A pressure-compensated three-product dense medium cyclone separation device

Abstract

This invention proposes a pressure-compensated mineral processing three-product heavy medium cyclone separator, relating to the field of ore separation. The separator includes: a first-stage cyclone separator with a first feed inlet, a first cyclone chamber, a first overflow outlet, and a first underflow outlet; the first cyclone chamber includes a first cylindrical section and a first conical section connected together, the larger end of the first conical section connected to the first cylindrical section, the first underflow outlet located at the smaller end of the first conical section, and the first feed inlet connected to the first cylindrical section; a second-stage cyclone separator with a second feed inlet, a second cyclone chamber, a second overflow outlet, and a second underflow outlet, the second feed inlet connected to the first underflow outlet; the second cyclone chamber includes a second cylindrical section and a second conical section connected together, the larger end of the second conical section connected to the second cylindrical section, and the second feed inlet connected to the second cylindrical section; and a first pressurization channel connected to the first cylindrical section. This application solves the core technical defects of traditional equipment, such as low and fluctuating self-weight feeding pressure and insufficient and unstable centrifugal force field.

Description

Technical Field

[0001] This invention relates to the field of ore beneficiation technology, and more specifically, to a pressure-compensated mineral processing three-product heavy medium cyclone separator. Background Technology

[0002] Ore beneficiation is a core mineral processing technology in the field of ore processing. This technology mainly relies on the density differences of different components in the ore to achieve efficient separation of valuable minerals and gangue through physical action, thereby achieving the goal of mineral enrichment and purification. It is widely used in the processing and production of various minerals such as tungsten, tin, iron, and coal, and is a key link in enhancing the utilization value of mineral resources.

[0003] Three-product ore sorting equipment is a specialized device in the field of ore sorting that can produce three types of products—concentrate, middlings, and tailings—in a single operation. Traditional three-product ore sorting equipment often uses a structure of two hydrocyclones connected in series, with the feeding process relying entirely on the material's own weight. This feeding method has inherent technical defects such as low feed pressure and fluctuating pressure.

[0004] For complex ores with high density, wide particle size distribution, and poor selectivity, the above-mentioned feeding method is unable to provide a sufficient and stable centrifugal force field for the hydrocyclone separation process, which leads to a series of prominent technical problems: the separation accuracy (Ep value) cannot meet the process standards of industrial production, especially the separation efficiency of fine-grained minerals and near-density materials is significantly low; the equipment processing capacity is significantly limited by the feed pressure, making it difficult to match the large-scale production needs of large-scale concentrators; at the same time, this feeding method is prone to uneven flow field distribution, which leads to significant differences in the degree of wear of different parts of the equipment, with local excessive wear being particularly prominent, greatly shortening the overall service life of the equipment. Summary of the Invention

[0005] The purpose of this invention is to provide a heavy medium cyclone separator for three products in a pressure-compensated mineral processing system, which aims to solve the technical problems mentioned in the background art.

[0006] The embodiments of the present invention are implemented as follows: This application provides a pressure-compensated mineral processing three-product heavy medium cyclone separator, comprising: a first-stage cyclone separator having a first feed inlet, a first cyclone chamber, a first overflow port, and a first underflow port; wherein the first cyclone chamber includes a first cylindrical section and a first conical section connected in communication, the larger end of the first conical section being connected to the first cylindrical section, the first underflow port being located at the smaller end of the first conical section, and the first feed inlet being connected to the first cylindrical section; a second-stage cyclone separator having a second feed inlet, a second cyclone chamber, a second overflow port, and a second underflow port, wherein the second feed inlet is connected to the first underflow port; wherein the second cyclone chamber includes a second cylindrical section and a second conical section connected in communication, the larger end of the second conical section being connected to the second cylindrical section, the second underflow port being located at the smaller end of the second conical section, and the second feed inlet being connected to the second cylindrical section; and a first pressurization channel connected to the first cylindrical section for tangentially feeding pressurized gas into the first cylindrical section.

[0007] In the above technical solution, the first pressurization channel can tangentially send pressurized gas into the cylinder to directly supplement the feed pressure. Moreover, the tangential gas delivery method matches the rotational motion direction of the fluid in the hydrocyclone, which will not cause flow field disturbance and can effectively ensure the stability of the pressure state, providing a basic pressurization effect for the construction of the centrifugal force field.

[0008] Furthermore, based on the aforementioned scheme, a second pressurizing channel is also included, which is connected to the first cylindrical section and is used to tangentially feed pressurized gas into the first cylindrical section; wherein the first pressurizing channel and the second pressurizing channel are arranged at intervals along the axial direction of the first cylindrical section.

[0009] In the above technical solution, the dual tangential pressurization channels arranged axially at intervals along the first cylindrical section can provide segmented pressurization along the slurry flow path, avoiding the problem of axial pressure attenuation in single-channel pressurization. This makes the pressure distribution in the cyclone chamber more uniform and the centrifugal force field more stable, thereby improving the separation accuracy and optimizing the flow field to reduce local wear.

