Advantages and methods for the real-time detection of hydrocyclone operating

problems
C.Bazin
Universidad de Laval, Quebec
M.Renaud
Universidad de Laval, Quebec
A.Faucher and M. Mai Manga
COREM, Quebec
RESUMEN
Circuitos de molienda operan en presencia de perturbaciones resultantes de cambios y mal
funcionamiento de equipos, tales como sobrecarga de hidrocicln, desgastado o tapado parcial de
pices, sobrecarga, y desprendimiento de revestimiento interno que puede causar efecto en el
redimiento de la clasificacion. Prdidas de recuperacin de metales en la lixiviacin aguas abajo o
circuitos de flotacin justifican el desarrollo de mtodos para la deteccin rpida de mal
funcionamiento del hidrocicln. Dos mtodos se presentan en este documento. El primer mtodo
utiliza sensores de medidas forman disponible en unos circuitos de molienda y la segunda utiliza
sensores de vibracin instalados en el hidrocicln individual de un nido.
Palabras Clave: Hidrociclon, Malfuncionamiento, Analisis de vibracion, Diagnostico
INTRODUCTION
Hydrocyclone are used for many purposes, ranging form water separation, fines removal, and the
preparation of the feed for subsequent concentration circuits in a mineral processing plant. The
strategic role of the hydrocyclone for the preparation of the feed to a concentration circuit is often
underestimated because of the hydrocyclones simplicity of operation and robustness (Melvor,
1998; Naiper-Munn, Morell, Morrison & Kojovic, 1996). It remains that in spite of their simplicity,
hydrocyclonehave been studied extensively from 1970 to 1990 with the objective of developing
mathematical models of their operation to be incorporated into grinding circuit simulators
(Flintoff, Plitt, & Turak, 1987; Lynch 1977; Naiper-Munn et al, 1996). Such a development effort is
already an acknowledge of the importance of these units in a mineral processing plant, several
authors (Casali, Vallebuona, Bustos, Gonzales, & Gimenez, 1998; Del Villar, Thibault, & Del Villar,
1996; Plitt & Kawatra, 1979) have proposed soft sensors to estimate the classification efficiency of
hydrocyclones using sensor measurements. However, few of the proposed sensors are used in the
industry. More recently several papers were published that explore the application of 3-DS
modeling of the hydrocyclones (Cullivian, Williams, Dyakowski, & Cross, 2004; Narasimba, Sripriya,
& Banerjee, 2005) and sensors (Bochicchio & Olson, 2010; Bond et al., 1999; Hou, hunt, &
Williams, 1998; Neese, Schneider, & Golyk, 2003 Hunt, & Williams, 1998, Neesse, Schneider, &
Golyk, 2003; Willams, Dickin, Gutierrez, & Dyakowski, 1997; Williams, Ilyas, & Dyakowski, 1995) to
help in the detection of hydrocyclone malfunction. Krebs (as cited by olsen, 2008) has developed
and commercialized a system to help in the detection of roping situations.
This paper examines the economic impact of a malfunction of one or more hydrocyclone units in a
nest on the operation of a subsequent concentration process. Two approaches are considered for
the detection of unit malfunction. The first approach is based on an analysis of the signals form
sensors currently available in a grinding circuit. The second approach is based on monitoring and
analysis of the hydrocyclone vibration intensity, as measured by sensors installed on a unit. The
llatter method was successfully tested in a pilot plant and was validated in an industrial plant.
OPERATION OF HYDROCYCLONES
The operation of a classifier is often characterized by the partition curve that is dependent on the
unit geometry and operating conditions. These aspects are briefly reviewed in this section
Characterization of a separation process
Hydrocyclone separate particles according to their weight or size, for particles of constant specific
gravity and shape, using a balance between centrifugal, fluid, drag forces, and gravity (Lynch
1977). The coarse (heavy) particles are directed to underflow of the hydrocyclone, while fines
and/or light minerals report to the overflow of the hydrocyclone. The quality of the separation
process is measured by the split of the particles between the feed and the underflow streams
using:

The proportion of particles in size class I that reports to the underflow is denoted ; the solids
flow rates in the Hydrocyclone feed and underflow are respectively noted

and

; while

and

stand for the weight fractions in size interval i. The values of are usually plotted
against the geometric mean particle size of a size interval to obtain the partition or efficiency
curve the classifier.
Hydrocyclone geometry

The main components of a hydrocyclone are shown in Figure 1. The hydrocyclone diameter
influences the cut size and the capacity of the unit. The cut size is the size of particle around which
the separation should occur in the classifier. For a perfect classifier, the cut size corresponds to
the position of the vertical line of the ideal separation curve (shown in Figure 2). Once the
hydrocyclone is commissioned, the operator can modify the apex (diameter of the underflow
pipe) and the vortex finder (diameter of the overflow pipe) to adjust the capacity and cut size of
the hydrocyclone. The slurry feed solid concentration influences the hydrocyclone operation
through slurry viscosity, which interferes with the movement of the particles submitted to
the classification process. Depending upon the required plant capacity, several hvdrocyclones may
be grouped in a nest or a row to carry out the classification.

