SEPARATION & CLASSIFICATION
AKW ’ s AKA-VORTEX
As one of AKW Equipment + Process Design ’ s core know-how and equipment , the hydrocyclones AKA-VORTEX are well-known since 60 years and successfully installed in a variety of processing plants of different business fields , worldwide including for ores and minerals .
Innovation is also fuelling further growth at AKW Equipment + Process Design , through the development of a unique material science that leads to new hydrocyclone systems and shapes as well as material concepts .
With the AKA-VORTEX modular system , it is possible to combine more than 3,000 different types of hydrocyclones with various modifications which can be carried out in nominal diameters ranging from 10 mm to 1,200 mm . In particular , these hydrocyclones can be configured in different shape versions : n Conical : The conical hydrocyclone is the historical and mainstream version of the AKA-VORTEX series . Used in almost all industrial applications they are available from 10 mm up to 500 mm in full wear resistant Polyurethane ( PU ). And up to 1,000 mm in other variants such as steel rubber-lined . n Flat-bottom : In comparison to the conical version , the flat-bottom design allows to achieve coarser cut sizes for the same diameter . Flat-bottom types have experienced growing popularity over time , and constitutes one of the key asset and differentiation edge for AKW Equipment + Process Design . n Twin Version : The AKW unique twin type is a version equipped with a proprietary designed feed part , allowing the feeding of two hydrocyclones at the same time and in equal capacity . It minimises the investment costs of the hydrocyclone system as a result of the reduction in the number of valves , the optimising of quantity of steelwork and the overall footprint reduction of the distributor units . Additional to the main function of the hydrocyclones , protection against abrasion and corrosion durability take first priority . Therefore , hydrocyclone manufacturing can be made from full pure polyurethane ( PU ) as well as in different other anti-abrasive , durable materials .
A further specific version worth mentioning as a good illustration of the wide flexibility and agility that exists in the way of designing the suitable hydrocycloning concepts , is the system equipped with the special feature of wash water injection in combination with fishtail AKA-TAIL . This concept is designed for unique purposes , for instance an improvement of the
fine material separation even under fluctuating feed conditions . sensors report the functional state of each individual cyclone by monitoring the slurry discharge conditions . This helps you reduce cyclone-related process upsets , improve cyclone overflow particle size distribution , and predict cyclone maintenance schedules .”
In addition , the SmartCyclone Roping Detection system enables users to quickly identify and correct upsets / disturbances . As an example , an overloaded cyclone or battery of cyclones can experience roping , leading to a greater bypass of coarse solids reporting to the overflow and more particle size variation . This condition creates an accumulation of slurry in the
FLS SmartCyclone roping detection technology lines and downstream flotation cells . With roping monitoring in place , operators can confidently run the plant closer to its limits because they do not have to worry about overloading the cyclones .
Added to this is ECS / ProcessExper t ® is a modern , advanced process control system that automatically stabilises and optimises key minerals processes . By balancing equipment loads , and managing and correcting process disruptions , this solution reduces equipment wear and thus helps minimise maintenance costs .
As an advanced , AI-driven system ,
ECS / ProcessExpert dramatically reduces or even eliminates the need for manual mill operation , and consistently ensures optimum plant performance for maximum efficiency and higher profitability . “ With our system , you can develop a uniform strategy for the best practice plant operations , reducing the burden of training new operators .” ECS / ProcessExpert software is capable of increasing or decreasing the water addition , pump speed and number of operating cyclones to optimise circuit performance .
The wireless controller is a handheld device that can be removed from its docking / charging station to conveniently sync and program the individual sensors . During operation , the wireless controller is housed in its docking station to communicate live operating data to the control room .
Weir Cavex ® hydrocyclone success at New Cerovo
Debra Switzer , Global Product Manager – Hydrocyclones , Weir Minerals , told IM how it recently partnered with Zijin Mining to optimise its classification process at its New Cerovo copper mine , located in east Serbia . The area is home to one of the largest copper ore bodies in the world , estimated to be in excess of 1,800 Mt with a 0.36 % copper grade .
18 International Mining | MAY 2023