Assessment of hydrocyclone operation in gravity induced stirred mill circuits

The performance data of hydrocyclones in circuits containing a gravity induced mill (hereafter referred to as a stirred mill) were evaluated to understand their performance in the circuits and the current operational practices. There are many studies conducted to understand and evaluate the hydrocyclone performances in the semi-autogenous mill (SAG) and ball mill circuits. The literature on hydrocyclone operation in stirred milling circuits is still limited. A database consisting of various hydrocyclone sizes, operating conditions, classification duties, and commodities was developed based on extensive circuit surveys. The database was used to evaluate the hydrocyclone performance. Among the key operational issues observed were poor circuit control strategies, improper hydrocyclone sizing and operation in the roping condition. Analysis of long-term operational data indicated that hydrocyclone feed solid density is an essential operating variable that needs to be controlled to maintain the cut size. An increase in hydrocyclone feed density leads to an increase in cut size. Almost 50% of the hydrocyclones (in the database) were operating in the roping condition. Besides the hydrocyclone feed solid density, high amounts of fine particles (−25 μm) in the hydrocyclone feed also caused the roping condition. Further research is required to operate the hydrocyclone in a spraying condition when the feed has high solid-density and a high content of fines. Plitt's cut size model was fitted to the data set to evaluate its capability to be used in the stirred mill's hydrocyclone. The analysis shows the Plitt's model can predict the cut size when the hydrocyclone is in spraying mode. This result indicates that Plitt's model can be used for the regrind duty hydrocyclones. An empirical model was developed relating the hydrocyclone feed density and the Plitt onset roping hydrocyclone underflow density. This model can be used to predict the roping condition. Finally, the impact of hydrocyclone performance on circuit performance was compared through the size specific energy of the mill. High size specific energy values were observed when the hydrocyclone is operating in the roping condition. These findings are based on the real operating condition, and it shows the importance of operating the hydrocyclone optimally to achieve overall circuit efficiency.