How to solve the five common problems of hydrocyclones?

Hydrocyclone is currently a more effective fine-grained grading equipment in mineral processing equipment.In daily production, the hydrocyclone will more or less have some equipment failures. If it cannot be found and resolved in time, it is likely to cause the hydrocyclone to stop.So, what are the common failures of hydrocyclones in daily operation?How can we solve these failures when we encounter them?This article starts from five common faults and analyzes their causes and countermeasures.

The feed pressure fluctuates greatly

In the production process, the ore feed pressure will affect the processing capacity and grading particle size of the hydrocyclone.Generally, the ore feed pressure of the hydrocyclone should be kept stable according to the required pressure and should not fluctuate greatly, otherwise it will damage the performance of the equipment and affect its grading effect.The reason for the large fluctuations in the ore feed pressure is usually due to the decrease in the liquid level of the pump tank or the insufficient supply of the pump due to air traction, or the blockage of debris entering the pump.If the feed pressure drop of the hydrocyclone occurs after a long period of operation, it is mainly caused by the wear of the pump.

solution：

1. If the ore feed pressure fluctuates due to the drop in the liquid level of the pump tank, it can be adjusted by increasing the liquid level, closing one or two cyclones, or reducing the pump speed.；

2. If the ore supply pressure fluctuates due to blockage or wear of the pump, the pump needs to be repaired.

The hydrocyclone is clogged

The judgment of whether the hydrocyclone is clogged is mainly made by observing whether the overflow and bottom flow discharge of the hydrocyclone in operation are unobstructed.When there are more coarse particles in the overflow, the flow rate of the overflow and bottom flow is reduced or the bottom flow is cut off, and the sedimentation sand is discharged in a columnar shape, it indicates that the hydrocyclone has been clogged.In addition, if the hydrocyclone vibrates violently for a long time, it also indicates that the hydrocyclone is clogged.

solution：

1. If the overflow and bottom flow rates are reduced, the inlet of the hydrocyclone may be blocked.At this time, the feed valve of the clogged hydrocyclone should be closed, removed, and the blockage should be removed.；

2. If the bottom flow is reduced or cut off, the bottom flow port is blocked.At this time, the flange can be removed to remove debris from the bottom flow port.

3. In order to prevent clogging, facilities (such as chip removal screens) to prevent coarse materials and debris can be set up in the feed tank of the hydrocyclone group. At the same time, the feed tank should be emptied in time when parking to avoid clogging due to precipitation and excessive concentration when driving again. Phenomenon.

Abnormal bottom flow concentration and discharge

During operation, the operator of the hydrocyclone needs to frequently observe the bottom flow discharge status of the cyclone, and regularly detect the bottom flow concentration and fineness. If the bottom flow concentration fluctuates or the “bottom flow is fine”, it should be adjusted in time.Under normal working conditions, the bottom flow discharge of the hydrocyclone should be “umbrella-shaped”.If the concentration of the bottom flow is too large, the bottom flow will be discharged in a “columnar” or intermittent “bulk”.

solution：

1. The large bottom flow concentration may be caused by the large concentration of the feed slurry or the bottom flow port is too small. An appropriate amount of water can be added to the feed first. If the bottom flow concentration is still large, the larger bottom flow port needs to be replaced.

2. If the bottom flow is discharged in an "umbrella" shape, but the concentration of the bottom flow is less than the concentration required for production, it may be caused by the low feed concentration. At this time, the feed concentration should be increased.

3. The "thin bottom flow clamp" may be caused by the wear of the bottom flow port, the diameter of the bottom flow is too large, the diameter of the overflow pipe is too small, and the pressure is too high or too low. It is necessary to adjust the pressure first, and then detect whether the bottom flow port is worn out or replace it with a smaller size bottom flow port, and gradually debug it to normal production.

Abnormal overflow concentration and fineness

During operation, the hydrocyclone operator also needs to regularly detect the overflow concentration and fineness of the cyclone.The increase in overflow concentration or “overflow running rough” is usually caused by the increase in ore feed concentration and the blockage of the bottom flow port.

solution：

1. It is found that the “overflow runs rough” can first detect whether the bottom flow port is blocked, then detect the ore feed concentration, and then adjust it according to specific circumstances.If the bottom flow port is blocked, the bottom flow port needs to be opened to clean up the blockage.

2.If the overflow concentration is small and the fineness is fine, the pressure can be reduced or the ore feed concentration can be adjusted at this time, and the requirements can also be met by replacing the small sedimentation nozzle.If the overflow concentration is large and the fineness is coarse, the requirements can be met by increasing the pressure and adjusting the ore feed concentration, or by replacing the large sand-sinking nozzle.

The sand-sinking nozzle is spray-like or rope-like

Under normal circumstances, the sedimentation sand of the hydrocyclone is discharged in an umbrella shape, the angle between the sedimentation sand is between 10°-20°, and the concentration reaches about 75%, which is the ideal working state of the hydrocyclone.If the sand-sinking nozzle is spray-like, the angle at which the sand-sinking nozzle spreads out is too large, indicating that the size of the sand-sinking nozzle is too large.If the sedimentation nozzle is rope-shaped, it may be due to the high ore feed concentration, the size of the sedimentation nozzle is too small, the sedimentation nozzle is partially clogged, or the slurry density is too low.

solution：

1. When the sand sink nozzle is spray-like, it can be adjusted by replacing the small sand sink nozzle.

2. When the sand-sinking nozzle is rope-shaped, the size of the sand-sinking nozzle can be appropriately increased to stop the operation of the cyclone and clean up the clogging phenomenon.

The above are the common causes and countermeasures of hydrocyclone failures.If you want the equipment to operate stably and efficiently, in addition to choosing the type of equipment that meets the mineral processing process, daily maintenance and maintenance are also particularly important.It is recommended that all mine owners consult with professional water cyclone manufacturers when purchasing, and comprehensively consider the mineral processing process and mineral processing equipment to further improve the work efficiency and economic benefits of the mineral processing plant.