[0010] Furthermore, based on the aforementioned scheme, the aforementioned hydrocyclone includes a first end cap, a first annular cylinder, a second annular cylinder, a first conical cylinder, and a second end cap connected coaxially in sequence. The first end cap, the first annular cylinder, the second annular cylinder, the first conical cylinder, and the second end cap together form the first swirling cavity. The first annular cylinder and the second annular cylinder together constitute the first cylindrical section, and the first conical cylinder constitutes the first conical section. The inner diameter of the first annular cylinder and the inner diameter of the second annular cylinder are both equal to the inner diameter of the large end of the first conical cylinder.

[0011] In the above technical solution, the hydrocyclone adopts a multi-segment coaxial splicing structure and makes the inner diameter of the first annular cylinder and the second annular cylinder consistent with the inner diameter of the large end of the first conical cylinder. This can avoid fluid disturbance caused by abrupt changes in the inner diameter of the cyclone cavity, making the slurry cyclone movement smoother, effectively optimizing the flow field distribution inside the first cyclone cavity, improving the stability of the centrifugal force field and the separation accuracy. At the same time, the split splicing structure also facilitates the processing, assembly and replacement and maintenance of worn parts in the later stage, reducing the equipment operation and maintenance costs.

[0012] Furthermore, based on the aforementioned scheme, the first end cap and the first annular cylinder, the first annular cylinder and the second annular cylinder, the second annular cylinder and the first conical cylinder, and the first conical cylinder and the second end cap are all detachably connected by a flange bolt structure.

[0013] In the above technical solution, each splicing section of the hydrocyclone adopts a flange bolt structure for detachable connection, which is convenient for disassembly and assembly. Weary single-section components can be replaced individually without replacing the whole system, which greatly reduces equipment maintenance costs and maintenance difficulty. At the same time, the flange bolt connection has good sealing performance and structural stability, which can ensure the sealing effect of the hydrocyclone cavity under high pressure conditions and avoid fluid leakage from affecting the sorting effect.

[0014] Furthermore, based on the aforementioned scheme, the two-stage hydrocyclone includes a third end cap, a third annular cylinder, a second conical cylinder, and a fourth end cap connected coaxially in sequence. The third end cap, the third annular cylinder, the second conical cylinder, and the fourth end cap together form the second cyclone cavity. The third end cap and the third annular cylinder together constitute the second cylindrical section, and the second conical cylinder constitutes the second conical section. The inner diameter of the third end cap, the inner diameter of the third annular cylinder, and the inner diameter of the large end of the second conical cylinder are all equal.

[0015] In the above technical solution, the two-stage hydrocyclone adopts a structural design in which the third end cap, the third annular cylinder, the second conical cylinder, and the fourth end cap are coaxially spliced ​​together. The inner diameter of the third end cap is consistent with the inner diameter of the large end of the second conical cylinder, which can avoid fluid disturbance caused by abrupt change in the inner diameter of the flow channel of the two-stage hydrocyclone, optimize the distribution of the internal swirling field of the two stages, and improve the stability of the centrifugal force field and the sorting accuracy of the secondary separation. At the same time, the simple three-stage coaxial splicing structure also facilitates the processing, assembly, and subsequent inspection and maintenance of the equipment.

[0016] Furthermore, based on the aforementioned scheme, the third end cap and the third annular cylinder, the third annular cylinder and the second conical cylinder, and the second conical cylinder and the fourth end cap are all detachably connected by a flange bolt structure.

[0017] In the above technical solution, each splicing section of the two-stage hydrocyclone is detachably connected by a flange bolt structure, which is convenient for disassembly, assembly and maintenance. Worn individual sections can be replaced individually without replacing the whole section, which greatly reduces equipment maintenance costs and maintenance difficulty. At the same time, the flange bolt connection has excellent sealing performance and structural stability, which can ensure the sealing effect of the two-stage hydrocyclone chamber under high pressure conditions, avoid fluid leakage from interfering with the secondary sorting process, and ensure the accuracy and efficiency of secondary sorting.

[0018] Furthermore, based on the aforementioned scheme, the axis of the first swirling cavity is arranged parallel to the axis of the second swirling cavity.

[0019] In the above technical solution, setting the axes of the first cyclone chamber and the second cyclone chamber parallel can greatly optimize the overall spatial layout of the equipment, effectively reduce the equipment footprint, adapt to production workshops with limited space, and at the same time make the material conveying channel from the underflow of the first cyclone to the second cyclone smoother, reduce the pressure loss caused by fluid bends, ensure the pressure stability of the second-stage separation, and facilitate the overall installation, commissioning and subsequent maintenance of the equipment.

[0020] Furthermore, based on the aforementioned scheme, it also includes a mounting frame, on which both the first-stage hydrocyclone and the second-stage hydrocyclone are mounted, and the axes of both the first-stage hydrocyclone and the second-stage hydrocyclone extend in the horizontal direction.

[0021] In the above technical solution, the installation provides installation positions for the first-stage hydrocyclone and the second-stage hydrocyclone, so as to achieve stable fixation of the two hydrocyclones, reduce vibration disturbance during equipment operation, and ensure sorting stability.

[0022] Furthermore, based on the aforementioned scheme, it also includes a first discharge pipe, one end of which is connected to the first vortex chamber and the connection is located at the second end cap, and the other end of which forms the first underflow port and is connected to the second inlet port; wherein, the first discharge pipe is configured to tangentially feed its internal material into the second vortex chamber.

