Key Benefits

  • High-efficiency cleaning
  • Higher feed rates
  • Long wear life

Heavy-media design and performance

Most coal and mineral producers are familiar with cleaning methods that utilise differences in density to separate the desirable coal and mineral particles from the refuse. Heavy-media vessels have been used for decades as a standard method for coal and mineral cleaning. But just because a practice is tried, doesn’t mean it is necessarily true. These vessels can be inefficient, and typically require considerable operator attention.

Like the heavy-media vessels, Heavy-media Cyclones also are designed to clean coal and minerals based on their density differences. Using finely ground magnetite and water as the media to create a buoyancy effect for gravimetric separation, the Heavy-media Cyclone forces the lighter solids to its centre, where the slurry transports them upward and through the vortex finder. The dense mineral matter spirals downward toward the apex and exits through that orifice.

 

These high-capacity units utilise centrifugal forces to enhance the separation of fine particles that cannot be efficiently recovered using static heavy-media vessels. Heavy-media Cyclones are relatively inexpensive and typically require little operator attention. Because Heavy-media Cyclones usually operate in a near-horizontal orientation, they allow for large apex sizes to assist in refuse removal. In addition, their heavy-duty ceramic lining plays a critical role in the efficient, long-term operation of these cyclones, as dense mineral matter can be very abrasive.

 

Our Heavy-media Cyclones can handle top-size feed particles ranging up to 102 mm (4-in), and have capacities of 77 mtph (85 STPH) to 894 mtph (985 STPH) per cyclone.

 


Tips and tricks


Media density primarily determines separation gravity. We recommend keeping pressure relatively low to reduce classification effects of magnetite particles.

 

Cyclones 660 mm (26-in) in diameter and larger utilise a patented ceramic “acceleration wedge” to adjust capacity and G-forces. Insert a smaller wedge to immediately reach greater capacity. If you require more efficient cleaning of fine coal, simply insert a larger wedge to achieve higher G-forces.

Extremely efficient coal cleaning device

High-efficiency cleaning

One of the most important benefits of our Heavy-media Cyclone is its high efficiency, stemming from a number of design features of the KREBS D26B cyclone – long established as the industry’s standard high-capacity cyclone – which we incorporated into our larger the heavy-media cyclones.


With our range of heavy media cyclone sizes, you can easily and effectively clean a relatively wide range of coal sizes.

Higher feed rates

Our large-diameter Heavy-media Cyclones accept larger top size material for efficient cleaning at higher feed rates within your coal preparation plant.

Long wear life
Our ceramic lining options, from 25 mm (1-in) to 38 mm (1.5-in) thick tiles at the inlet to monolithic ceramic at the apex, are available to deliver long wear life in abrasive, high-ash-content refuse applications.

Broad size range

Heavy-media Cyclones use finely ground (-325 mesh/44 microns) magnetite and water as the “media.”

Our Heavy-media Cyclones can handle top-size feed particles ranging up to 102 mm (4-in), and have capacities of 77 mtph (85 STPH) to 894 mtph (985 STPH) per cyclone.

 


Tile lining for Heavy-media Cyclones


A relatively thick ceramic tile lining is critical in our Heavy-media Cyclones, as dense mineral matter can be very abrasive.

 

We offer our pre-engineered tiles in two different grades, with 25 to 38 mm (1-in to 1.5-in) thickness, to optimise wear life.

 

During their manufacture, we machine each ceramic tile in its “green” state, and then fire the lot to become interlocking, serialised liner components. Although this process is relatively expensive, the resulting increase in wear life pays for itself, and is one more reason why operations choose our Heavy-media Cyclones over other models that utilise flat tile.

 

Cyclones 660 mm (26-in) in diameter and larger utilise a proprietary ceramic “acceleration wedge” to modify capacity and G-forces. By inserting a smaller wedge, you will immediately gain greater capacity. If you require more efficient cleaning of fine coal, simply insert a larger wedge to achieve higher G-forces.

Pre-engineered tile lining


Our ceramic tiles are machined in the green state and then

fired to become an interlocking, serialised component.

Tile lining inspection


After assembly of tile lined sections, all

cyclones are thoroughly inspected before

painting.

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