Lining of hydrocyclones

Hydrocyclones are highly efficient devices for separating particles in liquid media, widely used in the mining and metallurgical industries due to their ability to effectively separate solids from liquids based on the size and density of these particles.

The use of hydrocyclones is based on the principle of centrifugal force for particle separation, where heavier elements move to the periphery and accumulate in the conical section, forming a solid sediment. Meanwhile, the clarified liquid with reduced solid content is discharged through the top of the device.

The range of hydrocyclones includes both single-stage and multi-stage models, which can vary in diameter and cone angle, allowing for the selection of appropriate parameters for specific application conditions. In the mining industry, these devices are widely used for ore beneficiation, separation of heavy materials, and particle classification by size.

In the metallurgical sector, they are used to separate solid elements from metal melts, as well as in classification and grinding processes.

The advantages of hydrocyclones that ensure their popularity in the industrial sector include high separation efficiency, ease of maintenance, structural simplicity, and high performance.

However, it is worth noting that the internal surfaces of the devices undergo intensive wear during operation. To protect the metal parts from wear and corrosion, various types of linings are used, including cast basalt, wear-resistant ceramics, rubber, and various polymers and composites, which help extend the intervals between repairs, prolong the overall service life, and reduce the need for metal. This influences the reduction of product costs, increases productivity, and positively impacts the efficiency of the production process.

The company "Weartch" successfully applies various types of linings in the process of hydrocyclone lining, which have proven their effectiveness and durability over many years, including:

  • Silicon carbide (SiC) lining;
  • Ultra-high molecular weight polymer (UHMWP) lining;
  • Composite lining.
SILICON CARBIDE LINING

Silicon carbide lining stands out as a highly effective method for protecting the internal surfaces of hydrocyclones from wear, offering a range of advantages that make it a cost-effective choice. Key benefits include:

  • High material hardness, comparable to diamonds, ensures its resistance to abrasive wear.
  • Chemical inertness of silicon carbide contributes to its resistance to corrosion in aggressive chemical environments.
  • Thermal stability allows the material to withstand high temperatures, which is critical for some industrial processes.
  • Effectiveness against abrasive particles in the flow prevents rapid wear of internal surfaces.
  • High impact resistance increases durability and the ability to withstand mechanical loads.
  • The use of silicon carbide as lining reduces the need for frequent repairs and replacements, lowering overall operating costs.

It should be noted that the cost of lining materials can be significant, and their use is determined by the specifics of operating conditions and production process requirements. It is critically important to assess the costs and potential benefits before selecting the lining material for hydrocyclones.

HYDROCYCLONE LINING USING ULTRA-HIGH MOLECULAR WEIGHT POLYMERS (UHMWP)

The use of ultra-high molecular weight polymer (UHMWP) lining represents another effective method of wear protection in various technical applications, including hydrocyclones. UHMWP materials are characterized by excellent mechanical properties, including high wear resistance, strength, and chemical resistance.

Advantages of using UHMWP materials for hydrocyclone wear protection include:

  • Wear resistance: UHMWP materials are distinguished by their outstanding wear resistance, making them a preferred choice for working with abrasive materials.
  • Chemical resistance: UHMWP materials are resistant to a wide range of chemicals, which is a key factor in environments with aggressive liquids or gases.
  • High strength and impact resistance: These characteristics make UHMWP materials an ideal choice for conditions with high process dynamics and frequent pressure fluctuations.
  • Resistance to abrasive impact: UHMWP materials can effectively minimize the effects of abrasive particles on the treated surface.

Nevertheless, it should be emphasized that the effectiveness of using various lining materials is determined by the conditions of their use and the task specifications. It is crucial to conduct detailed tests under these operating conditions to confirm the material's compliance with established requirements.