In the complex process of industrial production, the separation and classification of substances is a crucial link, which is directly related to product quality, production efficiency and rational use of resources. As an efficient separation equipment, hydrocyclone group plays an irreplaceable key role. Its working principle is based on the powerful effect of centrifugal force, when the mixture containing different particles or components under a certain pressure, at a high speed along the tangential direction into the cyclone, it will be in the cylinder wall of the constraints, to do high-speed rotary movement. In this process, the particles or components in the mixture, due to the double effect of centrifugal force and gravity, will be according to their own density, particle size and shape and other characteristics, in the cyclone to different degrees of radial and axial movement, so as to achieve efficient separation.
Hydrocyclone group has a series of significant advantages by virtue of its unique working principle and structural design. It has a relatively simple structure without complex moving parts, which not only reduces the manufacturing and maintenance costs of the equipment, but also improves the reliability and stability of the equipment; it has a large production capacity per unit volume and a small footprint, which enables it to achieve large-scale production in a limited space and saves valuable site resources for the enterprise; it has a high separation efficiency and a fine grading granularity, which meets the stringent requirements of high-precision separation of different industries; moreover, the hydrocyclone group has a series of significant advantages by virtue of its unique working principle and structural design. Its high separation efficiency and fine grading granularity can meet the strict requirements of different industries for high-precision separation. Then hydrocyclone group can be applied to which industries?
一.Key applications in the mining industry
1.Ore classification
In mining production, ore classification is a crucial link, which directly affects the efficiency of the subsequent beneficiation process and concentrate quality.
Hydrocyclone group in the ore classification process, mainly based on the role of centrifugal force to achieve the separation of different particle size ore. When the slurry containing ore particles under a certain pressure, through the feed pipe in the tangential direction at high speed into the cyclone group of each cyclone, will form a high-speed rotating flow field in the cyclone. In this powerful centrifugal force field, the ore particles will be subjected to different degrees of centrifugal force. The particles with larger size and higher density are subject to larger centrifugal force, which will move rapidly to the direction of the cylinder wall of the cyclone, and under the joint action of gravity and centrifugal force, they will gradually move downward along the cylinder wall, and eventually be discharged from the bottom of the sedimentation port, becoming coarse-grained products; while the particles with smaller size and lower density are subject to smaller centrifugal force, and stay more in the region close to the central axis, and are discharged from the top of the overflow pipe with the upward internal cyclone, becoming coarse-grained products. With the upward internal cyclone from the top of the overflow pipe discharge, become fine-grained products. In this way, the hydrocyclone group can effectively separate ore particles of different sizes and achieve accurate classification.
2.Tailings treatment
In the process of tailings treatment, the hydrocyclone group achieves the reduction and resourcefulness of tailings by thickening and dewatering the tailings and other operations.
In terms of tailings concentration, hydrocyclone group can use centrifugal force to separate solid particles from liquid in tailings, so that the solid particles in tailings can be enriched, thus increasing the concentration of tailings. When the tailings slurry enters the hydrocyclone group, under the action of centrifugal force, the solid particles move rapidly towards the cylinder wall of the cyclone and gather near the bottom sedimentation port, forming a higher concentration of sedimentation products; while the liquid is discharged from the overflow pipe with the inner cyclone. In this way, the hydrocyclone group is able to increase the concentration of tailings from the original lower level to a higher level, which provides convenient conditions for subsequent tailings treatment and utilisation.
Tailings dewatering is also one of the important applications of hydrocyclone group in tailings treatment. After concentration of the tailings, although the concentration has been improved, but still contains a certain amount of water, need to be further dewatered to meet the requirements of subsequent treatment and use. Hydrocyclone group in tailings dewatering mainly plays the role of pre-dewatering, through the joint use with other dewatering equipment (such as dewatering screen, filter press, etc.), can achieve the depth of tailings dewatering.
二.An efficient aid for the chemical industry
1.Product separation and purification
In the catalytic cracking process in the petrochemical industry, the recovery and recycling of catalyst is crucial. At the end of the FCC reaction, the reaction products form a mixture with the catalyst, in which the catalyst particles usually have a particle size of micron level. In order to achieve effective separation of the catalyst from the reaction products, hydrocyclone packages are widely used. When the mixture enters the hydrocyclone group tangentially through the feed pipe at a certain pressure, under the action of strong centrifugal force, the catalyst particles, due to their higher density, move rapidly towards the cyclone cylinder wall and move downward along the cylinder wall, and are finally discharged from the sand sinking port to realise the recovery of the catalyst, while the reaction products are discharged from the overflow pipe with the inner cyclone flow to get preliminary separation. In this way, the hydrocyclone group can efficiently separate the catalyst from the reaction products, so that the recovery rate of the catalyst reaches more than 90%, which greatly reduces the production cost, and at the same time improves the purity of the reaction products, which provides a good condition for the subsequent processing and utilisation.
