Minerals Engineering, Vol. 4, No. 3/4, pp. 497-502, 1991 0892-6875/91 $3.00 + 0.

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Printed in Great Britain Pergamon Press pie

QEM*SEM IMAGE ANALYSIS OF CYCLOSIZER CLASSIFICATION

C.J. RESTARICK and P. GOTTLIEB

CSIRO Division of Minerals and Process Engineering, Clayton, Australia

ABSTRACT

Warman Cyclosizers have been used extensively throughout the world for over
twenty years as a means of hydraulically classifying fine particulate
matter, but some criticisms of their performance have been published.

A synthetic feed sample of alternating quartz and galena size fractions was
Cyclosized at standard conditions to demonstrate visually that white quartz
was correctly classified into CS1, 3 and 5, and black galena into C52 and
4. Each of the five recovered size fractions was dried, weighed to confirm
the weight distribution as fed and then analysed by QEM*SEM to
confirm that hydraulic classification was adequately completed. The
QEM*SEM analysis also showed that quartz and other diluents associated
with the impure galena concentrate were correctly classified into CS2 and
4. The visual demonstration and QEM*SEM data indicated that fine particle
transfer from CS1 was slower than desirable, so the apex of this cone was
drilled out to increase the rate of transfer and reduce the consequent
error.

Keywords
Image analysis; classification; QEM-SEM

INTRODUCTION
Although more than 400 units have been sold by Warman International since the
development of the Cyclosizer by Kelsall and McAdam (1), there has been very little
published data or comments on the device. Details of a temperature control system, and a
decant/centrifuge technique to recover slimes in the Cyclosizer effluent have been published
(2) and a nuclear sensing method has been proposed (3). Comparisons with other sizing
methods (1, 4, 5, 6) gave good agreement on a cumulative size distribution basis, but 50%
misplacement outside the calculated size range in individual cone products has also been
claimed (4, 5), which is at variance with the original data (1), most of which was obtained
from single cyclone tests. Minor design changes have occurred since 1963, so an experiment
was devised to confirm current Cyclosizer performance and check these claims of misplaced
particles.

CYCLOSIZER OPERATION

The Cyclosizer consists of five inverted closed pot 75mm diameter hydrocyclones in series
(Fig.l). Each successive cyclone is fitted with an inlet and vortex finder of smaller
diameter, thus increasing the centrifugal forces in each stage. In effect a series of
centrifugal traps is established, each retaining particles nominally coarser than 44, 33, 23,
15 and 10 microns (relative to quartz) respectively.
497
498 C.J. RESTARICK and P. GOTTLIEB

CS1

SAMPLE ~ CS2
CONTAINER CS3
= ~ 1 ~~ ~'~ CS4 CS5

FLOW
CONTROL

4U,
Fig.1 Cyclosizer arrangement

The particles retained initially in each pot are subjected to multiple hydraulic classification
by repeated circulation down the vortex column, such that the coarser particles recycle
back to the pot and the finer particles pass through the vortex finder to the next stage.

If classification could be continued for infinite time, all particles coarser than the limiting
size in that cone would be retained, and all particles finer would pass on to the next stage,
provided the flowrate and temperature conditions remained constant. Particles just finer
than the limiting size will have a low probability of transfer, but will eventually circulate
in the pot to an appropriate radius in the vortex column and be discharged. It is also
possible for a particle to travel down the axis of the vortex column to discharge without
centrifuging out. This can be easily demonstrated with oversize particles (plus 100 microns),
which occasionally spin down the axis to the next stage, but there is no evidence of finer
particles transferring by this mechanism. The probability of transfer of fines from each
cyclone stage is such that 91% of the retained particles will be coarser than the limiting size
of that stage after 10 rains. For longer elutriation times, the values are 95.5% after 20 rains
and 98.5% after 60 rains (7). These data are based on calibrations using crushed particles
with a continuous size distribution. Correction factors for time, temperature, flowrate and
particle density are used to calculate the effective classification size, defined as equivalent
Stokesian diameter for each cone. The recovered weights are used to calculate the size
distribution (7).
Any decrease in temperature or flowrate, however temporary, will irreversibly transfer
particles downstream, so that a finer, but incorrect size distribution will be obtained.
Downstream transfer also occurs, particularly from the low energy CSI cone, if too many
coarse, heavy particles are added too quickly (6). When overload occurs, a clear liquid
interface develops in the pot as the congregated particles slow down and gravitate into the
cone, forcing some through to the next stage.