[0023] In the above technical solution, the first discharge pipe tangentially feeds the internal material into the second cyclone chamber, which allows the underflow material of the first-stage hydrocyclone to directly form a stable swirling motion in the second-stage cyclone chamber, avoiding flow field disturbances caused by improper feeding direction, while reducing pressure loss during material conveying, ensuring the strength and stability of the centrifugal force field in the second-stage separation, and effectively improving the accuracy and efficiency of secondary separation.

[0024] Furthermore, based on the aforementioned scheme, the taper of the first conical segment is equal to the taper of the second conical segment.

[0025] In the above technical solution, setting the first conical section and the second conical section to have the same taper can match the rotation acceleration law of the fluid in the two hydrocyclones, ensuring the continuity of the swirling motion of the material after it enters the second swirling chamber from the bottom flow of the first section, avoiding flow field disturbance and pressure loss caused by taper difference, strengthening the stability and consistency of the overall centrifugal force field, and improving the secondary sorting accuracy. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a structural diagram of a three-product heavy medium cyclone separator according to an embodiment of the present invention; Figure 2 This is a schematic diagram of a section of a hydrocyclone according to an embodiment of the present invention; Figure 3 This is a partial cross-sectional view of a hydrocyclone according to an embodiment of the present invention; Figure 4 This is a cross-sectional view of the second-stage hydrocyclone according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of the second-stage hydrocyclone according to an embodiment of the present invention.

[0028] Icons: 1- Mounting bracket, 2- First stage hydrocyclone, 201- First cylindrical section, 21- First overflow port, 22- First feed port, 23- First end cap, 24- First annular cylinder, 25- Second annular cylinder, 26- First conical cylinder, 27- Second end cap, 28- First underflow port, 3- Second stage hydrocyclone, 301- Second cylindrical section, 302- Second conical section, 31- Second overflow port, 32- Third end cap, 33- Third annular cylinder, 34- Second conical cylinder, 35- Fourth end cap, 36- Second underflow port, 37- Second feed port, 4- First discharge pipe, 5- First pressurization channel, 6- Second pressurization channel. Detailed Implementation

[0029] The embodiments of this application will now be described in detail with reference to the accompanying drawings. Example

[0030] Currently, the hydrocyclones used in heavy medium concentrators are all pressureless three-product heavy medium hydrocyclones. This equipment can separate three products in one pass: heavy ore, middlings ore, and light ore. Light ore is a low-density product with a density of <2.8 g / cm³, mainly gangue or low-density useful minerals (such as coal); middlings ore is an intermediate-density product with a density of ≈2.8 g / cm³, mostly mineral intergrowths (a combination of useful and useless minerals); heavy ore is a high-density product with a density of >2.8 g / cm³, which can be high-value concentrate or waste tailings (such as metallic minerals and gangue).

[0031] The pressureless three-product heavy medium hydrocyclone has several technical shortcomings in practical applications: First, the second-stage separation power is insufficient and the separation accuracy is limited. The inlet pressure of the second-stage hydrocyclone 3 relies entirely on the overflow pressure of the first-stage hydrocyclone 2, which easily leads to insufficient pressure and fluctuations. This results in a weak centrifugal force field in the second stage, insufficient control accuracy of separation density, and low separation efficiency of fine-grained minerals and materials of similar density, thus affecting the concentrate grade and recovery rate. Second, the development of large-scale equipment and the improvement of processing capacity have encountered bottlenecks. The pressureless feeding method limits the feed rate and slurry throughput, making it difficult to further increase the single-unit processing capacity. Third, it has poor adaptability to ore properties. This equipment is more suitable for coal and other materials with low density and easy crushing. For materials with high density, high hardness, and wide particle size range, pressureless feeding cannot provide sufficient kinetic energy to achieve effective mineral stratification. Moreover, the ore will cause severe wear on the hydrocyclone lining, especially the first section of the cylinder, resulting in high equipment maintenance costs. Fourth, the process system and control flow are complex, requiring independent configuration and precise control of high and low density suspension systems, which makes daily management difficult. In addition, the system has a large inertia, and the automatic detection and feedback control of key process parameters such as density and pressure are slow to respond, making it difficult to ensure the stability of product quality. Fifth, the separation effect of fine minerals is poor, and the separation efficiency of ultra-fine particles with a particle size <0.5mm is significantly reduced, which easily leads to the loss of fine metal minerals.

[0032] Please refer to Figures 1-5This application provides a three-product heavy medium cyclone separator for pressure-compensated mineral processing, comprising: a first-stage cyclone separator 2, having a first feed inlet 22, a first cyclone chamber, a first overflow outlet 21, and a first underflow outlet 28; wherein the first cyclone chamber includes a first cylindrical section 201 and a first conical section connected in communication, the large end of the first conical section being connected to the first cylindrical section 201, the first underflow outlet 28 being located at the small end of the first conical section, and the first feed inlet 22 being connected to the first cylindrical section 201; and a second-stage cyclone separator 3, having a second feed inlet 37 and a second cyclone chamber. The second overflow port 31 and the second underflow port 36 are connected to the second feed port 37, which is connected to the first underflow port 28. The second vortex chamber includes a second cylindrical section 301 and a second conical section 302 connected to each other. The large end of the second conical section 302 is connected to the second cylindrical section 301. The second underflow port 36 is located at the small end of the second conical section 302. The second feed port 37 is connected to the second cylindrical section 301. The first pressurization channel 5 is connected to the first cylindrical section 201 and is used to tangentially feed pressurized gas into the first cylindrical section 201.