Hydrocyclone malfunctions

Various malfunctions can hamper the operation of hydrocyclones (Bond el al. 1999: Napier-Munn
el al.. 1996: Plitt. Flintoff. S: Neale. 19,6). The feed pipe or inlet valve may plug. Thereby reducing
the number of active hydrocyclones of a nest. The apex can be completely or
partly plugged (Plut et al., 1986) or the detachment of an internal liner may deteriorate the quality
of the separation (Bazin, Mai Manga, Renaud, & Caron. :2009). When the underflow of
hydrocyclone becomes overloaded, the apex discharge may shift from a normal spray discharge lo
a rope discharge, leading to a coarser cut size (Bond et al., 1999; Plitt. Flintoff, & Stuffco. 1987).
Hydrocyclone may also undergo surging that results from intermittent feed, leading to less
efficient classification.

Some of these malfunctions can be detected by a visual inspection of the hydrocyclones. However,
hydrocyclone nests are sometimes located in remotes areas of a plant and are, therefore, difficult
to access by operator (Napier- Munn el al. 1996). The lighting around a hydrocyclone nest is often
insufficient for good inspection of the individual hydrocyclone underflow streams. In some cases
the underflow discharge is covered by a wooden or rubber barrier to reduce splashing, which
makes its inspection difficult.

Instrumentation for grinding circuits
The degree of instrumentations available in a grinding circuit varies from plant to plant. The usual
sensors for a grinding circuit consist of a weight meter for the fresh feed conveyor, a pressure
meter on the hydrocyclone nest, volumetric flow and slurry density meters on the overall
hydrocyclone nest feed pipe, pump box level, power meters on the mill motors, and added
process water flow meters, Bearing pressure sensors are used to monitor changes in the mass of
ore in autogenous and semi-autogenous grinding mills. Particle size monitors are sometimes
available to monitor the size distribution of the hydrocyclone overflow. All these sensors provide
real-time measurements that are collected by a computer, stored in a data historian, and use for
process control and daily balance reports.

IMPACT OF HYDROCYCLONE MALFUN CTION
No detailed studies are available to assess the impact of an abnormal operation of hydrocyclones
on the downstream flotation or Leaching circuits. The analysis from actual plant data is difficult
because it requires identifying a problem and triggering a sampling campaign on the concentration
circuits. In both normal and abnormal situations, developing valid conclusions may require more
than one sampling campaign in order to establish a basics for comparison. However, it is obvious
that, if an abnormal situation is detected, it will be corrected rather than allowing it to continue
for the purpose of studying its impact on the downstream process. Simulation is used here to
provide a first approximation of the economic impact of a hydrocyclone malfunction on the
operation of flotation and gold leaching circuits.

Cu Pb flotation circuit

The circuit considered is operated by Xstrata Zinc Canadas Brunswick mine in New Brunswick.
The plant processes a complex sulphide ore consisting of sphalerite, galena, Chalcopyrite, Pyrite
and non-sulphide., to produce zinc, copper, Iead and bulk lead-zinc concentrates (Orford el al.,
2005). The circuit consists of primary grinding with a semi-autogenous mill, followed by flash
flotation of the lead and copper minerals. The tailings of flash flotation are processed in the
secondary grinding circuit (shown in Figure 3). The overflow from the hydrocyclones of the
secondary grinding circuit advance to a copper-lead flotation circuit that completes the rougher
recovery of the copper and lead minerals, The secondary grinding circuit is equipped with a nest of
18 hydrocyclones with typically, eight lo 10 operating units. The plugging of one of the (nine)
operating hydrocyclone apexes is simulated in order to generate the data for the analysis of the
impact of a hydrocyclone malfunction on CuPb scavenger flotation (see Figure 3). The dynamic
grinding circuit simulator used for this purpose is described by Bazin et al. (2009). The effect of the
plugged apex on process variables is summarized in Tables 1 and 2. A plugged apex forces the feed
of the hydrocyclone to the overflow, leading to a coarser overflow product (Table 1). The plugged
apex produces a decrease in the hydrocyclone feed rate because one of the unit underflows
bypasses to the overflow, The circulating load decreases, leading to decreased pressure to the
hydrocyclones and a lower pump box level, assuming that the pump is operated at a constant
speed (Table 2). lt should be noted that the effect of a plugged apex in a nest of nine hydrocyclone
is small and would be difficult to detect from measurements, which is the typical difficulty
associated with the detection of hydrocyclone malfunction from sensor measurement

Flotation response to the CuPb rougher circuit is simulated using recovery by size of the minerals
(Bazin. Grant, & Cooper. 1991) and b, the size distribution to the circuit feed (cyclone overflow ).
For this particular complex sulphide ore. Bazin et al. ( 1991 ) found that the size distribution of the
mineral is directly related to the ore size distribution. Therefore, using the ore size distribution, it
is possible to estimate the size distribution of the individual minerals. This information is
combined with the mineral recovery by size to estimate the overall mineral recovery of
the flotation process (Bazin et al., 1991). The application of this procedure to the ore size
distribution of Table 1 leads to the results found in Table 3.

