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Hydrocyclone Harmony
Hydrocyclone Harmony
hen considering hydrocyclone-based sand washing plants there are several factors which should be considered to ensure minimum plant wear. The benefits of replacing inefficient bucket-wheel systems with hydrocyclone washing plants have been well documented. However, these operational efficiencies can be further enhanced by considering a number of key factors that can help reduce operating costs.
Dewatering screen
While polyurethane screen media is generally accepted as the only sensible choice for sand washing plants, it is important to consider the type of polyurethane selected as well as the set-up of the screening panels. Often, it is assumed that all polyurethane
September 2012
is of the same quality no matter which supplier it comes from, but this is not the case. There are many polyurethane screenmedia suppliers in the market and the products they offer are all different.
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Consider, too, how the dewatering screen panels will be secured in place. When using panels that have to be bolted into position it is important to take into account the reduction in screening area that this
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Sand Processing
causes, as well as the increase in maintenance downtime when the panels need to be replaced. By selecting modular, non-bolted panels, maintenance time can be significantly reduced. Another factor to consider is the wear protection offered to the screen. For example, are polyurethane side panels included to offer this additional protection? Given its wear-resistance properties, polyurethane is, once again, the best option here. Finally, as with any dewatering operation, the longer the material can be held on the screen the more efficient the dewatering process will be. It is important that design of the sand washing plant ensures this objective is being met. The introduction of a dam bar at the end of the dewatering screen can help allow this to happen. Sand washing plants that do not have a means of retaining the sand on the screen for the longest possible time will deliver washed sand with a higher moisture content than should be the case.
screen frame from vibration that is likely to lead to plant failure. Systems that employ steel springs tend to transfer a lot of vibration to the screen frame compared with rubber springs. In CDEs experience, more often than not this results in damage to the frame, which means increased costs and downtime.
Float system
The purpose of the float is to maintain the required level within the sump even if there are variations in the slurry feed rate. This also ensures the sump never overflows leading to the loss of fine sand to ponds. Vertical float systems are much more robust than other types.
Summary
Important considerations when using a hydrocyclone system include: Maximizing the rubber lining within the hydrocyclone; this is a key factor in ensuring maximum wear resistance. Positioning a feed box to ensure the cyclone underflow is discharged across the full width of the dewatering screen; this maximizes the screening area. The longer the material can be held on the screen, the more efficient the dewatering process will be; consider a dam bar at the end of the screen to aid this. It is important to consider the type of polyurethane that is selected as well as the set-up of the screening panels. Matching the capacity of the cyclone to the dewatering screen will ensure optimum performance of the sand washing plant. For further information visit: www.cdeglobal.com
Rubber springs
It is important to consider the means by which the vibration from the screen is transferred to the material, to ensure it is dewatered most effectively. Typically, rubber springs transfer 1015% more energy to the screen than systems which employ steel springs. This results in better dewatering of the material and also helps protect the
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September 2012