[0033] This equipment consists of a first-stage hydrocyclone 2 and a second-stage hydrocyclone 3 connected in series with a first pressurization channel 5. The material enters the first cyclone chamber of the first-stage hydrocyclone 2 from the first feed inlet 22 and forms a cyclone. Under the action of centrifugal force, the material is initially separated. The heavier, high-density, coarse-grained heavy phase material flows out from the first underflow port 28 and enters the second cyclone chamber of the second-stage hydrocyclone 3 through the second feed inlet 37. The lighter, low-density, fine-grained light phase material is discharged from the first overflow port 21 as concentrate. The material entering the second cyclone chamber forms a cyclone again and completes secondary separation. The heavier material is discharged from the second underflow port 36 as tailings, and the lighter material is discharged from the second overflow port 31 as middlings. Finally, the concentrate, middlings, and tailings are produced in one go through the first overflow port 21, the second overflow port 31, and the second underflow port 36.

[0034] The aforementioned hydrocyclone separator addresses the core technical shortcomings of traditional equipment, namely, low and fluctuating self-weight feeding pressure and insufficient and unstable centrifugal force field, through a dual pressurization method of active pressurization via the first pressurization channel 5 and passive pressurization via the conical section structure. On the one hand, the first pressurization channel 5, connected to the first cylindrical section 201, can tangentially introduce pressurized gas into the cylinder to directly supplement the feed pressure. Moreover, the tangential gas delivery method matches the rotational motion direction of the fluid inside the hydrocyclone, preventing flow field disturbance and effectively ensuring the stability of the pressure state, thus providing a basic pressurization effect for the construction of the centrifugal force field. On the other hand, the first conical section of the first-stage hydrocyclone 2 and the second conical section 302 of the second-stage hydrocyclone 3 both adopt a reduced-diameter structure with the large end connected to the cylindrical section and the small end set with the underflow port. When the fluid rotates in the conical section, the flow velocity will naturally increase as the cavity diameter gradually decreases, forming a secondary pressurization through structural characteristics, further enhancing the strength and stability of the centrifugal force field. The dual pressurization creates a sufficient and stable centrifugal force field, which not only effectively improves the sorting accuracy (Ep value) and significantly improves the sorting efficiency of fine-grained minerals and near-density materials, but also breaks through the limitation of feed pressure on the equipment's processing capacity, making it compatible with the large-scale production needs of large-scale concentrators; it also optimizes the flow field distribution inside the equipment, making the wear of each part more uniform, significantly alleviating the problem of excessive local wear, and greatly extending the overall service life of the equipment.

[0035] It is worth noting that the hydrocyclone mainly achieves material separation by utilizing the centrifugal force exerted on the material within its internal channels. The material enters the hydrocyclone tangentially from the inlet and moves spirally along the inner wall of the hydrocyclone. Simultaneously, the material is pushed axially along the internal channels. The larger the mass of the material component, the greater the centrifugal force it experiences, and the more it moves radially to the outside of the rotating flow field. The smaller the mass of the material component, the smaller the centrifugal force it experiences, and the more it forms an internal vortex within the rotating flow field, pushing the smaller material component in the opposite direction to the movement of the larger material component.

[0036] The first and second cone sections 302 are both equipped with alumina wear-resistant corundum bricks to enhance the wear resistance of the first-stage hydrocyclone 2 and the second-stage hydrocyclone 3.

[0037] In a preferred embodiment, a second pressurizing channel 6 is also included, which is connected to the first cylindrical section 201 and is used to tangentially feed pressurized gas into the first cylindrical section 201; wherein the first pressurizing channel 5 and the second pressurizing channel 6 are arranged at intervals along the axial direction of the first cylindrical section 201.

[0038] In the above embodiment, a second pressurizing channel 6 is added to the first pressurizing channel 5. Both are connected to the first cylindrical section 201 and are arranged at intervals along the axial direction of the cylindrical section. At the same time, the pressurizing gas is introduced tangentially. The principle is that by using the dual pressurizing channels to supplement the pressure in segments at different axial positions of the first cylindrical section 201, the pressurizing gas gradually supplements the pressure along the flow path of the slurry in the cylinder. This not only matches the natural flow trend of the slurry from the feed inlet to the cone section, but also effectively avoids the problem of pressure attenuation along the axial direction when pressurizing with a single channel. This creates a swirling pressure field with uniform axial distribution and stable intensity in the first cylindrical section 201, providing continuous and stable power support for the subsequent acceleration and pressurization of the slurry entering the first cone section. The advantages of this design are significant. Compared to single pressurization channels or circumferentially spaced arrangements, the axially spaced dual pressurization channels enable precise control of the pressure across the entire first cylindrical section 201. This not only further compensates for the pressure limitations of traditional unpressurized feeding, ensuring the sufficiency and stability of the centrifugal force field, and significantly improving the stratification efficiency and sorting accuracy of fine-grained and adjacent-density materials, but also makes the slurry flow within the cylinder smoother, reducing flow field disturbances caused by sudden local pressure changes, alleviating localized wear on the equipment lining, and extending the equipment's service life. Simultaneously, the dual axial pressurization channels can flexibly adjust the air pressure and flow rate at different axial positions according to the density and particle size characteristics of the ore, adapting to complex sorting conditions such as high-density, high-hardness, and wide-range particle size metal ores, thus improving the equipment's adaptability. Furthermore, it can further increase the slurry throughput, helping to overcome the bottleneck of single-machine processing capacity.