Lead recovery is affected by the coarser feed (P
80
= 0.050mm) resulting from the plugged apex,
compared to the normal situation (P
80
= 0.043 mm). Recovery of copper is also negatively
impacted by the hydrocyclone malfunction.





Concentrate grade is not significantly affected by the plugged apex. In the actual circuit, the
rougher and scavenger concentrate streams (Figure 3) are combined and cleaned in three stages.
Approximately 95% of the lead minerals are recovered in the cleaner circuit. The overall
1055 of Pb recovery due to the plugged apex is estimated at 2.2% [= 0.95x (79.1 - 76.8)]%.
Assuming that the plugged apex is detected two weeks after the problem arose and that
the circuit feed rate is 435 t/h with a 2.2% Pb content the scavenger flotation feed, the loss of
gross revenue is approximately USS 1 22,000 (75.000 kg of Pb at US$ 1.65/kg). This evaluation,
which does not include losses of copper and silver (and possibly of zinc, due to the higher lead and
copper content in the zinc circuit flotation feed), clearly supports the financial incentive for
evaluating algorithms that detect hydrocyclone malfunction.


Gold leaching plant

The second example is based on the observation of a loss in quality of classification of a 50 cm (20
in.) hydrocyclone al the Mines Doyon gold concentrator, located near Rouyn Noranda, Quebec.
The grinding circuit configuration at the time of sampling is shown in Figure 4. This circuit differs
from the one shown in Figure 4 because a secondary grinding circuit has been added to process
the primary hydrocyclone overflow.

The partition curve of the primary hydrocyclones, observed from the data of two sampling
campaigns, is shown in Figure 5. Coarse particles escape to the overflow during operation, with
liner problems indicated by the top part of the curve that does not rapidly converge to 100%. This
effect was found to be caused by the detachment of an internal liner of the hydrocyclone.
Sampling campaign data conducted after the repair of the unit produced a second partition curve
(Figure 5). which indicates acceptable classification of the coarse particles. Such a problem is
difficult to detect because the concentration of coarse particles increases only marginally, with a
P
95
that shifts from 0.178 to 0.186 mm in the overflow product This increase could easily be
attributed 10 measurement error.

The impact of this type of hydrocyclone problem on gold recovery is simulated using variation of
the gold leaching rate and (infinite) recovery as a function of particle size, as observed in a
previous study (Bazin, Egan, & Hodouin, 2009). An assumption is made that gold con ten! in the
size intervals is not affected by the change in ore classification.
The gold leaching simulator from Bazin, Egan, Khalesi, llodouin, and BeIlec's (2007) study was run
with the size data from Figure 5 lo obtain the impact of the hydrocyclone malfunction on gold
recovery. The estimated lo s of Au recovery was found to be 0.2%, a small and even undetectable
decrease from daily balances. However, when reported over a period of two weeks, this loss
represents US$ 15,000 at a gold price of US$ 1,200 per troy ounce.

DETECTION METHODS FOR HYDROCYCLONE MALFUNCTION

Two detection method are described in this section. The first method is based on real-time
measurements, available from sensors usually installed on a grinding circuit. This method is
assessed with a dynamic grinding circuit simulator (Bazin et al , 2009), which is used to simulate
the effect of a a plugged apex in the CuPb secondary grinding circuit (shown 10 Figure 3). The
second method uses vibration sensors mounted on the body of the hydrocyclone. This method
has been extensively tested in a pilot plant environment , as well in an operating plant. The
operating plant results corroborated the pilot plant results. However, the plant results are
confidential and are property of COREM's members; therefore, only the pilot plant test results are
discussed In this paper.

First method: Detection from sensor measurements

This method is based on a comparison between the pressure observed at the inlet of a
hydrocyclone nest with the pressure estimated from hydrocyclone feed rate and slurry
solids density measurements from sensors. The detection algorithm is based on the hypothesis
that the inlet pressure to a nest of hydrocyclones is a function of variable and constant
parameters. The variable parameters are:

The slurry volumetric feed flow rate
The number of units in operation in the nest.
The slurry concentration of solids,
The constant parameters are the geometry (shape. diameter, length, apex, vortex size,
etc.) and mechanical condition (internal liner, plugged apex. etc.) and the nests
hydrocyclones. These variable and constant parameters, excluding the mechanical
condition, are included in Plitts model for predicting the pressure lo the nest of
hydrocyclones (Flintoff, Plitt, & Turak, 1987). Therefore, for a given hydrocyclone
number, geometry. and mechanical condition, the inlet pressure varies only with the
volumetric feed rate and slurry density.

