hydrocyclone

Abstract

A hydrocyclone comprising a main body having a separation chamber to deliver a first fluid stream to an upper outlet and a second stream to a lower outlet defined by a spigot; an overflow outlet control chamber mounted to the main body and in fluid flow communication with the separation chamber via the upper outlet, the overflow outlet control chamber including a discharge outlet and an upper opening remote from the overflow outlet in an upper portion of the overflow outlet control chamber; and an image sensor assembly including a sensor housing securable to the overflow outlet control chamber, the image sensor assembly further including an image sensor housed within the sensor housing so that the image sensor's field of view is orientated through the upper opening and upper outlet towards the spigot to capture image data relating to internal surface configuration or internal diameter of the hydrocyclone.

Description

[0001] HYDROCYCLONE

[0002] Technical Field

[0003] The present invention generally relates to a hydrocyclone and more particularly, but not exclusively, to a hydrocyclone suitable for use in the mineral and chemical processing industries. The invention is also concerned with a hydrocyclone wherein the internal surface configuration and / or internal diameter of the hydrocyclone at predefined locations can be measured and / or determined.

[0004] Background

[0005] Hydrocyclones are commonly used for separating suspended matter carried in a liquid into multiple discharge streams or “phases” of different densities. In the mining industry, for example, hydrocyclones may be used to separate particulates that are located in a slurry into a heavier (“coarser”) solid phase and a lighter (“finer”) solid phase, for classification purposes. A slurry is a two-phase mixture (a liquid with solid particles suspended or otherwise located therein).

[0006] During normal, stable operation of a hydrocyclone, fluid in the form of a slurry enters through an upper inlet of a hydrocyclone separation chamber in the form of an inverted cone, with the heavier solid phase discharged through a lower underflow outlet (also known as the spigot or apex) into an underflow tank and the lighter solid phase being discharged through an upper overflow outlet.

[0007] As the coarse particles rotate and fall toward the spigot, the density thereof increases and the abrasion caused thereby increases. Since the primary function of the spigot is to discharge the coarse material at the highest possible density, and since the amount of water leaving the cyclone with the coarse material is critical, the proper spigot diameter for a particular cyclone and set of operating conditions also is critical. If the spigot is too large due to wear, excessive amounts of water will pass out of the lower outlet of the cyclone. Such excessive amounts of water passing through the cyclone underflow outlet pull a high amount of fine particles that should otherwise be discharged through the upper outlet. The fine particles then unnecessarily pass back through the grinding mill, resulting in an inefficient milling operation.

[0008] The spigot is typically a cylindrical and / or conical body section with a liner which can be composed of loose ceramic, neoprene, urethane, or rubber, depending upon the abrasion and corrosion resistant properties needed for the material passing through the spigot. The primary function of the spigot is to discharge the coarse material at as high a density as possible without plugging the apex.

[0009] As the spigot and the spigot liner are prone to the highest wear it should be checked regularly to confirm the internal diameter is within acceptable ranges. To measure the internal diameter of the spigot, a gauge of the correct dimension can be inserted into the spigot through the underflow outlet. As the underflow outlet is located above the underflow tank a service engineer is required to enter inside the underflow tank during a plant stop to insert the gauge and measure the internal diameter of the spigot. This however increases risk to the service engineers and requires the classification line which the hydrocyclone forms part of to be stopped.

[0010] Approaches to reduce the need to measure the internal diameter of the spigot is to replace the spigot at scheduled intervals irrespective of the actual internal diameter. This may however lead to working parts being replaced too soon which increases operational cost or not replacing a worn spigot soon enough which may have a serious impact on downstream processes, often requiring additional processing (which, as will be appreciated, can greatly impact profits) and also result in accelerated machinery wear in the downstream processes.

[0011] It is an object of the invention to provide means which the Inventors believe will at least ameliorate this problem or other problems with the prior art, or provide a useful alternative.

