FLSmidth Cyclone

FLSmidth Cyclone

PRIMARY USES

1. High-Efficiency Classification and Separation in Mineral Processing

Primary Use: Hydrocyclones are used for classification, separation, and dewatering of slurry in mining and mineral processing applications. They are essential for grinding circuit classification, particle size control, and optimising downstream recovery in operations processing gold, copper, platinum, and other minerals .

How it helps: For process engineers and plant operators, FLSmidth KREBS® cyclones deliver superior separation efficiency and are the clear Number 1 supplier globally . The gMAX® inlet head geometry, developed using computational fluid dynamics (CFD), improves pre-separation and reduces turbulence for better classification, while extending inlet liner life by at least 33% . The gMAX® cone angle increases tangential velocity and residence time in the cone sections, resulting in substantially finer separation with fewer fines in the underflow and less coarse material in the overflow .

2. SmartCyclone™ Condition Monitoring

Primary Use: The SmartCyclone™ system provides automatic cyclone condition monitoring and control to maximise grinding efficiency .

How it helps: A wireless sensor mounted externally below the apex detects the condition called “roping,” where the underflow changes from a healthy conical flaring shape to a cylindrical rope shape, which significantly reduces separation efficiency . The system alerts operators immediately, allowing them to shut off feed to the affected cyclone and open a standby cyclone, restoring optimal performance . Users report downtime savings of up to US$250,000 per 1,000 tonnes of product .

SECONDARY USES

1. Wear Life Optimisation: FLSmidth can use different liner materials in cyclone sections, such as ceramics for high wear areas and rubber for lower wear areas, balancing wear life and extending operational efficiency .

2. Process Control Integration: SmartCyclone integrates with ECS/ProcessExpert control software, stabilising and optimising key minerals processes .

3. Chemical Applications: KREBS® cyclones are used in evaporators and crystalliser circuits to recover and concentrate nucleated particles, and to remove coke particles from quench oil to protect heat exchangers .

4. Fruit and Vegetable Washing: KREBS® cyclones are also used to remove sand and grit from wash water in food processing applications, enabling water reuse .