Fluid Mechanics Fundamentals of Hydrocyclones and Its Applications in the Mining Industry

Preface
Contents
1 Introduction
	1.1 Hydrocyclones
	1.2 Hydrocyclone Applications
	References
2 Classification Fundamentals
	2.1 Concentration Measures
	2.2 Variables that Affect Hydrocyclone Behavior
		2.2.1 Design Variables
	2.3 Material Parameter
		2.3.1 Mass Balance
		2.3.2 Selectivity Function
		2.3.3 Classification Function
		2.3.4 Reduced Classification Function Equations
		2.3.5 Fish-Hook
	2.4 Operating Variables
		2.4.1 Input Variables
		2.4.2 Output Variables
	2.5 Balance Adjustment
	References
3 Sedimentation of Particulate System
	3.1 Hydrodynamic Force on a Sphere in Stokes Flow
	3.2 Hydrodynamic Force on a Sphere in Euler’s Flow
	3.3 Prandtl’s Flow
	3.4 Sedimentation Velocity of a Sphere in Prandtl’s Flow 1 < Re < 1.5 × 10−5
	3.5 Sedimentation of a Suspension of Spheres
	3.6 Sedimentation of Particles of Arbitrary Shape
	References
4 Flow of Fluids in Circular Pipelines
	4.1 Newtonian Fluid in Laminar and Turbulent Flow
	4.2 Non-Newtonian Fluid Flows in Circular Pipelines
	4.3 Critical Transport Velocity
	References
5 Flow Pattern in Hydrocyclones
	5.1 Introduction
	5.2 Fluid Dynamics Equations
	5.3 Model Based on the Exact Solutions of the Reynolds Equation
	5.4 Extreme Solutions
		5.4.1 Euler’s Inviscid Isochoric Models
	5.5 Boundary Layer Models
	5.6 Similarity Solution of Reynolds Equations
	5.7 Asymptotic Solutions of the Reynolds Equations
	5.8 Modeling the Air Core
	5.9 Type of Hydrocyclone Discharge and Roping
	References
6 Numerical Models of Hydrocyclones
	6.1 Introduction
	6.2 Finite Element Method
	6.3 Turbulence Modeling
		6.3.1 Eddy Diffusivity Model (EDM)
		6.3.2 A k - ε Stress Model
		6.3.3 k - ε RNG Stress Model
		6.3.4 Reynolds Stress Model
		6.3.5 TFM Simulation
	6.4 Additional Experimental Measurements
	References
7 Phenomenological Hydrocyclone Models
	7.1 Equilibrium Orbit Model
	7.2 Flow Pattern in a Hydrocyclone
	7.3 Phenomenological Model
	7.4 Mathematical Model
		7.4.1 Classification Function
		7.4.2 Short Circuit to the Under Flow
		7.4.3 Leakage to the Overflow
		7.4.4 Selectivity Function
		7.4.5 Separation Size
		7.4.6 Capacity-Pressure Drop Relationship
	7.5 HYDROSIM Simulator
	References
8 Hydrocyclone Design
	8.1 Hydrocyclone as a Turbo Machine
		8.1.1 Turbo Machine Design Criteria
		8.1.2 Hydrocyclone Inlet Design
		8.1.3 Pressure–volume Flow in a Hydrocyclone as a Turbo Machine
	8.2 Industrial Application of the Design
	8.3 Vortex Finder Length and Apex-to-Vortex Ratio
	8.4 Cylinder Length and Cone Angle
	8.5 Apex Design
	References
9 Hydrocyclone Selection
	9.1 Arterburn Hydrocyclone Selection Model
	9.2 Hydrocyclone Simulation Models
		9.2.1 Lynch and Rao Simulation Model
		9.2.2 Plitt Simulation Model
		9.2.3 CYCLOSIM Hydrocyclone Simulator
		9.2.4 Nagewararao’s Model
	References
10 Hydrocyclone System Design
	10.1 Hydrocyclone as an Element in Grinding-Classification System Design
		10.1.1 Pulp Feeding Tank
		10.1.2 Hydrocyclone Configuration
		10.1.3 Construction Materials
		10.1.4 Hydrocyclones and Connecting Pipes
	10.2 Operating Conditions
	10.3 Hydrocyclones and Distributors: Design and Instrumentation
	10.4 Installation and Operation of Hydrocyclones and Batteries of Hydrocyclones
	10.5 Operating Recommendations
	References
11 Instrumentation and Control
	11.1 Feed Concentration Measurement
	11.2 Underflow Concentration Measurement
		11.2.1 Electrical Capacitance
		11.2.2 Acoustic Sensor
		11.2.3 Electrical Conductivity Tomograhpy
		11.2.4 Gravimetric Method
		11.2.5 Image Analysis
		11.2.6 Vibration Sensing
	References
12 Case Studies
	12.1 Application of Cavex Hydrocyclones in the Mining Industry
		12.1.1 Application of Cavex 650CVX13 Hydrocyclones at Placer Dome’s La Coipa Gold Plant in Chile
		12.1.2 Test of Cavex 400CVX10° Hydrocyclone at Minsur S.A., Puno, Perú
		12.1.3 Evaluation of Cavex650CVX Hydrocyclone in the Ok Tedi Grinding Circuit in Papua New Guinea (PNG) [4]
		12.1.4 ReCyclone at El Soldado Copper Mine in Chile
	12.2 Hydrocyclone Optimization for the Chuquicama Division of chile’s Codelco
	12.3 Optimization of Hydrocyclones for Brine Recovery in SQM SALAR
	12.4 Special Types of Hydrocyclones
		12.4.1 Grinding Circuits
		12.4.2 Coarse Classification (Fractioning)
		12.4.3 Desliming/Classification
		12.4.4 Thickening
		12.4.5 Classification/Thickening
		12.4.6 Densifications with Hydrocyclones
		12.4.7 Desliming Hydrocyclones
		12.4.8 Degritting
	12.5 Optimizing the Grinding-Classification Circuit at Pucobre S. A.’s Medium-Sized San José Copper Concentrator
	12.6 Economic Cost of Roping in Hydrocyclones: Evaluation of the Performance of the PST Instrument in Minera Escondida’s Laguna Seca Plant, Chile
	12.7 Hydrocyclones in Industrial Minerals and Other Industries
		12.7.1 Fine Silica Grinding for Fiber Cement Manufacturing
		12.7.2 Desliming, Classification and Refining of Silica Sand and Kaolin
		12.7.3 Desliming and Classification of Silica Sand for Fracking
		12.7.4 Quartz Sand Washing and Classification for Glass Production
		12.7.5 Washing and Desliming of Sand for Construction and Fine Sand Recovery
		12.7.6 Desliming and Classification of Dredging Sand
		12.7.7 Heating Oil Deggriting
		12.7.8 Alumina Classification
		12.7.9 Wolfram Mineral Ore Treatment
		12.7.10 Complex Sulphides, Cu, Pb, Zn, Closed Grinding Circuit
		12.7.11 Phosphate Classification
		12.7.12 Gold Process
	References