underflow as a dense slurry.[5]
4. INTRODUCTION
Slurry is injected into the
cylindrical zone
Cycloning starts to take
place in the feed
chamber.
Heavier particles move
to the outer walls by
centrifugal forces and
move toward the apex.
Lighter particles stay near the
center of the cone and are carried
away by the vortex finder.
[1,7]
5. Classification does not take-place throughout the whole body
of the cyclone.
5
INTRODUCTION
Region A: unclassified feed
Region B: fully classified coarse material
Region C : fully classified fine material
Region D: classification takes place.
Across this region, decreasing sizes show
maxima at decreasing radial distances
from the axis.[1]
6. Hydrocyclone design objectives:
Maximum efficiency
Maximum capacity
Lower operating costs
The process design criteria will be based on an interpretation
of testwork carried out on the particular ore.
As more test work result are available and the ore
characteristics and process become better defined a
continuous updating of the design criteria is under taken.
Pilot scale testing is regerded as the most reliable method of
selecting flowsheets and generating design criteria for
equipment sizing and selection.[4]
6
INTRODUCTION
7. Cyclone geometry
Area of the inlet
nozzle
Cyclone diameter
Cylindrical and
conical section
Vortex finder and
apex orifice
Feed features
Solids concentration
and Size distribution
Specific gravity of solid
and liquid
Slurry and liquid viscosity
Initial pressure of feed
7
DESIGN VARIABLES
Cyclone performance
0.05 times the
cyclone diameter
squared
−Retention time
−Length equal to
cyclone diameter
−Angle:10°- 20°
[1],[2]
8. The sharpness of the cut depends on the slope of the central
section of the partition curve; the closer to vertical is the
slope, the higher is the efficiency.[1]
8
HYDROCYCLONE EFFICIENCY
9. Small cyclone diameters give greater efficiency.
Efficiency and P increase with height; normally height is
between 2 and 6 diameters.
Smaller cone angle gives better efficiency.
Pressure drop is related to efficiency, It increases with
efficiency.
In practice the efficiency is limited because at high
P, velocities become high, and turbulence causes re
entrainment and loss of particles.
Efficiency increases with mass which increases with particle
size.[1,6]
9
HYDROCYCLONE EFFICIENCY
10. EFFICIENCY, FLOWRATE AND P
0
0
water Flowrate, Q
0
ΔP,mofwatercolumn
Efficiency
A
B
Optimum
Operation
Eff
P
Theory
Practice
40
100
[6]
11. You should start with calculating cyclone diameter:
Step1: Calculate required D50 using mass balance equations
from known information.
Step2: Calculate D50(base) with multiplying times a series of
correction factors designated by C1, C2, and C3:
D50C(application) = D50C(base)xC1xC2xC3
o C1: influence of the concentration of solids
11
HYDROCYCLONE DESIGN
[2],[3].[4]
12. Larger amount of fines
coarser separation
Absence of fines
finer separation 12
HYDROCYCLONE DESIGN
this is affected by particle
size and shape and liquid
viscosity.
higher concentration
results coarser separation.
[2]
13. o C2: influence of pressure drop
• Pressure drop is a measure of the energy being utilized in the
cyclone to achieve the separation.
• It is recommended that pressure drops, be designed in the 40
to 70 kPa range to minimize energy requirements. [2]
C2 = 3.27 x ∆P-0.28
13
HYDROCYCLONE DESIGN
15. o C3: Influence of specific gravity of the solids and liquid
GS = Specific gravity of solids
GL = Specific gravity of liquid
[2]
15
HYDROCYCLONE DESIGN
16. D = 0.204 x (D50(base))1.675
[2]
16
HYDROCYCLONE DESIGN
D50(base) = D50C(application)/C1xC2xc3
17. Then determine cyclone capacity and number of
cyclones:
The volume of feed slurry that a given cyclone can handle is
proportional to the pressure drop.
Number of cyclone= total slurry flow rate /cyclone capacity.