An empirical model is calibrated to relate the inlet pressure to the hydrocyclone nest feed rate
and solids concentration using normal (no hydrocyclone malfunction) operating data. Flow and
density meters, as well as a pressure sensor are usually available on the hydrocyclone nest
feed line (se e Figure 3 and 4). The model is used to predict the pressure drop by following the
variation in slurry flow rate and density that resuIt from changes in circuit through-
pur, feed-size distribution, and ore hardnes , as well as water addition into the circuit. The
estimated pressure is then compared to the observed pressure. A systematic deviation between
the two values can be attributed to a change in the geometry or mechanical condition of one or
more hydrocyclones in the nest. The principle of the detection method is illustrated in Figure 6.
The proposed detection algorithm was tested using a dynamic grinding simulator calibrated on
data collected from the secondary grinding circuit of the complex sulphide plant (shown in Figure
3). Details of the calibration and validation of the simulator can be found elsewhere (Bazin el al.,
2009). A dynamic simulator predicts the time response of a process following changes of the state
of the input variables.


In this application, the simulator was used to predict the effect of the disturbances listed in Table
4 when applied to the grinding circuit of Figure 3. The simulated disturbances correspond to
changes in circuit feed rate and water addition to the sump, applied in parallel to the plugging and
unplugging of one of nine apexes of the operating hydrocyclones.
The simulator generates measurements on a one-second frequency for all instruments in the
actual plant, Only data for the circuit feed rate and the hydrocyclone feed flow, density,
and pressure meters are presented in this analysis. The simulated trends are shown in Figure 7
and were used to test the detection algorithm for hydrocyclone malfunction.

The first 55 minutes were used to generate the data for the calibration of the equation employed
to relate the pressure to the hydrocyclones slurry feed rate and density. The calibration period is
free of mechanical disturbances associated with the hydrocyclones. The calibrated model
for the pressure is:

P(t) = -37.81 + O.062F(t) + 6.58p(t)

The estimated pressure at time t is denoted P(t), the feed rate in m3/h is F(t), and p(t) is the slurry
density in time Equation 2 is preferred over the Plitt model because it is linear and can be readily
calibrated using a conventional linear regression algorithm. A linear relationship is also sufficiently
robust when the hydrocyclones operate over a limited range of conditions, which was the case
here.

The detection algorithm is constructed with the model of Equation 2. Process measurements from
the flow and den sity sensors are passed through Equation 2 to calculate the effect of the flow
rate and slurry density on the pressure to the hydrocyclones. This calculated pressure is compared
to the pressure estimated by the dynamic grinding simulator and the deviation is used to infer a
change in the mechanical condition of one of the hydrocyclones. The deviation between the two
pressures is shown in Figure 8.

Prior to the plugging of one apex (Event F in Figure 8), the deviation averages zero. FolIowing the
plugging, the deviation becomes systematically larger than zero. This behavior is an indication that
an event unrelated to a change of hydrocyclone feed rate or slurry density is responsible for the
deviation, in this case, the plugged apex. The deviation remains different from zero despite
changes in the circuit feed rate and water addition during the period
of the plugged apex. At Event 1 in Figure 8, the faulty.

hydrocyclone is shut off for maintenance, The increased deviation is due to the fact that [he
model of Equation 2 uses the flow rate, assuming all hydrocyclones are in operation, and does not
account for the increased feed pressure with one unit out of service. During the shutdown, the
apex is unplugged and the repaired hydrocyclone is returned to operation (Event J). Following the
repair, the deviation returns to zero, indicating resumption of normal operation.

The signals used in the previous analysis are free of measurement errors. In practice, high-
frequency noise (due to electronic sensor sensitivity and rapid process variation) contaminates the
measurements, particularly flow rate measurements. Measurement noise can strongly hamper
the capability of any fault detection algorithms. To test the robustness of the algorithm in the
presence of process and instrument noise, the situation described in Table 4 is simulated with
measurement errors added to the signals.
The revised simulation trends are shown in Figure 9. with the added noise displaying statistical
characteristics (normal distribution and standard deviation) similar to those observed in practice.

The presence of noise complicates (he calibration of the model with respect to the pressure to
the slurry feed rate and density because the parameters exhibit more variability than those
estimated from noise-free measurements, In addition to the difficulty associated with model
calibration, the error on the measurements is amplified by the model which, in turn, leads to a
noisy prediction of the pressure drop. The deviation between the actual plant pressure drop
and the predicted pressure drop is shown in Figure 10, with the period of a plugged apex (between
Events F and I) identified as a rectangle. Although [he average deviation during that period is
slightly above zero. the deviation is not statistically significant and, therefore, does not trigger an
alarm. The problem is not only related to the model because the errors added to the pressure
measurements (in the range of +-1,4 kPa 0,2 psi) are of the same order as [he effect of a
plugged apex (i.e +- 1,4 kPa; 0,2 psi; see Figure 8).

