Prevention of Hydrocyclone Choking Through Detection of Sub-Hz Frequency Shift of Vibration Signal
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ORIGINAL PAPER
Prevention of Hydrocyclone Choking Through Detection of Sub‑Hz Frequency Shift of Vibration Signal Dilip Kumar Nayak1 · Debi Prasad Das2 · Santosh Kumar Behera2 · Sarada Prasad Das2 · Jitendra Kumar Sadangi2 Received: 10 November 2018 / Revised: 15 April 2019 / Accepted: 17 April 2019 © Krishtel eMaging Solutions Private Limited 2019
Abstract Purpose Hydrocyclones are extensively used in mineral processing and other industries to separate heavy and coarse particles from light and fine particles, respectively. Due to variation in the density of feed which contains water and particles, the hydrocyclone gets choked during continuous operation. Clearing the choking is a time-consuming and expensive affair which requires shutdown of the hydrocyclone. To prevent this, the hydrocyclone operation needs to be monitored continuously to alarm well before choking happens. Method A vibration sensing and analysis-based method is proposed in this paper to predict the choking condition well in advance. Vibration signals were collected by varying the solid percentage in the feed input to create choking condition. Vibration signal was processed using Fourier transform to observe the variations under different feed concentrations. Results and conclusions It was observed that higher slurry density in the feed input leads to choking of hydrocyclone. Vibration signal which is captured at the apex of the hydrocyclone is recommended here to be used to monitor the operational conditions of the hydrocyclone. After analysis of the captured vibration signals in frequency domain, it was found that there is shift of specific frequencies due to an increase in slurry density. By monitoring the shift in peak frequencies in those frequency ranges, the choking can be detected and cleared well in advance to avoid a shutdown of hydrocyclone. Keywords Vibration analysis · Hydrocyclone · Condition monitoring · Spectral analysis · Frequency shift
Introduction Mineral processing involves various processes for enhancing the grade of ores. Innovations in different processes are needed to achieve cost-effective mineral processing. Researchers have worked on both chemical and physical
* Debi Prasad Das [email protected] Dilip Kumar Nayak [email protected] Santosh Kumar Behera [email protected] Sarada Prasad Das [email protected] Jitendra Kumar Sadangi [email protected] 1
ITER, Siksha ‘O’ Anusandhan, Bhubaneswar, India
CSIR-Institute of Minerals and Materials Technology, Bhubaneswar, India
2
separation methods such as floatation, flocculation, and magnetic separation [1–5]. Out of many gravity-based separation processes, hydrocyclone is an important one. Hydrocyclone is a device which has no rotating parts. The pressurized slurry is fed tangentially at the top, and it classifies heavy and coarser particles from light and fine particles, respectively. The heavy or coarser particles are discharged from the bottom side named as “underflow” and the light or fine particles are taken up and removed through a separate pi
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