In the pharmaceutical industry, the purity of drugs is directly related to the efficacy and safety of drugs. Taking antibiotic production as an example, at the end of the fermentation process, the fermentation broth contains a variety of components such as antibiotics, bacterial bodies, medium residues and so on. In order to obtain high purity antibiotic products, the fermentation broth needs to be finely separated and purified. The hydrocyclone group can firstly carry out preliminary separation of the fermentation broth, separating the larger particles of bacterial bodies and culture medium residues, and discharging them from the sand sedimentation port; while the clear broth containing antibiotics will be discharged from the overflow pipe into the subsequent refining process.
2.Mixing and dispersion
In chemical production, many chemical reactions need to be carried out under uniform mixing and dispersion conditions to ensure the adequacy and consistency of the reaction. Hydrocyclone group shows unique advantages in this regard, can provide stable and uniform mixing and dispersing conditions for the chemical process, so as to improve the reaction efficiency and product quality.
In the coating production process, pigments, resins, solvents and other components need to be fully mixed and dispersed to ensure uniform colour and stable performance of the coating. The hydrocyclone group can be used as part of the mixing equipment to pre-treat the coating raw materials. When all kinds of raw materials are mixed according to a certain proportion and enter into the hydrocyclone group, the different components are fully stirred and dispersed under the effect of the high-speed rotating flow field inside the cyclone. The centrifugal force makes the contact between the denser pigment particles and the less dense components such as resin and solvent more adequate, thus achieving a uniform mixing. Compared with the traditional stirring and mixing method, the hydrocyclone group can achieve a more uniform mixing effect in a shorter time, which greatly improves the production efficiency. After the hydrocyclone group mixing treatment of the coating, in the coating process can be more uniformly attached to the object surface, the colour of the coating is more consistent, the quality is more stable, effectively improve the quality of the coating and market competitiveness .
三.Solid guarantees in the field of environmental protection
1.Sewage treatment
In the process of industrial production, many industries will produce a large number of sewage containing solid particles. The hydrocyclone group can use the role of centrifugal force to separate the solid particles in the sewage efficiently. When the sewage containing solid particles with a certain pressure through the feed pipe tangentially into the hydrocyclone group, in the high-speed rotating flow field, solid particles due to the higher density, by the centrifugal force is greater than the liquid, will quickly move to the cyclone cylinder wall, and in the gravity and the centrifugal force of the joint action, along the cylinder wall downward movement, and ultimately from the bottom of the sand sedimentation outlet, to achieve the effective separation of solid particles and sewage.
In the petroleum extraction, refining, chemical industry and other industries, a large amount of oily sewage will be generated. These oily wastewater, if discharged directly, will form an oil film on the surface of the water body, hindering the dissolution of oxygen, leading to a lack of oxygen in the water body, affecting the survival of aquatic organisms, and also causing pollution to the soil and groundwater. Hydrocyclone group in oily wastewater treatment can achieve rapid separation of oil droplets and water through the role of centrifugal force. Under the action of strong centrifugal force, the oil droplets, which are less dense than water, will move towards the centre axis of the cyclone and be discharged from the overflow pipe along with the internal cyclone; while the water will move towards the cylinder wall under the action of centrifugal force and be discharged from the sand sinking port, thus realizing the separation of oil and water.
2.Sludge dewatering
Sludge contains a large amount of water, organic matter, pathogens and heavy metals and other harmful substances, if not properly treated, it will cause serious pollution to the environment. Sludge dewatering is one of the key steps in sludge treatment, and its purpose is to reduce the water content of sludge, reduce the volume of sludge, and facilitate subsequent transport, disposal and utilisation. Hydrocyclone group plays an important role in the sludge dewatering process, through the synergistic work with other dewatering equipments, it can effectively improve the solid rate of sludge, reduce the subsequent treatment cost, and help the smooth implementation of environmental protection work.
The water content of sludge is usually high, generally above 90%, which makes the sludge volume is large, strong mobility, is not conducive to the subsequent treatment and disposal. As an efficient separation equipment, the hydrocyclone unit can firstly thicken the sludge initially during the sludge dewatering process, and use centrifugal force to separate most of the water in the sludge, thus increasing the solid content of the sludge. When the sludge enters the hydrocyclone group, in the high-speed rotating flow field, the water, due to its low density, will move towards the direction of the centre axis of the cyclone and be discharged from the overflow pipe with the internal cyclone; while the solid particles in the sludge will move towards the cylinder wall under the joint action of centrifugal force and gravity and be discharged from the sand sedimentation port at the bottom, so as to achieve the preliminary thickening of the sludge.
By virtue of its efficient separation performance, simple structure and low cost, hydrocyclone group plays an important role in many industrial fields, and in the future there is a broader application prospects. With the continuous deepening of its research and technological innovation, I believe that hydrocyclone group will be applied in more fields, and make greater contributions to the development of various industries.