Approximately 20% to 25% standby cyclones are
recommended for operational as well as maintenance
flexibility. [2],[3]
17
HYDROCYCLONE DESIGN
20. Vortex finder diameter:
where Dv is the vortex diameter and Dc is cyclone diameter
Inlet nozzle diameter:
[3]
20
HYDROCYCLONE DESIGN
Di = 0.05 × (Dc)2
21. Sizing Measurement Tests
Sizing analyses provide useful information on the size
distribution of a sample of ore or other material, using a
comprehensive set of screens and all screening done under
standard and unvarying conditions to ensure self-consistency
and reproducibility of the results.[8]
21
TESTWORKS
22. X-ray Diffraction (XRD):
Qualitative Identification - mineral present
Semi-Quantitative analysis - identification and
estimation of major/minor/trace components
Quantification of mineral species present - Rietveld
quantification[8]
The solids Specific gravity of the equivalent Mineral is:[9]
22
TESTWORKS
23. Testwork 1: To collect the data on the operational
performance of hydrocyclone, a series of pilot scale tests was
conducted.
These experiments were carried out using feed slurry
consisting of quartz
particles with a density of 2650 kg/m3. The feed size
distribution is shown in Table 1.
23
TESTWORKS
24. The liquid phase was water.
A hydrocyclone of 100 mm diameter and 435 mm total
length, at a constant inlet pressure of 10 psi was used.
The variable parameters were; the overflow opening diameter
in the range of 14–50 mm, the middling flow opening
diameter in the range of 4–12 mm, and the underflow
opening diameter in the range of 10–24 mm.
The inlet opening diameter was kept constant at 14 mm with
all other conditions.[10]
24
TESTWORKS
25. Test rig
Fig. 11 shows a schematic diagram of the test rig used in the
experimental work.
It comprises a 100 hydrocyclone, a variable speed slurry
pump and 80 l baffled sump.
The pressure drop across the cyclone was measured with a
pressure gauge using a diaphragm mounted on the feed inlet
pipe.
Stirring of slurry in the sump was achieved by a mechanical
agitator in conjunction with the turbulence created by the
returning flows and baffles which ensured a complete
suspension of solids in the sump.[10]
25
TESTWORKS
26. 26
TESTWORKS
Fig. 11. A schematic
diagram of the test rig
constructed at the
Mineral Processing
Laboratory, Faculty of
Engineering, Assiut
University.[10]
27. Test procedure, sampling and data analysis
In each test, the appropriate components are selected to
obtain the desired hydrocyclone configuration.
Feed slurry containing approximately 4.8% solids was
prepared in the sump. After attaining steady state
condition, the overflow, middling flow and underflow streams
were sampled simultaneously for a certain time.
This is immediately followed by sampling of the feed stream.
The slurry samples are weighed, filtered, dried and reweighed
to calculate the flow rates and solids percent in the different
products.
The obtained results were mass balanced and used for
subsequent calculations and interpretations.[10]
27
TESTWORKS
28. Testwork 2: Particle size distribution of the dispersed phase
A proper amount of tracer particles as the dispersion phase
and the continuous phase was mixed in the feed tank and
pumped into the pipe line with a centrifugal pump.
A return line was set near the inlet of the pump to manipulate
the feed rate and to avoid the strong impact to the
hydrocyclone by the inlet flow.
The light dispersion was separated and went back to the tank
with the overflow, while the continuous phase went back to
the tank directly with the underflow.
The position of the orifices in the hydrocyclone was
determined by the research purpose. [11]
28
TESTWORKS
29. For the study of the influence of the vortex finder’s structure
parameter on the flow distribution, some representative and
uniformly distributed axial cross-section should be chosen to
set the orifices.
The weighting method was used to test the separation
efficiency under the same material system.[11]
29
TESTWORKS
30. The results give a coordinated relationship of vortex finder
parameters and performance of hydrocyclones for separating
light dispersed phase.
