Classification

Classification
 Outcomes
Outcomes
 Learning outcomes
 have a knowledge and understanding of factors influencing
separation of particles.
 have a knowledge and understanding of the difference of
hindered and free settling and how this influences the
separation of particles
 have a knowledge and understanding the equations describing
the flow of particles through fluids and know how to derive
them
 have a knowledge and understanding of the cyclone as
classification devise.
 Outcomes
Outcomes
 Learning outcomes
 have a knowledge and understanding of cyclone
inefficiencies
 have a knowledge and understanding of the Artherburn
cyclone model and how this can be applied to evaluate
parameters
 have a knowledge and understanding of the concept of
cyclone performance and how it can be measured.
 have a knowledge and understanding of the cyclone as
classification devise.
Introduction
Introduction

 Classification

- Particles of various sizes, shapes and

specific gravities are separated by being
allowed to settle in a fluid.
Introduction
Introduction
 What factors influence the separation of the
particles

 Factors relating to the properties of the particles

 Factors relating to the property of the fluid (e.g.
water, air or dense medium)
 External acceleration forces (gravity, centrifugal
forces)
 Flow regime (e.g. laminar or turbulent)
Introduction
Introduction

 Factors relating to the particle properties

 size (equivalent diameter)

 density
 shape of particle
 surface roughness
Introduction
Introduction

Factors relating to the property of the fluid

 viscosity

 % solids (relates to the viscosity of

fluid)
 stability of medium in fluid

 density of fluid
Flow
Flow of
of bodies
bodies through
through fluids
fluids

 Classification - particles settling in a fluid

Two types of settling

 Free settling (no interference of flow patterns)

 Hindered settling (interference of flow patterns)

Flow
Flow of
of bodies
bodies through
through fluids
fluids

Free settling Hindered settling

- low number of solids - for a pulp

Flow
Flow of
of bodies
bodies through
through fluids
fluids
 Hindered settling vs free settling

 Substitute f with P (Density of pulp)

Hindered settling
- concentration

Free settling - classification

Classification
Classification Cyclones
Cyclones
Introduction
Introduction

 What is a classification cyclone?

 Static device (no moving parts)
 Purpose is to separate (classify) a feed
into a
 Coarse fraction
 Fine fraction

 On the basis of size

 Transport medium is water
Introduction
Introduction

 Terminology
 Hydrocyclone, classification cyclone and
cyclone used interchangeably
 Slurry – mixture of ore particles and water
 Feed – slurry being introduced into the
cyclone
 Overflow – contains the fine fraction
 Underflow – contains the coarse fraction
Principle
Principle of
of Cyclone
Cyclone Operation
Operation
Principle
Principle of
of Cyclone
Cyclone Operation
Operation
Separation forces

Fd = 3vd

Fc  (s -l)v2d3/r
Principle
Principle of
of Cyclone
Cyclone Operation
Operation

 Equilibrium orbit theory

 Particle moving on radius r
 Subject to two main forces
 Centrifugal force – Fc
 Drag force – F
d

 At equilibrium, the two forces are equal

Principle
Principle of
of Cyclone
Cyclone Operation
Operation

 Equilibrium orbit theory

 Centrifugal force – Fc
 Fc = mv2/r
 m = *volume
 Volume = 4/3d3
 Fc  vd3/r
 In fluid Fc  (s -l)v2d3/r
 where l is density of liquid
Principle
Principle of
of Cyclone
Cyclone Operation
Operation

 Equilibrium orbit theory

 Drag force Fd
 Assume laminar flow (incorrect)
 Fd = 3vd (Stokes)
 Fd  vd
where  = viscosity
Principle
Principle of
of Cyclone
Cyclone Operation
Operation

 Equilibrium orbit theory

 Fc = Fd
 d50c=k([Dc3]/[Qf(s-l)])n
 Does not apply to the real world
 Provides insight into the operation of a
cyclone
Principle
Principle of
of Cyclone
Cyclone Operation
Operation

