Hydrocyclones – The Cutting Edge Solution For Efficient Particle Separation

Hydrocyclones are an economical and straightforward separation device, perfect for sorting heavy fractions from light fractions. Heavier fractions exit at the bottom (reject) side while lighter ones come out through the top overflow side of the cyclone.

Changes in feed density can have an enormous effect on cyclone separation. An increase in pressure will decrease cut size while decreasing density can increase it.

Efficient Particle Separation

Hydrocyclones enhance operational efficiency across numerous sectors by sorting particles according to size and density, as they separate particles by size and density. Their use promotes sustainability and quality in products in the biotechnology and food industries for example; refining structural parameters further can enhance performance even further and increase operational efficiencies further still.

An effective cyclone is dictated by a delicate balance between centrifugal force and drag force, which act on particles to regulate their movement. A number of factors impact this balance between forces, including particle velocity in relation to fluid velocity, particle trajectories, kinetic energy and particle distribution within its inlet.

Pressure at the inlet of a cyclone is particularly critical; any drops below target will send more particles towards its overflow, while an increase will send them toward its underflow.

To maximize separation efficiency, it is critical that an optimal pressure is reached at the inlet of a cyclone. This ensures that larger particles will be drawn away from the center and into the overflow while finer ones will stay nearer the center and carried by liquid overflow. Park Process has developed their HydroSpin(r), an abrasion-resistant polyurethane or carbon steel construction model which offers highly effective separation solutions between solids and liquids.

High Efficiency

Hydrocycloneing involves injecting a mix of liquid solids into the cylindrical part of a Hydrocyclone’s head. As its rotational forces induce centrifugal force, separating out coarser and denser overflow from finer lighter overflow. Overflow is then discharged via its apex nozzle and a vortex formed at its center which collects finer particles.

Change the size of a Hydrocyclone by altering its conical section length or adding extensions to its feed box, as well as by altering its cone angle; longer Cyclones offer finer separation while shorter ones make coarser cuts.

Inside a cyclone, each particle seeks out an equilibrium point where its centrifugal force equals its drag force. If there is more centrifugal force than drag force present, a particle will report for overflow while otherwise, they will go toward underflow.

Therefore, it is vital that inlet pressure be kept within an acceptable range. Exceeding this target pressure can send more heavy material overflowing and lower d50 values for coarser cuts than desired; conversely if pressure falls too far below this mark it can send light material underflowing instead and lower d50 levels further still.

Low Maintenance

Hydrocyclones provide effective separations of heavy and light particles, helping reduce the load on more costly separation equipment. Their type of separation depends on a range of factors such as particle size and density, feed pressure concentration, liner shape/design considerations and particle cutting size options such as (d50 or p80).

Operating the hydrocyclone involves entering coolant through a tangential connection and creating a swirling flow, where heavier solid contaminants become concentrated along the outer wall due to centrifugal force. After being collected by centrifugal force, these heavier solid particles are discharged through a restrictive underflow nozzle at the bottom of the hydrocyclone while lighter liquids ascend and exit via an overflow outlet.

Regular inspections are vital to maintaining peak performance of any cyclone system. Noticing signs of wear such as thinned or scalloped linings helps ensure they are replaced on time to avoid reduced performance, while specialized professionals can advise upgrades using advanced materials and innovative designs that provide increased wear resistance, longevity, and separation efficiency. Flushing the cyclone regularly with clean water can also help dislodge debris that might impede separation, thus keeping its efficiency at peak levels and decreasing downtime required for cleaning or maintenance tasks.

Economical

Hydrocyclones can be surprising cost-effective solutions when used with other separation devices. The main variable that determines particle separation capacity is usually diameter of cylindrical section (with both inlet and outlet diameters adjustable independently to alter separation level), with relatively low operating pressure drop (1 bar).

As soon as a fluid enters a cyclone tangentially, its fluid begins to spin radial forces that create centrifugal force to concentrate heavier phases towards the edges before they pass out of its overflow due to differential pressure. Lighter phases are drawn toward its centre by inward fluid motion before discharging through its apex as reject streams.

DDPM allows the user to simulate the separation performance of hydrocyclones under various conditions, providing users with insights that help optimize design of separation processes while assuring systems operate within their optimal parameters.

DDPM not only improves the efficiency of separators, but it also allows the user to see whether their cyclone is “roping”, where rejected solids come straight down from its apex rather than exiting through an overflow outlet. If this occurs, this indicates an increase in cut size may be required.