Cavex® 2 High-Efficiency Hydrocyclone

About this product

The Cavex® 2 high-efficiency cyclone marks a new era in hydrocyclone separation technology with the ability to reduce turbulence and improve classification, with capacity increase of up to 30%. Overview With an ambitious goal to improve the industry-leading design of the original Cavex® CVX hydrocyclone, our new and improved Cavex® 2 maximises capacity and improves cyclone efficiency, separation, recovery and wear life. Many years of research, development and trials went into the creation of the intelligent Cavex® 2 classification cyclone. Compared to the original Cavex® hydrocyclone, the Cavex® 2 has an innovative and advanced LIG+™ design, which: • Stabilises flow pattern • Reduces turbulence in the hydrocyclone • Improves the efficiency of feed slurry classification and separation • Increases volumetric capacity by up to 30% • Occupies a similar footprint as the original Cavex® hydrocyclone and other classification cyclones, and • Reduces wear rates Moreover, the water and energy savings of this high-efficiency cyclone reduce its overall cost of ownership and deliver sustainability benefits over the long term. The superior performance of the Cavex® 2 hydrocyclone is what separates it from the rest. Frequently Asked Questions How does cyclone efficiency impact the performance of the overall circuit? High-efficiency cyclones help to: • Prevent overgrinding • Make the material more suitable for further processing • Increase the capacity of the circuit • Maximise plant recovery • Reduce operating costs and • Maximise profits. For example, maximising the cyclone underflow density in a mill circuit can reduce the amount of overgrinding and ultra-fines production in the mill. Additionally, ultra-fines recovery within the flotation circuit is difficult and can result in low metal recovery. Outside of the mill circuit, inefficient cyclone operation can result in missing plant classification, dewatering and solids recovery targets. What range of classification sizes can hydrocyclones produce? Hydrocyclones can be used to produce a wide range of classification sizes. Although dependent upon the feed conditions, the typical range of classification is 8 - 500 microns. How do I measure or know what type of efficiency of classification I am getting from my hydrocyclone? A cyclone's separation efficiency can be described by its sharpness, feed water split to hydrocyclone overflow stream and its cut size. It can be analysed and calculated by taking samples from the cyclone feed, underflow and overflow. Operating parameters such as flow rates, solids tph and cyclone pressure will also need to be collected. These metrics will help to identify whether the hydrocyclone is working at its full potential and maximum capacity. Once the particle size distribution data and % solids by weight have been determined for all streams, specialised software can be used to extrapolate the efficiency parameters. Alternatively, you can use a spreadsheet software to calculate them. If unsure of how to do this, simply send your samples to our team of Cavex® specialists and we will calculate the efficiency for you. How does the solids % of concentration by weight (Cw) of the feed stream impact the cut size and efficiency of the hydrocyclone? The solids % of concentration by weight (Cw) of the feed entering the hydrocyclone is an important factor. It will impact the cut size that a particular hydrocyclone can produce, particularly at high density. The higher the feed density to the hydrocyclone, the coarser the cut of that particular hydrocyclone. How can I find out how much of the solids in the feed will report to the underflow versus the overflow? To determine how many solids will report to each stream, it is important to gain a full understanding of the cyclone's feed conditions, including particle size distribution. For existing cyclone operations, you would need to measure the specific gravity of the cyclone feed, underflow and overflow to determine the amount of solids reporting to each stream. If you are unsure of how to do this, please get in touch with our team so we can help you. Features and benefits Improved Performance and Capacity The advanced LIG+™ laminar spiral inlet design enables the Cavex® 2 high-efficiency cyclone to classify up to 30% more feed slurry, while occupying the same footprint as other hydrocyclones. Ultimately, operators can now achieve more throughput with fewer operating hydrocyclones, reducing the upfront capital expenditure and resources required for operation. Increased Separation Efficiency The improved design, shape, angle and proportions of the Cavex® 2 high-efficiency cyclone ensure that fine particles (8-500 microns) pass through to the correct stream, rather than being returned for further processing. This optimises plant recovery by reducing the quantity of misclassified particles by an average of 10% and improving fines bypass by an average of 15%. Sustainability Benefits The Cavex® 2 hydrocyclone introduces a step-change in sustainability, with an advanced design that achieves the same separation as the original Cavex® hydrocyclone, but with significant water savings. The increased volume, capacity and separation efficiency of the Cavex® 2 hydrocyclone and its enhanced ability to separate fine particles, mean that less pressure is required to operate the hydrocyclone. This results in