[0012] Summary of Disclosure

[0013] According to a first aspect, there is provided a hydrocyclone for separating a fluid into a plurality of streams, the hydrocyclone comprising: a main body having a separation chamber therein, the separation chamber having an inlet for receiving the fluid, an upper outlet and a lower outlet, the separation chamber in communication with the inlet, upper outlet, and lower outlet to deliver a first fluid stream to the upper outlet and a second stream to the lower outlet, the lower outlet defined by a spigot attached to a lower end of the main body with the separation chamber and spigot coaxially aligned to define a central longitudinal axis; an overflow outlet control chamber mounted to the main body and in fluid flow communication with the separation chamber via the upper outlet, the overflow outlet control chamber further including a tangentially located discharge outlet and an upper opening remote from the overflow outlet in an upper portion of the overflow outlet control chamber; and an image sensor assembly including a sensor housing securable to the upper portion of the overflow outlet control chamber, the image sensor assembly further including an image sensor housed within the sensor housing so that the image sensor’s field of view is orientated through the upper opening and upper outlet towards the spigot to capture image data relating to internal surface configuration or internal diameter of the hydrocyclone.

[0014] The main body may include a cylindrical upper portion and a frusto-conical lower portion which tapers from the upper portion wherein an interior of the cylindrical upper portion and frusto-conical lower portion defines the separation chamber. The inlet may be configured to feed the fluid into the separation chamber at or close to the upper portion thereof generally tangentially to create a swirling flow of the fluid in the separation chamber. The image sensor may define a central focus axis which extends generally transversely through a lens of the image sensor. Optionally, image sensor may be secured to the image sensor housing so that the central focus axis of the image sensor is substantially parallel to the central longitudinal axis when the image sensor captures image data. Optionally, the image sensor may be secured to the image sensor housing so that the central focus axis of the image sensor is angled relative to the longitudinal axis at an angle between 0.1 and 20 degrees when the image sensor captures image data.

[0015] The overflow outlet control chamber may comprise a lower base which is securable to an upper surface of the main body, an upper base longitudinally spaced from the lower base and which defines the upper opening and a cylindrical body extending between the upper and lower base wherein the discharge outlet is located and the sensor housing is secured to the upper base. The lower base of the overflow outlet control chamber may comprises an annular flange securable to the upper surface of the separation chamber.

[0016] The image sensor housing may comprise an inverted cup-shaped body defining an internal cavity in which the image sensor is housed. It is to be appreciated, that the body of the image sensor may be any shape which defines an internal cavity. The sensor housing may comprise an annular flange which extends radially from a lower portion of the body and which is securable to the upper base around the upper opening.

[0017] The image sensor housing may be removably secured to the upper portion of the hydrocyclone allowing the image sensor assembly to be removed when the hydrocyclone is in operation. When image data is required the hydrocyclone may be turned off and the image sensor assembly may be re-installed.

[0018] An upper portion of the sensor housing may be removably secured to the remainder of the body and wherein the image sensor is secured to the removable upper portion of the sensor housing

[0019] In one example embodiment, the image sensor assembly may include a screen located in the internal cavity proximate to the image sensor. The screen may be displaceable between a first position wherein at least the image sensor is isolated from the remainder of the hydrocyclone so that the image sensor does not come into contact with the fluid in the hydrocyclone and a second position wherein the screen is moved out of the internal cavity allowing the image sensor to capture image data.

[0020] Alternatively, the image sensor may be displaceable relative to the upper portion of the hydrocyclone between a first position wherein the image sensor is not exposed to the fluid and a second position when the hydrocyclone is turned off wherein the image sensor’s field of view is orientated towards the spigot to capture image data relating to internal surface configuration or internal diameter of the hydrocyclone. The sensor housing may include a displaceable support member on which the image sensor is secured and which is rotatably displaceable within internal cavity of the sensor housing between a first position wherein the image sensor is positioned so that it is not exposed to the fluid in the overflow outlet control chamber when the hydrocyclone is in operation and a second position wherein the image sensor’s field of view is orientated towards the spigot to capture image data relating to internal surface configuration or internal diameter of the hydrocyclone. The displaceable support member may be in the form of a circular disc shaped and dimensioned to fit within the internal cavity of the sensor housing with the image sensor secured to one side of the displaceable support member.