Different types of noise filters are currently being tested lo identify methods for reducing the
sensitivity of the detection method to measurement noise. Techniques such as principal
component analysis can incorporate measurements from the grinding mill power meters, the
water flow meters, the circuit feed rare, and other variables, thereby enhancing the algorithm.
Principal component analysis compresses a very large amount of data into a two-dimension map,
where abnormal operating conditions become distinct from normal ones. The use of additional
sensors to complement the detection algorithm, such as vibration meters 011 the hydrocyclone. is
evaluated in the following section.


Second method: Detection from vibration measurements

In parallel lo the development of a soft sensor for the detection hydrocyclone problems, a test
program was initiated to assess various non-intrusive sensors that could be used in conjunction
with the usual sensors available in a plant in order to help in the detection of a classifier
malfunction. Various methods, such as tomography to monitor the shape of the air column inside
the hydrocyclone (Williams et al., 1997; Williams et al., 1995) and electronic or camera sensors to
monitor the shape (spray, roping, plugged) of the underflow di charge (0150n, 2008), have
previously been tested for that purpose. The approach investigated here is based on the
measurement of vibrations produced by a hydrocyclone. The idea was borrowed from one used
for predictive maintenance of rotating machinery, such as motors and pumps.

The sensors used for monitoring vibrations are one-axis accelerometers, provided by PCB
Piezotronics. They are small, inexpensive, and easily attached by magnets at the hydrocyclone
inlet vortex finder and apex. A vibration sensor is shown in Figure 11a. with the installation
positions indicated in Figure 11 b. The sensors receive the hydrocyclone vibrations and transform
them into a high-frequency (2,000 Hz) electrical signal of acceleration. This signal is then
processed in all analog-to-digital unit and transferred to an embedded processing unit that
incorporates the of software for signal processing and fault detection (see Figures 11 c,d).

The hydrocyclone used to test the potential of using vibration to monitor the operation of
hydrocyclone installed in the COREM pilot plant located in Quebec City, Quebec. Figure 12 shows
the pilot plant setup, which consists of a 15 cm (6 in.) Krebs hydrocyclone (Figure 11b) that has
feed, apex. and vortex finder diameters of 6.4 cm (2.5 in.), 3.8 cm (1.5 in.), and 5.1 cm (2 in.),
respectively. The hydrocyclone was operated in closed circuit with a variable speed pump that has
an inlet pressure ranging from 20 to 130 kPa (3 to 18 psi) at a feed flow rate varying from
175 to 500 l/min. Water can easily be added to change the solid concentration of the hydrocyclone
slurry feed. The pilot plant setup is constructed lo allow for easy sampling of the hydrocyclone
feed, overflow, and underflow streams. Sampling was conducted in parallel to the vibration sensor
testing to establish the hydrocyclone partition curves resulting from changes to operating
conditions. The ore used for the test was provided by Agnico Eagle La Ronde division (near Val
d'Or. Quebec) and consisted of approximately 65% sulphide and 35% silica gangue. A typical
partition curve for the hydrocyclone is shown in Figure 12. The cut size is in the range of25 to 50
um, which is consistent with the operation of a 15 cm hydrocyclone (Cilliers, 2007).

The detection algorithm was developed and tested using the following abnormalities:

Internal liner damages.
Partial and complete plugging of the apex.
Roping of the underflow.
Cycling to simulate a pump surging effect,


The damages lo the apex are simulated by the groove and liner detachment shown in Figure 13.
Partial and complete apex plugging situations were created with rubber plugs and roping of the
underflow was created by increasing the feed flow rate with a coarse feed-size distribution,
Surging was created by oscillating the pump speed over a specified period of time.

The accelerometer signal is typically sampled at a frequency of 2.000 observations per second.
Such a rate generates a large amount of data. Three sensors delivering a total of 6.000 data points
per second cannot be used directly for the detection of operating problems, The signals therefore
need to be processed into parameter that can be used specifically for fault detection purposes.
Various detection techniques were considered and the solution found was to first extract a
synthetic signature of the vibration signals, then classify this signature to assess the hydrocyclone
operating condition. This principle is illustrated in Figure 14. Mathematical tools, such as statistical

Analysis, frequency analysis, and other signal processing techniques, were used to obtain the
signature of the vibration signals. The use of the signal signature significantly reduces the mass of
data to be processed for the fault detection. Moreover, in order to keep track of the variation of
the process, the standard deviation over time of the signature vector was also considered in the
subsequent classification algorithm.

The hydrocyclone operating conditions are hierarchically classified in three stages lo improve the
detection sensitivity,

the first stage assesses whether or not the hydrocyclone is in operation. If the hydrocyclone is in
operation, the second stage assesses whether or not the hydrocyclone is operating normally. If the
hydrocyclone is operating abnormally, the third stage determines the type of operating problem.
Each stage has its own decision tree whose inputs are the vibration signature and its standard
variation over time. This classification scheme of the operating condition is illustrated in Figure 15.
The decision trees are calibrated on demand by a MATLABTM program running on a computer
connected to the embedded processing unit. The statistical performance of the decision trees is
also calculated against a subset of the input data. This calibration is a necessary step for the
implementation of the detection algorithm and has to be adapted for every hydrocyclone
individually. In the pilot plant setup, the result of the calibration process was used to construct the
decision tree (see Figure 15b) for the detection of abnormal operation. In this setup, note that the
calibration process had automatically eliminated the apex vibration signals and could as e the
hydrocyclone operating condition using only vibrations measured near the inlet and the vortex
finder.

