hydro classifier

Types of hydro classifiers

According to Particle sizes' distributions, specific gravity, minerals' qualities, and other characteristics, various materials will exhibit different sediments' qualitative properties when there is a uniform water flow. Hydro classifiers mainly separate materials into three or four sizes. Generally, sand, gravel, and sludge will be deposited in different settling zones. Underflow will be taken out from the classifier, while overflow will be used as the tailing of the process.

In the mineral processing industry, hydrocyclones are frequently used for classification. Their main purpose is to separate the ground material and return the oversize material to the mill for further grinding. Such classifiers improve the throughput of the grinding circuit and increase the recovery rate of valuable minerals. In some particular situations, hydro classifiers can be used for dewatering and desliming as well.

There are various types of hydro classifiers, including:

• Hydrocyclone classifier

  A hydrocyclone classifier uses centrifugal force to separate particles based on their sizes and densities. This classifier is created by injecting the slurry into a conical-shaped vessel. Larger and denser particles are pushed to the wall of the vessel, then move downward to the apex, while lighter and smaller particles will be carried out through the overflow.

• Spiral Classifier

  A spiral classifier is a device that utilizes a spiral-shaped rotor to separate particles. The spiral rotates in a basin of water, where it raises the water level. Smaller particles are carried away with the water, while larger particles settle at the bottom and are removed.

• Wet Screw Classifier

  The wet screw classifier consists of a gravity settling tank and a helical screw conveyor. The slurry will be evenly distributed across the tank's surface, and particles will be separated based on sizes and specific gravities. The sand will be collected by the screw conveyor and then dewatered through a filtration press.

• Fluidized Bed Classifier

  This type of classifier is radioactively vibrating, which creates stratification in the fluidized bed. Then, particles of different sizes and densities are separated and removed from the unit.

• Air classifier

  An air classifier separates materials according to their sizes, shapes, and densities using air flow. This classifier can be divided into two parts: the classifier body and the separating mechanism. The feed material will be injected into the classifier body. Then, the separating mechanism will separate the materials based on the airflow pressure.

• Magnetic hydro classifier

  This type of classifier uses a magnetic field to separate minerals having differing magnetic characteristics. After mixing with water, the minerals are sent into the classifier. Then, the magnetic ones will be attracted to the rods or discs that create a magnetic field. The others will be removed as tailings.

Specifications and Maintenance of Hydro Classifiers

Some of the key specifications of a typical hydro washing classifier are as follows.

• Diameter: The diameter of the classifier is specified according to the actual case and classifier model. The classifier diameter can vary from 1m to 5m for typical models.
• Length: The length of the hydro classifier also depends on the type and model. Hydro classifiers can have lengths from 5m to 25m or even more for larger models.
• Power: The classifier may work with a power motor that typically ranges between 10 hp to 200 hp depending on the model.
• Feed Size: The size of the material that can be fed to the classifier for processing typically ranges between 1mm to 100mm or even larger for some specific models.
• Production capacity: The classifier can process quantities of material that can range from 50tph to 5000tph depending on the model.

It is important to mention here that these specifications will vary for different types of classifiers. For example, a spiral classifier’s length, diameter, and power will be vastly different from a water screw classifier.

Maintenance

It is also imperative to keep in mind that maintenance is the key if one wants to get the best out of one’s hydro classifier machine. Some of the important classifier maintenance and servicing tips are as follows.

• Take care of the classifier. It is very important that the classifier is always used, maintained, and repaired according to the manufacturer's user manual and guidelines.
• The equipment environment must be well-lit and properly ventilated at all times.
• The working environment should be dust-free, clean, and pollution-free. In case there is no way to control the dust and pollution, empty bags and other sealing tools should be used to protect the device from contamination.
• The machine's fasteners should be checked periodically to see if they are loose. If any parts are found to be loose the users should immediately stop the working of the classifier and rectify the fault before resuming work.
• The lubrication system of the classifier should be applied to the oil as per the prescribed oil quantity and standards. Regularly inspect grease leakage and other conditions and timely supplement the lack of grease.
• The classifiers should be checked regularly to see if there is any abnormal noise or heat. In case users find any such workings anomalies, the machine should be stopped and checked to identify and rectify the fault.
• Pipelines associated with the classifier should be regularly inspected to find if they have any cracks, leaks, or other issues.
• Pipelines should be cleaned periodically to see if there is any blockage and timely cleaning.

