Operating conditions in the hydrocyclone process have a direct impact on plant availability and on grinding and flotation circuit efficiency. To help ensure continuously optimal hydrocyclone operation, Metso Outotec has introduced CycloneSense, which it calls a ‘smart measurement system’ that provides direct, continuous, and reliable online monitoring of the hydrocyclone air core.

“In order to optimise the process, hydrocyclones should be run so that the fraction of water returned to grinding is the smallest amount possible. In order to do that, you need to know when you are approaching the limit of your hydrocyclone’s coarse discharge rate to avoid going too far and ending up with problems, such as roping,” said DSc., Professor Emeritus Kari Heiskanen, a well-known expert in the field and the author of the book Particle Classification.

He continued: “CycloneSense allows you to see what is happening inside the hydrocyclone and helps to push the limits of the process.”

According to Metso, the unique CycloneSense technology allows to visualise the performance inside the cyclone. It allows continuous online measurement of the cyclone’s air core shape, size, and location based on process tomography, thus helping to find and maintain the optimal operating point for the hydrocyclone. In addition, the measurement system helps to detect and prevent potential problem situations, such as roping, where the slurry is not properly separated and instead some of the larger particles are sent to the overflow and directly to the next stage of processing.

Combining CycloneSense with the Metso Outotec PSI particle size analyser allows easy optimisation of the cyclone cluster and grinding circuit. Metso Outotec’s ACT Cyclone Control and Grinding Optimisation is designed to take full advantage of the measurement data and to provide significant and continuous benefits to customers.

The CycloneSense measurement system is available for new Metso hydrocyclones and any existing hydrocyclone installations. Metso also provides Life Cycle Services with remote monitoring.

To summarise, the key benefits of CycloneSense are: continuous, direct, and reliable online measurement of hydrocyclone air core shape, size, and location; helps to prevent problem situations in hydrocyclones, such as roping, and increases uptime and production; enables automated hydrocyclone control and performance optimisation of the system; provides valuable additional information for grinding optimisation; and is simple to install, operate, and maintain with no moving parts. n