[0039] In a preferred embodiment, the aforementioned hydrocyclone 2 includes a first end cap 23, a first annular cylinder 24, a second annular cylinder 25, a first conical cylinder 26, and a second end cap 27 connected coaxially in sequence. The first end cap 23, the first annular cylinder 24, the second annular cylinder 25, the first conical cylinder 26, and the second end cap 27 together form the first swirling cavity. The first annular cylinder 24 and the second annular cylinder 25 together constitute the first cylindrical section 201, and the first conical cylinder 26 constitutes the first conical section. The inner diameters of the first annular cylinder 24 and the second annular cylinder 25 are equal to the inner diameter of the large end of the first conical cylinder 26.

[0040] In the above embodiment, the hydrocyclone 2 adopts a split structure in which the first end cap 23, the first annular cylinder 24, the second annular cylinder 25, the first conical cylinder 26, and the second end cap 27 are coaxially connected in sequence. The principle is that the inner diameter of the two annular cylinders constituting the first cylindrical section 201 is set to be completely equal to the inner diameter of the large end of the first conical cylinder 26, so that a smooth flow channel with no sudden change in inner diameter is formed inside the first cyclone cavity. After the slurry enters from the first feed port 22, it can smoothly rotate at high speed along the flow channel. It will not cause eddies or flow field disturbances due to sudden changes in the flow channel size, and it can also reduce the pressure loss during the flow of slurry, laying the foundation for the construction of a stable centrifugal force field. The advantages of this design are significant. On the one hand, the smooth flow channel with a consistent inner diameter ensures the stability and uniformity of the swirling field, avoiding local flow field turbulence from affecting the centrifugal stratification effect and greatly improving the sorting accuracy of fine-grained and adjacent-density materials. On the other hand, the split-type coaxial splicing structure not only facilitates the processing, manufacturing, assembly, and debugging of each component, but also allows for the individual replacement of easily worn annular or conical cylinders without the need for overall equipment disassembly, effectively reducing subsequent maintenance costs and repair difficulties. At the same time, the segmented cylindrical section design allows for flexible adjustment of the annular cylinder length according to the sorting requirements of different ores, adapting to diverse sorting conditions.

[0041] Preferably, the first bottom outlet 28 is located at the small end of the first conical cylinder 26, and the first overflow outlet 21 is located at the first end cap 23 and is positioned close to the first feed inlet 22.

[0042] In a preferred embodiment, the first end cap 23 and the first annular cylinder 24, the first annular cylinder 24 and the second annular cylinder 25, the second annular cylinder 25 and the first conical cylinder 26, and the first conical cylinder 26 and the second end cap 27 are all detachably connected by a flange bolt structure.

[0043] In the above embodiment, relying on the rigid connection and positioning characteristics of the flange bolt structure, the first end cap 23, the first annular cylinder 24, the second annular cylinder 25, the first conical cylinder 26, and the second end cap 27 of a section of hydrocyclone 2 are sequentially coaxially and detachably spliced. This ensures the coaxiality of each component through the precise positioning of the flange, ensuring that the first cyclone cavity forms a smooth flow channel with no abrupt change in inner diameter after splicing. It also strengthens the sealing performance of each connection part with the tightening force of the bolts, effectively coping with the high-pressure working environment inside the hydrocyclone, while retaining the flexibility of individual disassembly and assembly of each component. The advantages of this design are significant. First, it greatly reduces equipment maintenance costs and repair difficulty. When easily worn parts such as the first annular cylinder 24 and the first conical cylinder 26 are damaged due to high-speed impact of slurry, it is not necessary to replace the entire hydrocyclone 2 section. Only the flange bolts of the corresponding parts need to be disassembled to replace the worn parts individually, significantly shortening the maintenance time. Second, it ensures the stability of the flow field and the sorting accuracy. The high-precision positioning of the flange connection can maintain the coaxiality of each component for a long time, avoiding sudden changes in the inner diameter of the flow channel due to assembly deviations, preventing flow field disturbances, thereby stabilizing the centrifugal force field and improving the sorting effect of fine-grained and adjacent-density materials. Third, it has strong adaptability to working conditions. Different lengths of annular cylinders or different taper cones can be flexibly replaced according to the sorting requirements of different ores without redesigning the overall structure. It is suitable for diverse mineral processing scenarios, and the excellent sealing effect of the bolt tightening can effectively prevent high-pressure slurry leakage, ensuring a clean production environment and stable sorting process.

[0044] In a preferred embodiment, the two-stage cyclone separator 3 includes a third end cap 32, a third annular cylinder 33, a second conical cylinder 34, and a fourth end cap 35 connected coaxially in sequence. The third end cap 32, the third annular cylinder 33, the second conical cylinder 34, and the fourth end cap 35 together form the second cyclone cavity. The third end cap 32 and the third annular cylinder 33 together constitute the second cylindrical section 301, and the second conical cylinder 34 constitutes the second conical section 302. The inner diameters of the third end cap 32, the third annular cylinder 33, and the large end of the second conical cylinder 34 are all equal. Optionally, the ratio of the inner diameter of the third annular cylinder 33 to the inner diameter of the fourth end cap 35 is 2.5:1.