significant energy savings throughout the mill circuit. Cost Savings The increased capacity of the Cavex® 2 hydrocyclone presents an opportunity for operators to service and install spare classification cyclones while the cluster still operates, without the need to shut down operations, thus saving plant revenue. Customisable Options To ensure that the hydrocyclone meets your needs and application, a wide range of vortex finders and spigot sizes are available. You can also choose between multiple cone angles and feed chambers to maximise hydrocyclone separation and efficiency. In some instances, the Cavex® 2 hydrocyclone can retrofit into existing installations, even if the installation was designed for the original Cavex® cyclone or competitor products. Improved Safety Rather than using glue to secure hydrocyclone liners, we offer liners that snap into place within the housing. This eliminates the need to burn the rubber or adhesive and the risk of inhaling the fumes when removing old liners, improving the overall safety of employees. Another benefit of snap-in liners is that installation is a lot quicker and less messy compared to needing to apply glue. Suited to a Variety of Applications To suit a wide range of applications, a selection of tough housings (corrosion-resistant, polyester or carbon steel) and wear-resistant linings are available. Local After Sales Support All Cavex® classification cyclones are backed by our unrivalled global support network that spans across more than 60 countries world-wide. Our team are always there for you, no matter how remote your operation is. We can also service machinery on site for added convenience. Why Weir? At Weir, our team have been manufacturing high efficiency cyclones for over 45 years, with the original Cavex® hydrocyclone setting new industry benchmarks when introduced over 20 years ago. Our continued commitment to research and development means that we're always innovating and pursuing further improvements to ensure that our hydrocyclones stay at the forefront of the industry. With the addition of Cavex® 2 hydrocyclone, we provide a diverse range of classification cyclones of different sizes and capabilities. This allows us to proactively meet the varying needs of customers and their diverse applications with: • Our knowledgeable technical team • Reliable supply and inventory levels • Global presence and • Extensive after sales and service networks Applications The Cavex®2 high-efficiency cyclone is designed for heavy-duty industrial and abrasive applications where above-average wear rates are present, requiring frequent replacement of liners. These classification cyclones are renowned for their performance in separating solids and slurry thickening processes with a wide range of feed materials (e.g. desliming, dewatering and solids washing). Suitable to be used with the following feed materials: • Aggregate • Aluminium • Asphalt • Bauxite / Alumina • Biomass • Chrome • Coal • Concrete • Copper • FGD/ Power • Glass • Gold • Graphite • Gravel • Iron • Iron Ore • Kimberlite • Lead • Limestone • Lithium • Mineral Concentrate • Mineral Sands • Molybdenum • Nickel • Oil • Oil Sands • Other Hard Rock • Palladium • Phosphate • Platinum • Potash • Rare Earths • Salt • Sand and Aggregates • Silica Sand • Silver • Slag • Soda Ash • Sumps • Super Fines • Wastewater • Water with heavy solids • Water with light solids • Water with medium solids • Zinc Processes • Dredging • Fines Recovery • Fines Removal / Desliming • Heavy / Dense Medium Separation • Mill Circuit Dewatering • Primary Separation • Processing Fines • Producing Dry / Stackable Tailings • Secondary Separation • Tailings Recovery • Tertiary Separation • Thickening (Paste) • Tunneling • Water Recovery • Wet Classification Product specifications At Weir, we can develop customised hydrocyclone solutions and provide simulations, drawings and mass balances depending on your application and requirements. Replacement parts The highest-wearing parts of a high-efficiency cyclone are the spigot and apex. These will need to be replaced throughout the lifetime of your hydrocyclone, depending on the application. Product upgrades and modifications The Cavex® 2 high-efficiency cyclone can be customised to suit almost any application, with a variety of spigots, vortex finders and liners. Our team can also design them to retrofit into existing installations to maximise production and address any operational or maintenance issues. The Cavex® 2 hydrocyclone comes with a range of liner options including robust natural rubbers (e.g. R55®) or the industry-leading Linatex® premium rubber. The hydrocyclone's rubber lining can be replaced via a ‘snap-in’ system, requiring zero adhesive. Smaller models (i.e., 400CVD and below) are also available with moulded fibreglass housings. Other available upgrades include: • Our range of Air Core Boosters (ACB) Services and maintenance Cavex® hydrocyclones are backed by our unrivalled global support network that spans across more than 60 countries world-wide. This means that our experts are here to support you, every step of the way, wherever you may be. Our expert team will work alongside you to deliver: • Customised cluster solutions • Customised lining to maximise wear life and reliability and • Total hydrocyclone performance analysis Our extensive global network can provide services on site or at one of our 160+ dedicated service centres.