Zero velocity profile

Cyclone
Cyclone Components
Components

1. Overflow elbow
2. Vortex finder
3. Inlet head
4. Barrel
5. Conical section
6. Spigot
Cyclone
Cyclone components
components

 Nomenclature
 Cyclone diameter (Dc) not a ratio
 Inlet diameter (Di) – equivalent circle
diameter/cyclone diameter
 Vortex finder (Do) – vortex finder diameter/
cyclone diameter
 Barrel (Bl) – barrel length/cyclone diameter
 Cone angle () not a ratio
 Spigot diameter (Du) not a ratio
Inlet
Inlet designs
designs

 Inlet designs

Inlet head
Cyclone
Cyclone Inefficiencies
Inefficiencies

Major reasons

 Residence time
 Short circuit stream to overflow
 Short circuit stream to underflow
 Cyclone
Cyclone Inefficiencies
Inefficiencies
Overflow
Bypass to Overflow

Ideal
classifier

Feed
Non-Ideal
classifier

Bypass to underflow
Underflow
Cyclone
Cyclone Inefficiencies
Inefficiencies

 Short circuit stream to the overflow

Cyclone
Cyclone Inefficiencies
Inefficiencies

 Short circuit stream to the underflow

Cyclone
Cyclone Inefficiencies
Inefficiencies
Cyclone
Cyclone modelling
modelling

 Cyclone performance
 Defined by the particle recovery or Tromp
curve.
 Normally expressed as recovery to
underflow
Cyclone
Cyclone modelling
modelling

 Terminology
 d50 – actual cutpoint from the actual
recovery curve
 d50c – corrected cutpoint from the
corrected recovery curve
 Short circuiting (w) – intersection of
actual recovery curve on the y axis
Cyclone
Cyclone modelling
modelling

 Terminology
 Imperfection (Imp) – slope of the
corrected recovery curve
 Imp = (d75-d25)/2d50 (all corrected)
 Imp = 0  perfect separation
 Imp = 1  no separation
Cyclone
Cyclone modelling
modelling

 Terminology
 Typical values
 Imp <= 0.25 – excellent
 0.25 < Imp <=0.35 – good

 Imp > 0.35 – poor (check for density effects!)

Cyclone
Cyclone modelling
modelling
Efficency Curves

1.00

0.90
d 50 = 55 micro n Corrected
0.80
% Recovery to Underflow

m = 1.7 Actu al
a lpha wa te r = 30 %
0.70

0.60

0.50

0.40

0.30

0.20

0.10

0.00
1 10 10 0 10 00
Particle Size (micron)
Factors
Factors affecting
affecting cyclone
cyclone performance
performance

 Cyclone diameter
 Feed pressure
 Vortex finder and spigot diameter
 Solids concentration in feed
Factors
Factors affecting
affecting cyclone
cyclone performance
performance

Cyclone diameter

 Determines capacity
 Smaller cyclones
 High velocities and forces
 classify finer (other things being equal)
 d50c  Dcx
Factors
Factors affecting
affecting cyclone
cyclone performance
performance

Feed pressure

 Flowrate of slurry determines feed pressure

 Pressure  Flowrate
 d50c  1/ Pn
 Normal operating pressure = 85 kPa
Factors
Factors affecting
affecting cyclone
cyclone performance
performance

Vortex finder and spigot diameter

 Sizes determine volumetric split of feed fluid

 Water to underflow reduced by:
 spigot diameter 

 larger vortex finder

 higher pressures
Factors
Factors affecting
affecting cyclone
cyclone performance
performance
Most important variable controlling its performance

 Solids Optimum
in feed~ 15% solids by
volume
Practical
Practical aspects
aspects

 Underflow density
 high as possible - reduces amount of

bypassing
 affects cut-point

 Max 50% solids by volume

Circuits
Circuits
Circuits
Circuits

Underflow Overflow
Circuits
Circuits

Effect of mineral density on cut-point

Circuits
Circuits

1.0

0.9
Fractional recovery to underflow

0.8

0.7

0.6

0.5

0.4 Cr2O3

0.3 SiO2

0.2 Total solids

0.1

0.0
0.01 0.1 1
Particle mesh size [mm]