[0045] In the above embodiment, a split structure is adopted in which the third end cap 32, the second conical cylinder 34, and the fourth end cap 35 are coaxially connected in sequence. The principle is that the inner diameter of the third end cap 32 constituting the second cylindrical section 301 is set to be completely equal to the inner diameter of the large end of the second conical cylinder 34, so that the second swirling cavity forms a smooth flow channel without abrupt changes in inner diameter. After the material flowing from the bottom of the first-stage swirling device 2 enters through the second feed port 37, it can smoothly rotate at high speed along the flow channel. This avoids eddies and pressure losses caused by abrupt changes in flow channel size, and ensures the stability and uniformity of the two-stage swirling field, thus creating a continuous and stable centrifugal force field for secondary separation. The advantages of this design are significant. First, it effectively improves the accuracy of secondary sorting. The smooth flow channel reduces flow field disturbance and enhances the centrifugal stratification effect, which can greatly improve the sorting efficiency of fine-grained and near-density materials, solving the problems of insufficient power and limited accuracy in the secondary sorting of traditional pressureless equipment. Second, it simplifies the processing and maintenance process. The split structure facilitates the individual processing and manufacturing of each component. When easily worn parts such as the second conical cylinder 34 are damaged due to slurry impact, they can be disassembled and replaced individually without replacing the entire secondary hydrocyclone 3, significantly reducing operation and maintenance costs and maintenance difficulty. Third, it enhances the adaptability to working conditions. The second conical cylinder 34 with different tapers can be flexibly replaced according to the sorting requirements of different ores, and the intensity of the secondary centrifugal force field can be adjusted to adapt to the sorting of metal ores with high density, high hardness, and wide particle size range. At the same time, the precise coaxial assembly can maintain the smoothness of the flow channel for a long time, avoiding additional wear and slurry leakage caused by component misalignment, and ensuring the stability of equipment operation.

[0046] Preferably, the second feed inlet 37 is disposed on the third end cap 32, the second overflow outlet 31 is also disposed on the third end cap 32, and the second bottom outlet 36 is disposed on the fourth end cap 35.

[0047] In a preferred embodiment, the third end cap 32 and the third annular cylinder 33, the third annular cylinder 33 and the second conical cylinder 34, and the second conical cylinder 34 and the fourth end cap 35 are all detachably connected by a flange bolt structure.

[0048] In the above embodiment, relying on the rigid fastening and precise positioning characteristics of the flange bolts, the third end cap 32, the third annular cylinder 33, the second conical cylinder 34, and the fourth end cap 35 of the two-stage hydrocyclone 3 are coaxially and detachably spliced. The positioning surface of the flange ensures the coaxiality of each component and ensures the consistency between the inner diameter of the third end cap 32 and the inner diameter of the large end of the second conical cylinder 34, so that the second cyclone cavity forms a smooth flow channel without abrupt changes in inner diameter. The pre-tightening force of the bolts enhances the sealing performance of each connection part, which can cope with the high-pressure cyclone working conditions in the hydrocyclone and prevent slurry leakage, while retaining the flexibility of individual disassembly and assembly of each component. The advantages of this design are significant. First, it greatly reduces equipment maintenance costs and repair difficulty. As a core component of the second-stage hydrocyclone 3 that is prone to wear, when the second conical cylinder 34 is worn or damaged due to high-speed impact of the slurry, it is not necessary to replace the entire second-stage hydrocyclone 3. Only the flange bolts of the corresponding part need to be disassembled to replace the worn part, which significantly shortens the maintenance time. Second, it ensures the accuracy and stability of secondary separation. The high-precision positioning of the flange connection can maintain the coaxiality of each component for a long time, avoiding flow field disturbances caused by abrupt changes in the flow channel due to assembly deviations. This allows the material entering from the underflow of the first-stage hydrocyclone 2 to form a stable and sufficiently strong centrifugal force field, which greatly improves the secondary separation efficiency of fine-grained and near-density materials. Third, it enhances the adaptability of the equipment to different operating conditions. The second conical cylinder 34 with different tapers can be flexibly replaced according to the separation requirements of different ores to adjust the strength of the second-stage centrifugal force field, adapting to the separation of metal ores with high density, high hardness, and wide particle size range. At the same time, the excellent sealing effect of the bolt tightening can effectively suppress the leakage of high-pressure slurry and maintain the stability of equipment operation.

[0049] In a preferred embodiment, the axis of the first swirling cavity is arranged parallel to the axis of the second swirling cavity.

