Liquid hydrocyclone KREBS®

Overview
KREBS® heavy-media hydrocyclones from FLSmidth provide high-efficiency separation of mineral particles from gangue using a fine magnetite-water dense medium. They deliver efficient separation at high feed rates with relatively low maintenance requirements compared with traditional static heavy-media vessels.

Key benefits

• High-efficiency separation — Centrifugal hydrocyclone action improves recovery of fine particles that static heavy-media vessels cannot recover efficiently; cyclones are cost-effective and normally require limited operator attention.
• Higher feed rates — Large-diameter designs accept larger top-size feed for efficient separation at increased throughput.
• Long service life — Thick ceramic tile inlet linings, pre-engineered interlocking liner components and heavy-duty monolithic ceramic protection at the lower cone and apex extend wear life in abrasive dense-media service.

Our heavy-media cyclones
Units handle top-size feed particles up to 102 mm (4 in.). Typical per-cyclone capacities range from ~77 tph (85 stph) up to ~894 tph (985 stph) depending on model and duty. Equipment is supplied as single hydrocyclones or multi-unit clusters with isolation valves, pressure gauges, piping, launders, support structures, instrumentation and accessories. Operation uses a dense medium (magnetite and/or ferrosilicon) suspended in water to establish density-based separation in a pressurised swirling flow.

Design and wear protection
To resist abrasive dense-media service, KREBS® cyclones use thick ceramic inlet tiles in two pre-engineered grades (typical thickness 25–38 mm / 1–1.5 in). Tiles are machined in the green state and fired to produce interlocking, serialised liner components for extended life. The lower cone and apex are protected by a heavy-duty monolithic ceramic lining.

Applications

• Coal cleaning (classic heavy-media separation application)
• Nickel, diamond and other industrial-mineral dense-media separation duties

Model comparison (selected values)
Note: values shown are representative per model/cyclone and correspond to typical manufacturer data for the compared sizes.
Model | Feed particle maximum size (in., mm) | Dry Feed Capacity (stph, mtph) | Pulp flowrate Range (gpm, m3/h) | Head equivalent (ft, m)
D20B | 3/4 in., 19 mm | 85 stph, 77 mtph | 1,050 gpm, 238 m3/h | 15 ft, 4.6 m
D26B | 1½ in., 38 mm | 150 stph, 136 mtph | 1,910 gpm, 434 m3/h | 20 ft, 6.1 m

Notes on testing and supply
FLSmidth supports validation testing (laboratory and site trials) and offers aftermarket services including maintenance training, spare parts and consumables, and cyclone rebuild/exchange programmes. Selection is supported by process evaluation to ensure correct equipment and cluster configuration for the application.

Technical specifications

• Commercial designation: KREBS® heavy-media hydrocyclones
• Manufacturer / brand: FLSmidth
• Top-size feed capability: up to 102 mm (4 in.)
• Typical per-cyclone capacity range: ~77 tph (85 stph) to ~894 tph (985 stph) depending on model and duty
• Pulp flowrate examples: ~1,050 gpm (238 m3/h) to ~1,910 gpm (434 m3/h) for selected models
• Head equivalent examples: ~15 ft (4.6 m) to ~20 ft (6.1 m) for selected models
• Dense medium: magnetite and/or ferrosilicon in water
• Wear protection: pre-engineered ceramic inlet tiles (25–38 mm / 1–1.5 in) and heavy-duty monolithic ceramic lining for lower cone and apex
• Supply options: single cyclones or multi-unit hydrocyclone clusters with valves, gauges, piping, launders, support structures and instrumentation