[0021] Optionally, the image sensor assembly may include sealing members positioned around an outer periphery of the displaceable support member to create a fluid tight seal between an interior sidewall of the sensor housing and the displaceable support member.

[0022] Optionally, the image sensor assembly may include sealing members secured to an interior sidewall of the sensor housing against which the displaceable support member sits to create a fluid tight seal between an interior sidewall of the sensor housing and the displaceable support member.

[0023] The sensor housing may further include a drive mechanism connected to the displaceable support member to rotationally displace it between the first and second positions. The drive mechanism may include a shaft secured to the displaceable support member at one end with an opposed end extending through the sensor housing and coupled to a motor to impart rotational movement to the displaceable support member between the first and second position.

[0024] The interior surface of the upper portion or the displaceable support member may define a mounting formation which is complementary to a mounting formation on the image sensor such as a bayonet fitting or a screw thread fitting.

[0025] The hydrocyclone may further include a controller in communication with the image sensor to receive image data from the image sensor, the controller arranged to calculate the internal diameter of the hydrocyclone at predetermined locations.

[0026] The image sensor assembly and controller may preferably be arranged to capture image data relating to the spigot and / or spigot liner and calculate the internal diameter of the spigot and / or spigot liner from the image data. Alternatively or in addition, the sensor assembly and controller may be arranged to capture image data of the vortex finder and calculate the internal diameter of the vortex finder from the image data. It is to be appreciated that the image sensor remains housed within the image sensor housing which is secured to an upper portion of the overflow control chamber when the image sensor capture the image data.

[0027] The controller may include an input interface for coupling to the image sensor, one or more processors for implementing various analytical functions, non-volatile storage and a user interface. The input interface may be arranged to couple to the image sensor either via a sensor cable or wirelessly. The user interface may comprise an LCD screen although other configurations are possible.

[0028] The controller may be arranged to receive the image data, in the form of two- dimensional images of the spigot, spigot liner and / or vortex finder and calculate the internal diameter of the spigot, spigot liner and / or vortex finder. The controller may be arranged to display the calculated internal diameter of the spigot, spigot liner and / or vortex finder via the user interface. The controller may be arranged to calculate the internal diameter of the spigot, spigot liner and / or vortex finder based on the data analysis of the image data and initial references with a known diameter. The initial references against which the data analysis is done may be based on data captured at a prior point and which is stored in the non-volatile storage.

[0029] The image sensor assembly may further include at least one light source housed within the image sensor housing adjacent to the image sensor. Alternatively or in addition, the at least one light source may be integrated with the image sensor.

[0030] Preferably, the hydrocyclone may be arranged to measure the internal diameter of the spigot and / or spigot liner as the spigot and spigot liner is prone to the highest wear and the internal diameter should be measured to ensure the internal diameter is within predefined limits. The system may furthermore be arranged to measure the internal diameter of the vortex finder.

[0031] According to an unclaimed second aspect, there is provided a method of measuring the internal diameter of a hydrocyclone, the method comprising: obtaining image data from an image sensor which is housed within an image sensor housing secured to an upper portion of the hydrocyclone which relates to internal surface configuration or the internal diameter of the hydrocyclone; calculating the internal diameter of the hydrocyclone at predefined locations based on the image data.

[0032] The method may preferably determine the internal diameter of the spigot and / or spigot liner of the hydrocyclone. Alternatively or in addition, the method may determine the diameter of the vortex finder.

[0033] It is to be appreciated that the method does not require the image sensor to be inserted into separation chamber of the hydrocyclone to obtain the image data. This reduces the overall complexity of the image sensor assembly.

[0034] The method may include a prior step of configuring the image sensor based on a distance between the image sensor and the spigot, spigot liner, and / or vortex finder of the hydrocyclone.

