The Performance Prediction Model of W-Shaped Hydrocyclone Based on Experimental Research

Abstract

Fine particles misclassification in the underflow (UF) of grinding-classification hydrocyclones might result in ore over-grinding, leading to both reduced ball mill throughput and metal recovery. In the current research, a W-shaped hydrocyclone is proposed, to efficiently decrease the misclassification of fine particles in UF. The effects of the following parameters (including cross-effects) on W-shaped hydrocyclone classification performance were studied experimentally—inlet pressure, apex diameter, and vortex finder insertion depth and diameter. A mathematical model on the basis of the response surface method was established for the prediction of W-shaped hydrocyclone separation performance. The significance of the effects of the factors on the fine particle content in UF decreased in the following order—vortex finder diameter > inlet pressure > vortex finder insertion depth > apex diameter. The significance of influences of different factors on quality effectively decreased in the following order—inlet pressure > vortex finder insertion depth > vortex finder diameter > apex diameter. The significance of factor effects on the quantity efficiency decreased in the following order—inlet pressure > vortex finder insertion depth > apex diameter > vortex finder diameter. All influence factors were considered to obtain the optimal parameter configuration—an apex diameter of 0.14 D, a vortex finder diameter of 0.31 D, an insertion depth of 1.87 D, and an inlet pressure of 0.18 MPa. The corresponding optimal result was a −25 μm particle content (C−25) in UF of 11.92%, a quality efficiency of 42.48%, and a quantity efficiency of 98.99%.