The statistical accuracy of this decision tree on the pilot plant setup was 97% (based on 2,000
observations made over 49 test periods); only 3% of all observations were misclassified. Results
showed that the algorithm was able to correctly detect, with a reasonable error, the abnormal
operating conditions imposed on the pilot-plant hydrocyclone.

Robustness against faJse alarms (alarm activated in normal operating condition) was increased
with the addition of a persistence delay before actually activating the alarm.
The initial objective of the project was to differentiate an abnormal hydrocyclone situation from a
normal operating condition. However, it soon became clear that the detection algorithm could be
improved upon to further allow specific identification of the above noted problems and,
therefore.
help the operator in pinpointing the problem. The sensors, embedded processing unit, and
computer were tested on an industrial 25.4 cm (10 in.) hydrocyclone in a nest of 10 units at the
LaRonde division of Agnico-Eagle, Results are consistent with those observed for the pilot plant
hydrocyclone. However, detailed results must be kept confidential because they belong to COREM
members.

CONCLUSIONS

A grinding simulator is used to demonstrate the potential savings associated with the
development of an algorithm for the detection of hydrocyclone malfunction. The demonstration
was carried out for a CuPb flotation circuit and a gold leaching plant. Two methods were rested
for the detection of a hydrocyclone malfunction. The first method used measurements typically
available from grinding circuit instruments, namely the hydrocyclone feed rate, slurry density, and
inlet pressure, to detect a hydrocyclone malfunction. This method, which uses a dynamic grinding
simulator, works well in the absence of instrument noise. The use of vibration sensors
(accelerometers) installed on the body of a hydrocyclone was tested in paral1eJ to the previous
algorithm. The signals of the sensors installed on the hydrocyclone inlet and vortex finder were
processed to assess a signal pattern, which was then used to identify a hydrocyclone malfunction.
This second method was tested in a pilot plant and was found lo successfully identify an abnormal
operating condition in 97% the rested cases, The algorithm was also able to specifically attribute
the fault to a damaged liner, a partly plugged apex, or overloading or surging condition.































Higher classification efficiency by hydrocyclone control



ABSTRACT This paper presents two new options for hydrocyclone control. Volume split control
using a control valve in the overflow is applied for the stabilization of separation results at
changing feed conditions. Controlled water injection to the conical part of the cyclone Leads to the
reduction of fine particles in the underflow, Hydrocyclone monitoring in both cases is performed
by optical sensors that indicate the spray angle of the underflow, Applications in mineral
processing for desmiling, classification in closed-circuit grinding, and dewatering are demonstrated

KEYWORDS Hydrocyclone control, Desliminq, Classification. Dewatering

INTRODUCTION

In mineral processing, the hydrocyclone is the favoured device for closed-circuit grinding,
desliming, and dewatering, the advantages of the hydrocyclone include it simplicity, ease of
operation. and high volumetric throughput. as well as the relatively low capital, operating. and
maintenance costs, However, the physical principle of the hydrocyclone includes two
disadvantages, First, varyjng feed conditions Iead to considerable fluctuation of cut size
and separation sharpness, Second, fine particles are discharged with the liquid of the underflow to
compensate for these difficulties , significant efforts have recently been undertaken to control the
hydrocyclone.

Various types of equipment have been employed to control the volume split of the
hydrocyclone (Martin, 1978), these devices include collapsible tubing made of resilient
material, flap valves and counterbalanced piping applied to the apex of the hydrocyclone. The u e
of such devices al the underflow has resulted in the need for increased maintenance, as well as in
choking or plugging of the hydrocyclone,

Alternatively, separation may be controlled by manipulating the feed side, The feed solid
content is controlled by water addition (Walters & Placha, 2002), which leads to an increased
hydrocyclone feed rate. Consequently, water

Addition must be combined with speed control of the feeding pump and/or the automatic
switch of additional hydrocyclones. This method is often applied to hydrocyclones in closed-circuit
grinding (Rajarnani & Herbst. 1991). However, the varying feed rare i a di advantage in
downstream processes.

This paper focuses on two new control concepts developed at the Erlangen University, together
with AK W Apparate + Verfahren GmbH in hirschau, Germany (Neesse, Golyk, Kaniut & Reinsch,
2004; Neesse, SAchneider Dueck, Donhauser, Regler, & Tiefel, 2003; Neesse, Schneider, Tiefel, &
Kaniut, 2007).

MONITORING

Fluctuating the feed conditions with respect to solid content and particles size distribution results
in the varying of operating conditions, as indicated by three different shapes of the underflow
discharge (Figure 1).

