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Common Failures and Maintenance Points of Hydrocyclone

Introduction

Hydrocyclone has become an important part of the production process in many industries. From the fine screening of ore in the field of mineral processing, to the coal industry to achieve efficient separation of coal and impurities, and then to the oil industry to help purify crude oil. In the mineral processing industry, hydrocyclone uses centrifugal force to effectively separate coarse and fine particles in the ore slurry. In the coal industry, hydrocyclone can be used in coal washing, desliming and dewatering. In the process of washing, it can separate coal from gangue and other impurities, and improve the purity of coal; in the desliming and dewatering process, it can effectively remove fine particles of impurities and moisture in coal, reduce the ash and moisture content of coal, and improve the quality of coal.

Hydrocyclone common failure analysis

Long-term operation process, it is inevitable that will encounter a variety of failures, not only affect the normal operation of the equipment, but also may lead to a series of problems such as reduced productivity, product quality instability, and so on, to the enterprise to bring economic losses.

Pressure fluctuations

In the operation of hydrocyclone, stable feed pressure is the key to normal operation of the equipment and achieve good classification results. Once the feed pressure fluctuations will have a serious negative impact on the performance of the equipment. When the feed pressure fluctuates, the capacity of the hydrocyclone will fluctuate. The reasons for the fluctuation of feed pressure are more complicated. Pump tank level drop is one of the common reasons, when the level is too low, the pump can not fully inhale the slurry, it will cause to feed the ore is not enough, and then cause pressure fluctuations. In addition, air entering the pump can also lead to insufficient ore feeding, triggering pressure fluctuations. Debris entering the pump to cause clogging is also an important factor leading to pressure fluctuations. When the pressure fluctuation caused by the decline in the pump tank level, you can increase the level to stabilise the pressure. Closing one or two cyclones can also reduce the diversion of the slurry and improve the feeding pressure of a single cyclone; reducing the pump speed can likewise reduce the flow rate of the slurry and make the pump work more stable, thus alleviating pressure fluctuations. If the pressure fluctuation is caused by pump clogging or wear, the pump needs to be overhauled.

Clogging failure

The clogging fault of hydrocyclone is one of the common problems affecting its normal operation. In actual production, the overflow and underflow discharge can be observed to determine whether the hydrocyclone is clogged. When there are more coarse particles in the overflow, and the overflow and underflow flow is reduced, or even the underflow flow is cut off, and at the same time the sand is discharged in the form of a column, these are the obvious signs of hydrocyclone clogging. The clogging part is mainly concentrated in the inlet and bottom flow mouth. When the overflow and underflow flow are reduced, it is likely that the hydrocyclone inlet is clogged. If the underflow flow is reduced or cut off, it is very likely that the underflow port is clogged. In order to effectively prevent the occurrence of clogging, facilities to stop the entry of coarse materials and debris can be installed in the feed pool of the hydrocyclone group, such as the installation of a debris removal screen.

Bottom flow abnormalities

In the operation of the hydrocyclone, the state of the underflow is one of the important indicators to reflect whether the equipment is working properly. Under normal circumstances, the underflow discharge of the hydrocyclone should be ‘umbrella-shaped’. When the concentration of the underflow is too large, the underflow will appear ‘columnar’ or intermittent ‘lumpy’ discharge. High underflow consistency can be caused by a number of factors, with high feed slurry consistency or a small underflow opening being common causes. On the contrary, if the bottom stream is discharged in an ‘umbrella shape’, but the concentration of the bottom stream is less than the required concentration, it may be caused by the low concentration of the feed material.

Hydrocyclone maintenance points in detail

Routine inspection and maintenance

Daily inspection and maintenance is to ensure the long-term stable operation of hydrocyclone foundation. In the daily inspection, it is necessary to carry out a detailed inspection of all key parts of the equipment. First of all, it is necessary to check whether the bolts of each ministry are complete and whether there is any looseness. Check whether the cyclone discharge port is blocked. At the same time, it is necessary to check the wear and tear of the sand sinking port and overflow port. Whether there is a leakage phenomenon in each connection of the equipment should not be ignored. The flexibility and role of the pneumatic gate also need to be checked. In addition, it is also necessary to regularly clean the debris in the air compressor air filter, and it is generally recommended to clean it once a week.

Wear and tear maintenance

Hydrocyclone in the operation process, due to the solid particles in the slurry in the high-speed flow of the internal components of the equipment to produce a strong scouring effect, wear and tear problems are inevitable. As one of the main parts of the cylinder wall subjected to slurry scouring, its wear directly affects the service life of the equipment. The inlet is also easy to wear parts, because the slurry in the entry of the cyclone, will produce a large impact on the inlet. Wear on the inlet can be addressed by installing wear-resistant bushings at the inlet. Good maintenance of hydrocyclone is the key to guarantee its stable operation, prolong service life and improve production efficiency.