[0050] In the above embodiment, the axes of the first cyclone chamber and the second cyclone chamber are set to be parallel, so that the first-stage cyclone 2 and the second-stage cyclone 3 form a regular layout. The flow channel from the first underflow port 28 of the first-stage cyclone 2 to the second inlet port 37 of the second-stage cyclone 3 can be designed to be straighter, reducing the bending angle in the conveying path, avoiding the disruption of the cyclone movement trend of the material due to the bending of the flow channel, and reducing the pressure loss of the material during the conveying process. This ensures the stability of the feed pressure of the second-stage cyclone 3 and lays the foundation for building a stable centrifugal force field for secondary separation. The advantages of this design are significant. First, it effectively optimizes the overall spatial layout of the equipment. The parallel axis arrangement significantly reduces the horizontal and vertical space occupied by the equipment, making it more suitable for space-constrained mineral processing workshops and improving site utilization. Second, it reduces pressure loss during material transport. The straight flow path allows material discharged from the first stage to smoothly enter the second-stage cyclone chamber, avoiding pressure fluctuations caused by flow path bends. This further enhances the stability of the centrifugal force field in the second stage and improves the secondary separation accuracy of fine-grained and near-density materials. Third, it facilitates equipment installation, commissioning, and subsequent maintenance. The neat and parallel layout makes it easier for staff to perform coaxiality calibration of the hydrocyclones, pipeline connections, and component maintenance, reducing operational difficulty. Fourth, it avoids flow field disturbances during material transport. The straight transport path maintains the swirling inertia of the material, allowing it to quickly form a stable swirling flow after entering the second-stage cyclone chamber. This reduces the interference of abnormal flow fields such as eddies on the separation effect and ensures stable separation quality of concentrate, middlings, and tailings.

[0051] In a preferred embodiment, the device also includes a mounting frame 1, on which the first-stage hydrocyclone 2 and the second-stage hydrocyclone 3 are both mounted, and the axes of the first-stage hydrocyclone 2 and the second-stage hydrocyclone 3 extend in the horizontal direction.

[0052] In the above embodiment, the axes of both hydrocyclones extend horizontally, which allows the material conveying channel from the underflow of the first hydrocyclone 2 to the second hydrocyclone 3 to be designed to be straighter, minimizing bending losses during material conveying, avoiding pressure loss, ensuring the stability of the feed pressure of the second hydrocyclone 3, thereby strengthening the centrifugal force field intensity of secondary separation and improving the separation accuracy of fine-grained and adjacent-density materials.

[0053] In a preferred embodiment, the system further includes a first discharge pipe 4, one end of which is connected to the first vortex chamber and the connection is located at the second end cap 27. The other end of the first discharge pipe 4 forms the first underflow port 28 and is connected to the second inlet port 37. The first discharge pipe 4 is configured to tangentially feed its internal material into the second vortex chamber.

[0054] In the above embodiment, the first discharge pipe 4 tangentially feeds the underflow material from the first hydrocyclone 2 into the second hydrocyclone chamber, allowing the material to directly enter the second hydrocyclone chamber with its swirling inertia without needing to re-establish swirling motion. This significantly reduces flow field disturbance and pressure loss, ensuring the stability and strength of the centrifugal force field in the second hydrocyclone chamber. Simultaneously, the tangential feeding method allows the material to quickly integrate into the second-stage swirling stratification process, improving the secondary separation accuracy and efficiency of fine-grained and near-density materials, and reducing the loss of valuable minerals. Furthermore, the precise connection of the discharge pipe ensures a straighter conveying path for the underflow from the first stage, avoiding slurry impact caused by improper feeding direction, reducing wear on the lining of the second hydrocyclone 3, and extending the equipment's service life. Moreover, this connection design makes the separation process between the first and second stages smoother, further optimizing the overall equipment's separation performance and adapting to complex separation conditions such as high-density, high-hardness, and wide-range particle size metal ores.

[0055] Optionally, the second overflow port 31 is parallel to the second underflow port 36, allowing smaller materials in the second-stage hydrocyclone 3 to be fully discharged from the second overflow port 31. The horizontal arrangement of the first-stage hydrocyclone 2 and the second-stage hydrocyclone 32 allows the materials in the first-stage hydrocyclone 2 and the materials in the second-stage hydrocyclone 3 to be separated under the action of the flow field, reducing the influence of material gravity on the separation effect.

[0056] In a preferred embodiment, the taper of the first conical segment is equal to the taper of the second conical segment 302.

[0057] In the above embodiment, setting the first conical section and the second conical section 302 to have the same taper can match the rotation acceleration law of the fluid in the two hydrocyclones, ensuring the continuity of the swirling motion of the material after it enters the second swirling chamber from the bottom flow of the first section, avoiding flow field disturbance and pressure loss caused by taper difference, strengthening the stability and consistency of the overall centrifugal force field, and improving the secondary sorting accuracy.

[0058] Optionally, the taper of the first conical segment and the second conical segment 302 can be set to be greater than 20°.

[0059] Furthermore, unless otherwise explicitly specified or limited, the terms "installation" and "connection" in this application embodiment should be interpreted broadly. For example, "connection" can be a detachable connection or a non-detachable connection; it can be a direct connection or an indirect connection through an intermediate medium. The terms "upper," "lower," "left," "right," "inner," "outer," and "side," etc., are merely for reference to the direction in the accompanying drawings or the usual placement of the product during use. They are only for clearly describing this application and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. They should not be construed as limitations on this application. The terms "first," "second," etc., are only used for distinguishing descriptions and should not be construed as indicating or implying relative importance; "multiple" refers to at least two. In this application embodiment, the limitations on relative positional relationships such as parallel, perpendicular, and aligned are all relative to the current technological level and are not absolutely strict limitations. Slight deviations are allowed; approximations of parallel, perpendicular, and aligned are all acceptable. For example, "A and B are parallel" means that A and B are parallel or approximately parallel, and the angle between A and B can be between 0 degrees and 10 degrees.