1. In dense flow separation at high feed solid content, the sediment is stored in the conical
part of the hydrocyclone. The coarse particles are partly moved toward the overflow,
consequently reducing recovery of solid in the underflow The air core, which oscillates
intensely, does not extend over the complete hydrocyclone length. The underflow
discharge assumes the shape of a rope and is characterized by high solid content and less
fine particles, which are the advantage of this variation.

2. In dilute flow separation with a typical spray discharge, a continuous air core can be
observed that extends lo the underflow. The separation proceeds with an advantageous
high solid recovery in the underflow, but al o with low solid concentrations that result in
more fines being swept into the underflow.

3. The transition state between spray and rope discharge entails advantages in terms of both
high solid recovery and high solid content in the underflow. Using the product (i.e,
recovery multiplied by solid content) as an optimizing criterion, a maximum exists at the
rope/spray transition point (Figure 1). Because of the remarkable separation effects in the
transition phase, the monitoring of this state is of special interest. Taking the above listed
features of the operating state as a basis, the following different monitoring methods
have been tested by Neese. Schneider, Dueck, optical measurement using an infrared (IR)
beam, optical measurement. In cases where a yes/no signal at one point of discharge
was sufficient for control, the best results were obtained using IR measurements.

4. The sensor may be installed about 1 m from the splashing underflow (as illustrated in
Figure 2). Figure 3 shows the principle of a more demanding optical device. A charge-co
pled device camera records the shape and the movement of the underflow discharge in a
more sensitive manner. The PC- supported pattern recognition of these images considers
shape and time behavior of the underflow discharge.

ACOUSTIC SENSING

Hydrocyclones in operation are vibrating units. Vibration- generating mechanisms are non-
stationary movements of the turbulent multiphase flow in the hydrocyclone. Here, the eccentric
and un table movement of the air core and of the discharged rope in den e flow separation plays
an important role, Furthermore, turbulent movements and particle impacts to the hydrocyclone
wall cause higher frequency oscillations. These stimulations act on the natural oscillation of the
hydrocyclone, influencing the oscillation mode.

The measurement system shown in Figure 4 consists of the acceleration-type sensor a pre-
amplifier, and the computer-supported signal conditioning. The sensor is mounted to the exterior,
in the vicinity of the apex. Figure 5 indicates typical oscillation spectra for rope and spray
discharge, and for pure water. Obviously, the intensive, non-stationary movement in dense flow
separation results in high amplitudes in the low-frequency range. Spray discharge shows higher
intensities in the range 100-600 Hz, where the vibrations for rope di charge are damped.


VOLUME SPLIT CONTROL BY OVERFLOW THROTTLING

The new control concept is based on a conventional fuzzy logic data analysis and makes use of
detailed analysis of measured underflow behavior, as well as (he operator experience to build
fuzzy rules. Figure 6 depicts the generic structure of the fuzzy hydrocyclone control. The optical
sensor produces the database for the control.

Signals from the optical sensor, which indicate the shape and time behavior of the underflow
stream, are transmitted to the fuzzification interface, together with the pump power input and
control valve opening. Thus, a set of four state variables is considered for the fuzzy logic. Control
action is performed by a valve in the hydrocyclone overflow that regulates both the volume split
and the solid discharge in the
underflow. Each control interval is 0.3 s. The control mechanism, actuated by stepwise overflow
throuling. intensifies the pressure in ide the hydrocyclone. Figure 7 indicates that with increasing
overflow throttling the partition curve is shifted to the left. Toward finer cut size.

APLICATIONS
Closed circuits grinding

In mineral processing. Grinding circuits (Figure 8) require control mechanisms to change the
hardness of the feed. For harder material, the mill discharge becomes coarser. Consequently, the
recirculated load and the solid mass flow that is to be treated by the hydrocyclone increase.
Because the hydrocyclones separation effect is dependent upon feed conditions, changing feed
propertics must be compensated by a hydrocyclone control system. This compensation ensures
that the following conditions are achieved:

1) Al a constant mill feed rate to the properties of the hydrocyclone overflow should be stabilized
for varying material hardnes .
2) An increase of the mximum particle size in the hydrocyclone overflow is not permitted; as a
consequence, the maximum particle has lo be stabilized.
3) The variations of the hydrocyclone volume flow should be compensated by pressure drop
regulation.

Figure 9 illustrates how the separation curve is modified ir the overflow valve becomes
increasingly closed (Necsse, Schneider, Dueck, Golyk, et al., 2004). As can be seen, the reduced
efficiency curve of a 150 mm hydrocyclone has not been changed by the control process.
Nevertheless, at higher feed solids contents, the to value is increased due to higher solids
recovery; at the same time, the cut size is reduced. The results of hydrocyclone control for
grinding both soft and hard feed are presented in Table 1. For harder feed,

the mill discharge becomes coarser, Consequently, solids recovery of the hydrocyclone circulating
load and solids content in the hydrocyclone feed increases. With increaing solids content in the
hydrocyclone feed, the cut size is regulated down by overflow thrortling, whereby the to value of
the effieieney curve increases frorn 31 to 45% (see Figure 3). With hydrocyclone control by
volume plit regulation a grinding circuit can be operated in a wide range of circulating loads,
between approximately 150 and 620%.

