I. Structural Principle

The flat-bottom hydrocyclone is a structurally optimized version of the traditional Hydrocyclone. Its core feature is an increased cone angle to 180°, resulting in a cylindrical flat-bottom structure. A removable bottom cover and grit trap are located at the bottom. The feed body is connected to the tangential feed pipe via a curved connecting pipe, and the overflow pipe is located at the top center. Its operating principle is based on centrifugal separation:

Strong cyclonic flow formation: After material enters the hydrocyclone tangentially at a certain pressure, a three-dimensional elliptical rotating flow field is generated within the cylindrical chamber. Centrifugal force causes coarse particles to move toward the walls, while fine particles accumulate toward the central axis.

Flat-bottom classification mechanism: Coarse particles flow down the walls and are discharged through the grit trap, while fine particles are discharged through the central internal vortex and out of the overflow. The flat-bottom design avoids the material accumulation problem found in traditional conical sections. Furthermore, the bottom circulation flow creates a circular fluidized bed, further preventing fine particles from mixing into the underflow. 

II. Performance Characteristics

High Classification Accuracy: Through optimized flow field design, overflow and underflow of coarse particles are effectively suppressed, resulting in classification efficiency improvements of approximately 10% compared to traditional Hydrocyclones. For example, in the first stage of iron ore grinding, the overflow particle size can reach -200 mesh, accounting for over 90%.

Large Processing Capacity: Suitable for high-concentration, coarse and heavy materials (such as tin and iron ore), a single unit can process 50-500 tons/hour, and multiple units can be connected in parallel to meet large-scale production needs.

Wear and Impact Resistance: Lining materials include high-Alumina ceramic (Al₂O₃ content ≥95%), silicon carbide, or polyurethane, offering a wear life 3-5 times that of ordinary metals, making it particularly suitable for long-term operation with high-hardness ores.

Strong Stability: The flat bottom structure reduces the risk of coarse particles settling in the cone section, reducing operating vibration by over 30% and significantly reducing the failure rate. 

III. Application Scenarios

Metal Ore Beneficiation:

Iron Ore: Replaces spiral classifiers for primary grinding and classification, reducing circulation load by 150% and increasing ball mill capacity by 10%-25%.

Tin Ore: Through twin-vortex coupling and optimized feed guide, classification efficiency is increased by 5%, reducing the amount of sand and fines carried over, making it suitable for sorting high-density minerals.

Non-Metallic Ore Processing:

Tailings Sand Separation: Reduces the amount of fine particles carried over from underflow, improving the quality of finished sand for construction sand or tailings reuse.

Chemical and Environmental Protection:

Wastewater Treatment: By adjusting the underflow outlet size, sludge can be concentrated and dehydrated, achieving underflow concentrations of 40%-60%, reducing subsequent treatment costs.

IV. Cleaning Methods:

Daily Maintenance:

Shutdown for Cleaning: Close the feed valve and pump, remove the bottom cover and sand trap, and use a high-pressure water jet (pressure ≥10 MPa) to flush the inner walls and underflow outlet to remove adhered sludge and coarse particles. Regular Inspection: Check the overflow pipe and grit outlet for wear weekly. If wear exceeds 20% of the original size, replace them promptly.

Deep Cleaning:

Chemical Assistance: For stubborn dirt (such as calcium deposits), soak in a dilute hydrochloric acid solution with a pH of 2-4 for 1-2 hours, then rinse with clean water.

Internal Inspection: Remove the top cover quarterly and inspect the inner wall of the cylindrical chamber and the feed body guide plate to remove any scale or wear.

VI. Troubleshooting and Solutions

VII. Maintenance and Optimization Recommendations

Preventive Maintenance:

Inspect the underflow outlet for wear every 8 hours of operation and the inner wall of the overflow pipe for wear every 24 hours.

Lubricate the bearings and seals monthly to prevent equipment vibration caused by friction.

Process Optimization:

Install an electromagnetic iron remover before the feed pipe to prevent metal impurities from entering the hydrocyclone and damaging the inner wall.

For materials prone to scaling (such as those containing calcium minerals), add 0.1%-0.3% of a dispersant (such as sodium hexametaphosphate) to the feed to reduce the risk of scaling. Intelligent Upgrade:

The addition of pressure sensors and concentration detectors allows for real-time adjustment of feed flow and underflow opening via a PLC system, enabling dynamic optimization of classification parameters.

Through these design features and operational strategies, the flat-bottom hydrocyclone demonstrates efficient and stable performance in mine classification, particularly suitable for processing high-concentration, coarse-grained materials. It is a core piece of equipment for improving production capacity and product quality in modern mineral processing plants.