Cloudiness in fractions discharged from cones CSI and 2 was reported in some tests (5).
This is due to inadequate dispersion prior to cyclosizing, and reduces the accuracy of these
data, since the agglomerated fines should have been distributed to downstream cones.

CYCLOSIZER CLASSIFICATION DEMONSTRATION

A sample of pure quartz and a sample of impure galena flotation concentrate were
separately classified in the Cyclosizer. Three quartz fractions CSI, 3 and 5, and two galena
fractions CS2 and 4 were combined to synthesize a stepped feed size distribution of
alternating quartz and galena fractions. Details of the cyclosizing procedure for feed
preparation are given in the Appendix, and the stepped size distribution obtained is
 QEM*SEM image analysis of cyclosizer classification 499

illustrated in Figure 2. This shows the size gaps produced between each fraction, the median
size and size range (calculated for pure quartz and galena) for each fraction and the
classification or cut size of each Cyclosizer cone for the demonstration conditions (11
litres/min, flowrate, 23°C temperature and 60 rains, elutriation time). The Cyclosizer cut
sizes were deliberately placed in the gaps between the alternating size fractions of quartz
and galena, so that minor changes in the conditions (if they did occur) would not cause
misplacement, but major misplacement would be evident.

FRACTION 19.29 13,35 9.19 8.89

MEDIAN SIZE >26
CSI CS2 CS3 CS4 CS5
CYCLOSIZER
CLASSIFICATION [~'~
SIZE
1
GALENA 24.83 21.02 17.31 14.65 11.85 1110.03 6.22 6.96 6.38

QUARTZ 49.17
I°°,1 I
GALENA

41.62 34,28 29.09

QUARTZ
I"1, °"11 °°'1
! GALENA

23.48 119.86
I
16.28113.78
I
QUARTZ

12.64

I I
CYCLOSIZER
CLASSIFICATION ~'~
SIZE

FRACTION
MEDIAN SIZE >52 38.20 26,41 18.19 13.25

Fig.2 Stepped size distribution of quartz and galena

The synthetic feed sample was completely bled into the system within 8 mins at high
flowrate and then the elutriation flowrate was reduced and set at 11 litres/min for 60 mins.
On completion the flowrate was increased to prevent any further classification, and the
fractions recovered, dried and weighed. The recovered weights were slightly higher in CSI
and 2, and slightly lower in CS3, 4 and 5, which indicates that transfer from CSI and 2 to
CS3, 4 and 5 was incomplete even after an hour (Table 1).

TABLE 1 Cycioslzer fraction weights

WEIGHT (glns) CS1 CS2 CS3 CS4 CS5 TOTAL

FEED 4.924 1.240 5.610 1.269 2.052 15.095

RECOVERED 5.084 1.282 5.382 1.220 1.934 14.902

GAIN/LOSS +0.160 +0.042 -0.228 -0.049 -0.118 -0.193

ERROR % +3.25 +3.38 -4.06 -3.86 -5.75 -1.27

The observed changes in colour in the pot and cone of each stage are recorded in Table 2.
The cone data are included because the fine particles close to the limiting size preferentially
circulate down the vortex column, and clearly showed up as the colour of the next stage to
which they were being slowly transferred. This was particularly obvious in CS3 and 4. The
initial reversal of colours in CS2 (white) and CS3 (black) is partly due to the high flowrate
during feeding which displaced the fractions. Only white particles were collected in the last
cyclone, CS5, indicating that no galena passed CS4. The first cyclone, CSI, was the slowest
to change from grey, and was never as white as CS5, suggesting that transfer was
incomplete. The change to black was faster in CS4 than in CS2, which appeared to change
faster than CS1. The rate of colour change is a visual indication of the recycle rate in each
stage and clearly supports the theory that the recycle rate and hence probability of
completion of transfer of fine particles increases in each successive stage.
500 C. J. RESTARICK and P. GOTTLnm

