To help ensure continuously optimal hydrocyclone operation, Metso Outotec is introducing CycloneSense™, a smart measurement system that, it says, 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,” DSc., Professor Emeritus, Kari Heiskanen, a well-known expert in the field and the author of the book ‘Particle Classification’ says. “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,”

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

CycloneSense allows operators to visualise the performance inside the cyclone, facilitating 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, Metso Outotec says. 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, according to the company. Metso Outotec’s ACT Cyclone Control and Grinding Optimization 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 Outotec hydrocyclones and any existing hydrocyclone installations. As an optional service, Metso Outotec also provides Life Cycle Services with remote monitoring.