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Heavy media hydrocyclones

High-efficiency KREBS® heavy-media hydrocyclones

Traditional heavy-media vessels can be inefficient separating fine material and their maintenance requirements are both costly and time consuming. KREBS heavy-media cyclones offer an alternative, delivering high-efficiency and relatively inexpensive separation of mineral particles from gangue using a fine magnetite-water medium.

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Key benefits of our heavy-media cyclones

  • High-efficiency separation

    FLS heavy-media cyclones boast exceptional efficiency thanks to various design features incorporated from the KREBS D26B cyclone, the industry’s standard high-capacity cyclone as well as for larger sizes. The use of centrifugal force enhances separation of fine particles, which cannot be efficiently recovered using static heavy-media vessels. Our heavy-media cyclones are relatively inexpensive and typically require little operator attention or maintenance.

  • Higher feed rates

    Our large-diameter heavy-media cyclones accept larger top size material for efficient separation at higher feed rates within your mineral processing plant.

  • Long service life

    A thick ceramic tile lining is critical, as dense media can be very abrasive. At the inlet, we offer pre-engineered ceramic components in two grades, with 25-38mm (1in.-1.5in.) thickness. We machine each pre-engineered tile in its ‘green’ state and fire the lot to create interlocking serialised liner components for extended wear life. The lower cone section and apex are protected by a heavy-duty monolithic ceramic lining.

Our heavy-media cyclones

Heavy-media vessels have been used for decades in mineral separation applications. But just because a practice is tried, doesn’t mean it’s true. KREBS heavy-media cyclones offer a more efficient and easy-to-operate alternative, handling top-size feed particles up to 102mm (4in.) and with capacities of 77tph (85stph) to 894tph (985stph) per cyclone. We work with you to understand the process challenges and ensure the correct equipment is selected, offering individual hydrocyclones and complete multi-unit Hydrocyclone clusters with isolation valves, pressure gauge(s), piping, launders, support structures, instrumentation, and other accessories.  

Models

Compare our heavy-media cyclones

Feed particle maximum size (in.-mm)
¾, 19
1½, 38
Dry Feed Capacity (stph,-mtph)
85, 77
150, 136
Pulp flowrate Range (gpm, m3/h)
1,050, 238
1,910, 434
Head equivalent (ft,-m)
15, 4.6
20, 6.1

Maintenance & service of our heavy media cyclones

Our experienced engineers will quickly and thoroughly evaluate potential applications and provide detailed recommendations and performance estimates. When validation testing is required, our hydrocyclone test laboratory provides prompt testing at low cost. We can also arrange to run test cyclones at your site. For operating hydrocyclones, we offer comprehensive aftermarket services, including maintenance training, spare parts, consumables, and our cyclone rebuild exchange program.

Learn more about FLS service centres

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Frequently asked questions

FAQs for heavy media cyclones

A heavy-media cyclone is a type of separation equipment used in the mineral processing industries to separate minerals from gangue based on density differences. The use of a dense medium, such as magnetite and/or ferrosilicon, forms a pseudo-fluid with a higher relative density than water, which establishes the separation process. 

A slurry of mineral solids, water and a dense medium, using magnetite and/or ferrosilicon, is fed into the cyclone under pressure, creating a swirling motion inside the cyclone. Denser particles are pushed to outer edges under centrifugal force and exit through an outlet (apex/spigot) at the bottom. Lighter particles remain in the centre and are carried upwards due to drag forces, exiting through the top. 

Heavy-media separation is common in the coal cleaning process. Other applications include nickel, diamonds, industrial minerals, etc.