TABLE 2 Visual estimation of classification

Time Cone CS 1 CS2 CS3 CS4 CS5

After Feeding Pot Light Grey White Dark Grey Grey White
8 Mins Cone Clear White Grey White White
Elutriation Pot Black
for 12 Mins Cone White
Elutriation Pot Off White Off Black White Black White
for 20 Mins Cone Clear Clear Grey White White
Elutriation Pot White Black White Black White
for 60 Mins Cone Clear Clear White Grey White

QEM*SEM IMAGE ANALYSIS

Description
QEM*SEM is an automated image analysis system which uses backscattered electron a n d
energy dispersive x-ray signals from a scanning electron microscope (SEM) to create digital
mineral images in which each pixel corresponds to the mineral species in a small region
under the electron beam. The system was developed to help solve mineralogical and
metallurgical problems in the processing of ores.

The material of interest is usually sized particulate matter resulting from crushing and
grinding. The size fractions are mixed with crushed graphite and epoxy resin and east to
form a sample block which is polished and coated with a thin layer of carbon to ensure
electrical conductivity. The particles are thus well separated and mounted in random
orientations with random sections exposed.

In the SEM, each particle is individually identified and is distinguished from the
mounting medium by its backseattered electron contrast. Each particle section is scanned
by a grid of points and the backscattered electrons and the x-ray photons emanating from
a given point are used to identify the elements present and thus classify the mineral species
present. The image of the particle section is built up p o i n t - b y - p o i n t in this manner. Each
pixel in each particle section image is assigned a number which is a unique identifier of
the species at that point in the section. Many hundreds of particle sections are measured
on each sample and their images stored.

Later detailed analysis of the images provides comprehensive statistical information

about mineral proportions, associations and distributions and about particle composition,
size and shape. The information is obtained as averages over all particles or as distributions
by classifying each particle section on the basis of some individual parameter.

Cyclosizer Fraction Analysis

In the QEM*SEM analysis of the Cyclosizer fractions, approximately 1000 particle sections
were examined from each of the five cones. Each particle section was then categorised
from its composition and degree of liberation as clean quartz, clean galena or galena
concentrate diluents. The proportion of particles and the mean particle size in each category
were determined to assess the cyclosizer classification of particles of known density. The
data are shown in Table 3.

The number of galena particles in CS3 and 5 is too low for accurate size calculation, but
indicate that major displacement of galena did not occur.

However galena was retained in CSI (3.6%), confirming that transfer from CSI was
incomplete.
 QEM*SEM image analysis of cyclosizer classification 501

TABLE 3 QEM*SEM Data

Cone CS1 CS2 CS3 CS4 CS5

Number of Particles
Quartz 969 212 975 90 942
Galena -40 668 15 760 8
Other 26 151 26 223 83
Total 1035 1031 1016 1073 1033
Weight Distribution %
Quartz 94.88 18.37 96.55 5.30 95.00
Galena 3.57 69.06 1.83 82.83 1.51
Other Sulphides 0.20 5.81 0.08 4.63 0.53
ECD (microns)
Quartz 42.1 27.6 21.4 14.2 10.8
Galena 24.8 18.2 13.9 11.6 8.1
Cyclosizer Mean Size
Quartz (microns) >52.0 38.2 26.4 18.2 13.3
Galena (microns) >26.0 19.3 13.3 9.2 6.7

The distribution of other sulphides is similar to the galena ie, mostly to CS2 and 4, with
very little in CSI, 3 and 5.