[0060] The above are only some embodiments and implementation methods of this application. The protection scope of this application is not limited thereto. In the absence of conflict, the embodiments and features in the embodiments of this application can be combined with each other. Any combination of features in different embodiments is also within the protection scope of this application. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the protection scope of this application.

Claims

1. A pressure-compensated mineral processing three-product heavy medium cyclone separator, characterized in that, include: A hydrocyclone (2) has a first feed inlet (22), a first swirling chamber, a first overflow outlet (21) and a first underflow outlet (28); The first swirling cavity includes a first cylindrical section (201) and a first conical section that are connected to each other. The large end of the first conical section is connected to the first cylindrical section (201). The first underflow port (28) is located at the small end of the first conical section. The first feed port (22) is connected to the first cylindrical section (201). The two-stage hydrocyclone (3) has a second feed inlet (37), a second cyclone chamber, a second overflow outlet (31) and a second underflow outlet (36), wherein the second feed inlet (37) is connected to the first underflow outlet (28); The second swirling chamber includes a second cylindrical section (301) and a second conical section (302) that are connected to each other. The large end of the second conical section (302) is connected to the second cylindrical section (301). The second underflow port (36) is located at the small end of the second conical section (302). The second feed port (37) is connected to the second cylindrical section (301). The first pressurization channel (5) is connected to the first cylindrical section (201) and is used to tangentially feed pressurized gas into the first cylindrical section (201).

2. The pressure-compensated mineral processing three-product heavy medium cyclone separator according to claim 1, characterized in that, It also includes a second pressurization channel (6), which is connected to the first cylindrical section (201) and is used to tangentially feed pressurized gas into the first cylindrical section (201); The first pressurizing channel (5) and the second pressurizing channel (6) are arranged at intervals along the axial direction of the first cylindrical section (201).

3. The pressure-compensated mineral processing three-product heavy medium cyclone separator according to claim 1, characterized in that, The hydrocyclone (2) includes a first end cap (23), a first annular cylinder (24), a second annular cylinder (25), a first conical cylinder (26), and a second end cap (27) connected coaxially in sequence. The first end cap (23), the first annular cylinder (24), the second annular cylinder (25), the first conical cylinder (26), and the second end cap (27) together form the first swirling cavity. The first annular cylinder (24) and the second annular cylinder (25) together constitute the first cylindrical section (201), and the first conical cylinder (26) constitutes the first conical section; The inner diameters of the first annular cylinder (24) and the second annular cylinder (25) are equal to the inner diameter of the large end of the first conical cylinder (26).

4. The pressure-compensated mineral processing three-product heavy medium cyclone separator according to claim 3, characterized in that, The first end cap (23) and the first annular cylinder (24), the first annular cylinder (24) and the second annular cylinder (25), the second annular cylinder (25) and the first conical cylinder (26), and the first conical cylinder (26) and the second end cap (27) are all detachably connected by a flange bolt structure.

5. A pressure-compensated mineral processing three-product heavy medium cyclone separator according to claim 1, characterized in that, The two-stage cyclone separator (3) includes a third end cap (32), a third annular cylinder (33), a second conical cylinder (34), and a fourth end cap (35) connected coaxially in sequence. The third end cap (32), the third annular cylinder (33), the second conical cylinder (34), and the fourth end cap (35) together form the second cyclone cavity. The third end cap (32) and the third annular cylinder (33) together constitute the second cylindrical section (301), and the second conical cylinder (34) constitutes the second conical section (302); The inner diameter of the third end cap (32), the inner diameter of the third annular cylinder (33), and the inner diameter of the large end of the second conical cylinder (34) are all equal.

6. The pressure-compensated mineral processing three-product heavy medium cyclone separator according to claim 5, characterized in that, The third end cap (32) and the third annular cylinder (33), the third annular cylinder (33) and the second conical cylinder (34), and the second conical cylinder (34) and the fourth end cap (35) are all detachably connected by flange bolts.

7. The pressure-compensated mineral processing three-product heavy medium cyclone separator according to claim 1, characterized in that, The axis of the first swirling cavity is set parallel to the axis of the second swirling cavity.

8. The pressure-compensated mineral processing three-product heavy medium cyclone separator according to claim 1, characterized in that, It also includes a mounting frame (1), on which the first-stage cyclone separator (2) and the second-stage cyclone separator (3) are both mounted, and the axes of the first-stage cyclone separator (2) and the second-stage cyclone separator (3) extend in the horizontal direction.

9. A three-product heavy medium cyclone separator for pressure-compensated mineral processing according to claim 3, characterized in that, It also includes a first discharge pipe (4), one end of which is connected to the first vortex chamber and the connection is located at the second end cap (27). The other end of the first discharge pipe (4) forms the first underflow port (28) and is connected to the second inlet port (37). The first discharge pipe (4) is configured to tangentially feed its internal material into the second vortex chamber.

10. A pressure-compensated mineral processing three-product heavy medium cyclone separator according to claim 1, characterized in that, The taper of the first conical segment is equal to the taper of the second conical segment (302).

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