Fine sand dewatering at the transition point rope/spray

In sand processing, fine sand thickening of < ISO unconsiderable before proceeding to the
dewatering screens. It is dfficult to achieve residual moistures of < 20%, which are necessary for
the transport and storage of the dewatered sand. The combination of the fuzzy controlled
hydrocyclone with a dewatering screen can solve this problem. In this application, the operator is
interested in high solid recovery and high solid content in the underflow, Thus in this application,
the tranditional point represents the operational optimum.

Figure 10 how the plant cheme. The controlled ISO mm hydrocyclones are feed with slurry, at a
solid content varying between 50 and 150 g/L. The volume split control stabilizes the underflow
olid contenr al about 55 w/w%.

This thickened slurry is directed al ihe dewatering screen.which is equipped with a 0.5 mm lining.
Actually, dewatering screens are not uitable for fine sand dewaterina. sually, a 0.5 mm screen
cannot hold fine particles of 50 um on the sieve plan. Nevertheless, due to the high solid contem
in the feed, a dewatering bed of about 300 mrn thickness is formed, which leads the effective
dewatering with a residual moisture of about 17 w/w% in the screen overflow,

A dewatering plant for 400 m
3
/h can be seen in Figure J1. The controlled hydrocyclone group
consists of a number of single hydrocyclones, connected in parallel in a round battery, The sensor
ihat deteet the underflow hape (rope or spray) is actix e al only one of the hy drocyclone .
Additional sensor are installed al one or two hydrocyclones, which are automatically activated if
disturbance at the active hydrocyclone are detected. The overflows of all hydrocyclone are
collected in a special pressure chamber. where a collecting discharge pipe with a control valve is
installed (Figure 11).

Desliming by controlled water injection at the apex

For desliming of ludge, fine particles in the cyclone underflow should be rninimized. As
mentioned above. fine particles are discharged through the cyclone underflow togetber with the
liquid. Tberefore. low water content and a water exchange in the underlow can improve the
quality of the coar e product. The use ofwater injection in the conical part of the cyclone for
underflow washing is a known method. New investigations indicate that the washing effect best if
the injector i installed al the upper end of the apex. which results in high reduction of fine
particles, relatively stable cut size. and low water consumption (Farghaly. Golyk. lbrahim, Ahmed,
& Nee: se. 20 I 0). Nevertheless, the washing effect is sens itive to variations in the feed making
controlled water injection necesary.

Figure 12 shows the principle of the control. For monitoring. the shape of the underflow
discharge was used as a criierion. With increasing water injection. the pray angle of the underflow
tends toward higher values, To oprate with high solid content in the under flow, the cyclone i et
to low spray angles near the transitional point.

The desliming effect resulting from increasing waterinjections can be seen frorn the partition
curves in Figure 13. The data indicate that an optimal injection rate exists, which in this case is 3
L/min. Two contra-effects are responsible for this optimal injection rate. First, improved settling
conditions are dorninant at low injection rates. The radially directed injection flow rransports fine
panicles to the centre of the cycJone and finally to the overflow, Second, at higher injection rates,
the increasing turbulence leads to a deterioration of the separation. Higher injection rates lead
to higher cut sizes and higher T
0
values of the fine particles (Iower washing effect). The controlled
water injection enables changing feed conditions and a stable operation at the optimum.

CONCLUSION

Control concepts for the hydrocycJone have to con ider that the simplicity of the cyclone design
should not be altered by complicated control devices. Frorn this point of, optical monitoring
devices that measure the shape of the underflow, which are installed at a certain distance from
the hydrocyclone, seem to be advantageous. Under the rough practical conditions of a splashing
and mechanically tressed hydrocyclone battery, the safe installation of a remote sensing system
plays an important role. Furtherrnore. systems that continuously produce large data quantities in
a short sampling time should be given preference. Then. this procedure should be combined
with a demanding, PC-supportcd signal treatment.

The target of the hydrocyclone control is the stabilization and improvernent of the partition curve.
Variaton in feed solids content and feed size distribution leads to a shift of the cut size, which can
be compensated by volume split control using a control valve in the overflow, Applications in
mineral processing for closd-circuit grinding and thickening have been presented here. The
minimization offine particles in the cyclone underflow is important if over-grinding is to be
prevented and the deslirning is to be maximized.

Then, a wash water injection at the end of the apex leads to less fines in the underflow, which
means that the T0 value of the partition curve will drop. This sensitive process is influenced by the
feed conditions. Therefore, the controlled water injection, based on the measurement of the
discharge shape of the underflow, stabilizes the washing effect.