There are sufficient numbers of quartz particles in CS2 and 4 to obtain a good estimate of
their size, which is intermediate to the sizes in the adjacent quartz cones CSI, 3 and 5,
indicating that this quartz has been correctly reclassified as an original contaminant
constituent of the impure galena concentrate. It is also most unlikely that the galena would
be correctly classified as indicated, and that the quartz be misplaced from adjacent cones.

The size measure used, the average equivalent circle diameter (ECD), has been calibrated
against particles screened on standard Tyler series sieves. The calibration factor used in
this study expresses the mean particle size as an equivalent mean sieve size. Although the
discrepancy between the Cyclosizer and QEM*SEM sizes requires further investigation,
the relative size data is adequate for this study.

CYCLOSIZER MODIFICATION

The slow transfer of fines from the first cone, CSI, can be partly explained by the large
diameter of the vortex finder (18.3 ram), which creates a vortex column of similar diameter
to the apex (12.7 mm) and almost blocks off the flow circulating into the pot. After the
plastic apex was carefully drilled out to 18.3 mm, the particles in the pot spun faster and
the recycle rate was visibly faster. Comparative tests confirmed that the transfer rate from
CSI increased by approximately 10% without detriment to the operation of the Cyclosizer.
This modification is recommended, but the Cyclosizer would need recalibration.

CONCLUSIONS

Major misplacement of coarse particles to downstream cones did not occur. The rate of
transfer of fine particles from the first cone was slower than expected such that fines would
be reproducibly and incorrectly retained, particularly at low flowrates for short times. This
error was considerably reduced by drilling out the apex of the first cone to increase the
internal recycle rate. QEM*SEM analysis confirmed that the galena was not misplaced, and
also differentiated, by size, between the pure quartz in CSI, 3 and 5, and the contaminant
quartz associated with the impure galena concentrate.
502 C. J. RESTARICK and P. Go'r'ri.iL~

REFERENCES
. Kelsall D.F. and McAdam J.C.H. Design and operating characteristics of a hydraulic
cyclone elutriator. Trans. Instn. Chem. Engrs. Vol 41, 84 (1963).
. Kelsall D.F., Restarick C.J. and Stewart P.S.B. Technical note on an improved
cyclosizing technique. Proc. Australas. Inst. Min. Metali. No 251, 9 (1974).

. Daellenbach C.B., Mahan W.M. and Armstrong F.E. Rapid particle size analysis by
hydrosizing and nuclear sensing. USBM RI 7879 (1974).

. Treasure C.R.G. The Warman Cyclosizer for particle size analysis. Proc. Soc. Analyt.
Chem. Vol 6, 169 (1969).

. Finch J.A. and Leroux M. Fine sizing by Cyclosizer and microsieve. CIM Bulletin,
Vol 75 No 839, 236 (1982).
. Napier-Munn T.J. The determination of the size distribution of ferrosilicon powders.
Powder Technology 42, 273 (1985).
. Anon. Particle size analysis Cyclosizer Instruction Manual. Warman International Bull.
WCS/2 (1964)

APPENDIX

PREPARATION OF A QUARTZ-GALENA STEPPED SIZE DISTRIBUTION

Ten grams of quartz from each Cyclosizer fraction (CS1-5) were combined and reclassified
for 60 rains at 23°C and 12.8 litres/min flowrate. Cone fractions CS2 (-41.62+29.02 microns)
and CS4 (-19.86+13.78 microns) were removed and discarded. The flowrate was then
reduced to 9.15 litres/min. The resultant coarser classification distributed more quartz from
CSI, 3 and 5, and effectively extended the top size of the CS2 (49.17 microns) and CS4
(23.46 microns) fractions and truncated the size range of the CSI, 3 and 5 fractions. The
CS2 and 4 fractions were again discarded. A -38 micron sample of galena concentrate was
also Cyclosized under identical two stage conditions, but the CS1, 3 and 5 fractions were
discarded and the truncated CS2 and 4 fractions were retained. Quartz fractions QI, Q3 and
Q5 were combined with galena fractions G2 and G4 to synthesize a stepped size distribution
of alternating white and black minerals as illustrated in Figure 2.