Solids separator CrossFlow XF

hydrodynamicfor oremining

Overview
The CrossFlow Separator is a fluidized-bed (teeter-bed) hydraulic classifier engineered for industrial mineral processing. It separates solids by particle size, shape and density using an upward flow of fluidising water and a top-fed slurry design to ensure stable, repeatable and sharp cut-point separations. The teeter-bed of suspended solids behaves as a fluid where hydrodynamic forces govern particle interactions, enabling efficient elutriation of fines into the overflow while coarser, denser particles exit via the underflow.

Process Different Types of Ores

• Phosphate
• Potash
• Lithium
• Iron ore
• Coal
• Heavy minerals
• Mineral sands
• Others

Applications

• Sizing & classification for downstream processes
• Tailings classification (clean sand production)
• Density separation & concentration
• Washing & neutralization (counter-current washing capability)

Benefits
Superior Separation Efficiency

• Sharp cut sizes (d50) with minimal misplaced fines
• High selectivity by size and density for improved downstream performance
• Produces cleaner flotation feed or product streams

Lower Operating Costs

• Lower energy demand compared with hydrocyclones or vibrating screens
• Reduced maintenance due to no internal moving parts
• Increased equipment life and uptime
• Suitable for remote operations and high‑wear environments

Intelligent Control & Automation

• Optional sensors for bed pressure and water flow monitoring
• Real-time control adjustments to maintain optimal separation
• Easy PLC/DCS integration for process automation

Features
The CrossFlow is a high-capacity, fluidised-bed separator. Feed slurry is introduced across the top of the unit, producing a plug-flow descent against a uniform upward flow of fluidising water. This counter-current arrangement maintains a consistent vertical velocity profile across the section, improving separation sharpness and reducing bypass. The unit operates without internal moving parts, using distributed injection pipes and nozzles to ensure even fluidisation across the transversal section. Teeter water flow rate, bed pressure and bed level are controlled to tune cut size and separation sharpness.

Product Line — Models and Nominal Capacities (t/h)
Model | Feed Capacity (t/h) | Width (mm) | Length (mm)
CrossFlow XF-30 | 30 | 1500 | 1500
CrossFlow XF-50 | 50 | 1800 | 1800
CrossFlow XF-80 | 80 | 2400 | 2400
CrossFlow XF-130 | 130 | 3050 | 3050
CrossFlow XF-150 | 150 | 3300 | 3300
CrossFlow XF-200 | 200 | 3650 | 3650
CrossFlow XF-250 | 250 | 4250 | 4250

Technical specifications

• Separation principle: teeter-bed (fluidized-bed) hydraulic classification based on terminal settling velocity.
• Feed presentation: top-fed slurry design to minimise turbulence and maintain stable separation conditions.
• No internal moving parts; fluidisation via network of injection pipes and nozzles.
• Control variables: teeter water flow rate, bed pressure and bed level to tune cut size and sharpness.
• Available models and nominal feed capacities: XF-30 (30 t/h), XF-50 (50 t/h), XF-80 (80 t/h), XF-130 (130 t/h), XF-150 (150 t/h), XF-200 (200 t/h), XF-250 (250 t/h).
• Typical widths and lengths by model are indicated in the product line table.
• Primary uses: coarse desliming, gravity separation, cut-point classification, counter-current washing and acid neutralisation.
• Designed for high capacity, sharp cut-point classification with reduced maintenance and lower energy demand versus alternative technologies.