The size of vortex finder has great influence on the
distribution of the centrifugal separation factor, but the
different depth of vortex finder has little influence on the
centrifugal separation factor.
With the reduction of the vortex finder diameter, the size of
the dispersed particles gets smaller and the separation of the
hydrocyclone gets better. [11]
30
TESTWORKS
31. Testwork3: Effect of particle size and shape on hydrocyclone
classification
The hydrocyclone tests were carried out as follows: 30 L of the
slurry, in the slurry tank was circulated by the circulation pump
through the circulation line to agitate and disperse the particles
in the slurry.
After the slurry flow through the hydrocyclone reached a steady-
state, the overflow product (hereafter referred to as OP) from the
vortex finder and the underflow product (UP) from the apex of the
cyclone were sampled in plastic bottles.
the flow rates of the overflow and underflow were measured
using measuring cylinders and a stopwatch.
Both the overflow and underflow products were dried, and the
solids were weighed for calculations of the solid concentrations
of the OP and UP as the solid mass per unit volume of the
samples.[12]
31
TESTWORKS
33. Size distributions of particles contained in the OP and UP
samples were measured using a laser-diffraction-dispersion-
type particle size distribution analyzer, Microtrac MT3300SX
(Microtrac Inc.), with the measurement condition:wavelength
of light source, 780 nm;measured range of particle
size, 0.021–1408 μm; measuring time, 30 s; refractive
index, 1.55 for PTFE, 1.51 for glass flake, 1.33 for water;
measure mode, transparent and nonspherical.
The results in the table suggest that the settling velocity of
large particles is smaller than that of small particles when
the particle Reynolds number is large.
In the hydrocyclone tests of PTFE and glass flake, recovery of
coarser particles as underflow product decreased at high inlet
velocities.[12]
33
TESTWORKS
35. [1] will’s mineral processing technology, eddition7
[2] THE SIZING AND SELECTION OF HYDROCYCLONES, Richard A. Arterburn
[3] mineral processing, Dr. Nematollahi
[4] mineral processing plant design practice and control,I
[5] Fundamental understanding of swirling flow pattern in
hydrocyclones, Aurélien Davailles a,b,⇑, Eric Climent a,b, Florent Bourgeois
c
[6] apresentation: Powder Technology – Part II, DT275 Masters in
Pharmaceutical and Chemical Process Technology, Gavin Duffy, School of
Electrical Engineering Systems, DIT
[7] a presentation: An Introduction to Basic Hydrocyclone Operation
[8] JK hydrocyclone test
[9] DESIGNING AND TESTING THE REPRESENTATIVE SAMPLERS FOR
SAMPLING A MILLING CIRCUIT AT NKANA COPPER/COBALT
CONCENTRATORChibwe, P.1, Simukanga, S.1, Witika, L.K.1,Chisanga, P.2
and Powell, M. 2005
35
REFERENCES
36. [10] Performance of a three-product hydrocyclone Mahmoud M. Ahmed
a,, Galal A. Ibrahim a, Mohamed G. Farghaly b, 2008
[11] The coordinated relationship between vortex finder parameters and
performance of hydrocyclones for separating light dispersed phase Qiang
Yang, Hua-lin Wang∗, Jian-gang Wang, Zhi-ming Li, Yi Liu, 2011
[12] Effect of particle shape on hydrocyclone classification Kouki
Kashiwaya , Takahiko Noumachi 1, Naoki Hiroyoshi, Mayumi Ito, Masami
Tsunekawa, 2012
36
REFERENCES
Editor's Notes
Apex orifice: . must be large enough to permit the solids that have been classified to underflow to exit the cyclone without pluggingvortex finder: control both the separation and the flow leaving the cyclone. extended below the feed entrance to prevent short circuiting of material directly into the overflow
flow rate given in Figure is for water rather than slurry, it should be mentioned that slurry normally increases thecapacity of a cyclone
An underflow density can be assumed which establishes the total flow rate that must report through each cyclone apex.