Hydrocyclone Monitoring

Hydrocyclones are mineral processing equipment used in slurry pulps to separate coarse and fine particles according to their size and density. Under certain conditions roping and plugging can occur where the hydrocyclone ceases to classify the particles, the shapes of the discharge are visibly different than normal operating conditions.

The roping condition occurs when the number of solids in the underflow increases to such a point that its discharge velocity is limited, resulting in the accumulation of coarse solids in the separation chamber. Roping conditions reduce recovery rates and efficiency in metals processing and lead to quality losses in copper processing. If not corrected in time the flow may clog and stop—a plugging condition which can result in contamination and downstream processing efficiency losses. Plugging reduces recovery efficiency, can cause flotation cell damage, and reduces overall availability while the situation is addressed.

To avoid these conditions and operate productively and reliably, Emerson mining controls experts developed hydrocyclone optimizer technology. This control and optimization application addresses the problems associated with roping, plugging, and undesired particle classification. It characterizes the different operating parameters of each cyclone and facilitates the execution of efficient control strategies.