Scenarios of Hydro Classifiers

• Mineral processing companies: Hydro classifiers are widely used in ore dressing plants and mineral processing factories. In these places, they classify different minerals according to the particle size to meet the requirement of following processing stages. For instance, they separate valuable ores like gold, copper, and iron from gangue minerals. Moreover, there is a combination of hydro classifiers and other equipment, such as ball mills and hydro classifiers, which constitute a closed-circuit grinding and classification system. This system can improve the fineness of ores and optimize ore extraction yield. Additionally, hydro classifiers can be used to deslime minerals. Mud and fine particles can be removed through this operation, which helps to reduce the contamination of subsequent processing links.
• Sand and aggregate classification: Hydro classifiers are used for sand and aggregate classification in the construction industry. For example, they can separate fine particles from sand in rivers or quarries to obtain quality sand meeting construction standards. Hydro classifiers can also classify different types of aggregates, such as gravel and pebble, according to the required size. Furthermore, they are used to remove impurities in sand and aggregates, such as clay, silt, and organic matter, improving the quality and purity of materials.
• Chemical and pharmaceutical industries: Hydro classifiers can be found in chemical and pharmaceutical industries as fine powder classifiers and separators. For instance, after grinding, they can separate powders of different sizes in chemical processing to obtain products that comply with specifications. In the pharmaceutical industry, hydro classifiers can be used to produce drugs, excipients, and active ingredients, ensuring the uniformity and quality of products.
• Food processing companies: Some food processing companies also use hydro classifiers. For instance, they may be used to classify flour in wheat milling to obtain flour with the desired particle size and texture, which is fit for the production of baked goods. Besides, hydro classifiers can also be used to separate starches from tubers and legumes, such as potato starch and soybean starch. Additionally, hydro classifiers can be used to extract valuable components in food, such as oils and sugars, improving the extraction rate.

How to Choose Hydro Classifiers

When buying hydro classifiers for sale, it is important to choose the right model for the target market. Start by choosing the classifier that suits various processing needs. For instance, the type of material can affect the choice of classifiers. Some classifiers work best with specific mineral shapes, sizes, and densities.

Investing in classifiers with flexibility is a good option for business owners. This means that the classifiers should be able to handle different properties of minerals. Choose classifiers that can be adjusted to work with various feed rates. This may include hydro cyclone classifiers that have adjustable cylinder diameters and apex sizes.

Pay attention to the capacity of the classifiers. Select classifiers that have a processing capacity. This is the maximum amount of feed the machine can handle per unit of time. Make sure the capacity of the classifier aligns with the expected processing volume. Choose classifiers that are energy efficient. Energy-efficient machines help reduce operational costs and increase profit margins.

Registering a hydro cyclone classifier supplier can help in the decision-making process. It is easy to get valuable information about the classifier and how it works when dealing with a reputable supplier. Consider the classifiers that are easy to maintain and operate. Those machines tend to have a simple instruction manual with illustrations. It is also possible to reduce running costs and minimize downtime with easy maintenance requirements.

Finally, choose classifiers that comply with local regulations for mineral processing. Such classifiers promote a sustainable business practice because they reduce environmental impacts.

Hydro classifier Q&A

Q1: What type of material can a hydro classifier handle?

A1: Hydro classifiers can handle various solid materials, including minerals, sands, soils, and industrial by-products. However, the specific design and operating parameters of the hydro classifier may influence the nature of the materials it can effectively process.

Q2: What are the main parts of a hydro classifier?

A2: A hydroclassifier is mainly composed of feed inlet, water distributor, classifier chamber, overflow outlet, discharge con, and sludge pump. These parts work together to classify particles based on their size and density through the use of water and gravity.

Q3: How does a hydro classifier differ from a hydro cyclone?

A3: A hydro classifier is used mainly to separate particles based on size and density, whereas a hydro cyclone separates particles based on size and weight. Moreover, Hydro classifiers tend to have a flatter body, while hydrocyclones have a cylindrical body with a cone-shaped bottom.