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avex 2 hydrocyclone range expands

The Cavex 2 650 is the new hydrocyclone size to be released in the Weir Mineral’s Cavex 2 product line and it translates to increased savings for brownfield sites where the existing hydrocyclones do not have enough capacity and are maxed out, while greenfield projects benefit from savings in capital expense. The new model will be available globally, with assembly in local regions.

The latest Cavex 2 650 hydrocyclone was tested in a large copper ore mine in Chile. The mine had a SAG mill in a closed circuit with the cyclone cluster. The trial tested one Cavex 2 650 in a 6-place cluster of existing Cavex cyclones and saw an improvement of up to 48.5% in circulating load and 31.7% in water bypass versus the original cluster.

A lab water test with the same hydrocyclone fittings as above also yielded positive results: a 211mm inlet and 260mm vortex finder delivered 16% more capacity at 100kPa, and 17% more capacity at 250kPa.

Cavex hydrocyclone cluster. Image credit: The Weir Group PLC

Cavex hydrocyclone cluster. Image credit: The Weir Group PLC

This new model offers significant benefits to mining customers including:

  • Increased operational and circuit capacity up to 30%
  • Maximised plant recovery by reducing the quantity of misclassified particles with an average improvement of the alpha parameter more than 10%
  • Improvements in bypass with an average of over 15%
  • Opportunity to retrofit Cavex 2 650 cyclone into existing cyclone cluster footprints
  • Less turbulence during the separation process due to the LIG+ inlet and elongated chamber design
  • Enhanced performance with a Synertrex-enabled monitoring system which can detect roping or blockage conditions in advance for continuous, efficient operation of the hydrocyclone
  • Improvement of environmental footprint.

A more sustainable mining future

The enhancements of the new model’s performance go hand in hand with improving the environmental footprint of the equipment.

By reducing bypass returning to the mill, fewer fines are returned back to the mill in the closed-circuit milling process, thus reducing the need for energy to be used to further process particles that are already small enough to move on to the next stage. This frees up mill capacity, previously used up with fine particles, for the size reduction of larger particles.

As a hydrocyclone that can make a finer separation, the new model can operate at a lower pressure allowing for further energy savings or a higher feed density for water savings while maintaining the existing cut size from the hydrocyclone.

And finally, using equipment with a higher volumetric capacity requires fewer units to be installed upfront as well as fewer consumable spare parts used over the life of the hydrocyclone.

Cavex 2 650 model. Image credit: The Weir Group PLC

Cavex 2 650 model. Image credit: The Weir Group PLC

Greater efficiency

The new hydrocyclone comprises a robust metal casing with a unique elongated chamber design. The additional length guarantees turbulence is decreased inside the cyclone, allowing for additional volume and increased efficiency during the process.

To satisfy all process conditions and slurry types, the new model comes with a range of material technology options including industry leading Linatex premium rubber, the industry standard R55 rubber, neoprene for high levels of hydrocarbon and ceramic.

The new model can be customised to suit almost any application with a variety of spigots, vortex finders and cone angles. The company will tailor the hydrocyclone to suit your unique application and goals.

Applications and industries

The new model is suited for use in a range of heavy-duty, industrial, abrasive industries and processes including:

  • Mining
  • Aggregates
  • Utility/FGD/General industrial
  • Classification and separation (Mining)
  • Classification and separation (Aggregates)
  • Mine dewatering systems
  • Tailings management