[0035] The method may further include the step of obtaining reference image data of a spigot, spigot liner, and / or vortex finder wherein the internal diameter of the spigot, spigot liner, and / or vortex finder is known and conducting data analysis using the reference image data and the obtained image data to calculate the internal diameter of the spigot, spigot liner, and / or vortex finder.

[0036] The method may include the prior step of shutting down the hydrocyclone before image data which relates to the internal surface configuration or the internal diameter of the hydrocyclone can be obtained.

[0037] Where the image sensor is removably secured to the hydrocyclone the method may include the step of installing the image in an operative upper part of the hydrocyclone.

[0038] Where the hydrocyclone includes an image sensor assembly wherein the image sensor is displaceable the method may include the step of displacing the image sensor from a first position wherein the image sensor is isolated from the remainder of the hydrocyclone to a second position wherein the image sensor is able to capture image data.

[0039] Brief Description of Figures

[0040] These and other aspects will be apparent from the following specific description, given by way of example only, with reference to the accompanying drawings, in which:

[0041] Fig. 1 is a schematic view of a hydrocyclone according to a first embodiment of the present invention; and

[0042] Fig. 2 is a simplified cross section view of part of the hydrocyclone of Fig. 1 showing features thereof in more detail;

[0043] Fig. 3 is a sectional perspective view of an alternative image sensor assembly of the hydrocyclone; and

[0044] Fig. 4A and 4B are simplified cross sectional views of a further alternative image sensor assembly of the hydrocyclone in a first and second position respectively.

[0045] Detailed Description

[0046] Reference is now made to the drawings and particularly to Fig. 1 , which is a schematic view of a hydrocyclone 10 according to a first embodiment of the present invention.

[0047] It is to be noted that even though only a single hydrocyclone 10 is shown in the Figures the hydrocyclone 10 may form part of a larger hydrocyclone system (also known as a hydrocyclone cluster) which comprises a plurality of hydrocyclones 10 according to the present invention.

[0048] The hydrocyclone 10 having a main body defining a separation chamber Therein. The main body comprising a generally cylindrical upper chamber 12 at an upper end thereof and a generally frusto-conical shaped lower portion 16 extending from a lower surface of the cylindrical upper chamber 12 to an underflow outlet at which a spigot 18 is mounted. The hydrocyclone 10 further comprises an overflow outlet 24 which comprises an upper outlet generally co-axial with the spigot in an upper portion of the cylindrical upper chamber in which an overflow cap 14 (also referred to as a vortex finder) is mounted and which extends into the cylindrical upper chamber 12.

[0049] The upper chamber 12, vortex finder 14, separation chamber 16, and spigot 18, are mounted generally coaxially such that they define a longitudinal axis 20, also referred to as a central axis or a fluid transport axis.

[0050] A feed inlet 22 is provided generally tangential to the cylindrical upper chamber 12 and extends into the cylindrical chamber 12.

[0051] In the illustrated example, the hydrocyclone 10 includes an overflow outlet control chamber also known as an air core booster 26. Hydrocyclones with air core boosters produce improvements in capacity and cyclone efficiency by reducing the total pressure across the hydrocyclone, increasing the volume flow split to the overflow outlet. An air ore booster allows the use of a larger spigot for a given bypass of water to the underflow, which produces a more stable, larger diameter air core, increasing capacity and reducing the bypass of fines. Air core boosters also reduce the chances of operating the hydrocyclone under roping conditions.

[0052] The air core booster 26 is mounted to the main body generally coaxially with the upper chamber 12 and is in communication with the upper chamber 12 and the separation chamber 14 via the overflow outlet 24. The air core booster 26 further includes a tangentially located discharge outlet 28 (tangential to the air core booster 26) and an upper opening 30 which is remote from the overflow outlet 24. The upper opening 30, overflow outlet 24, and underflow outlet 18 are generally co-axially aligned.

[0053] The upper chamber 12 may comprise a feed chamber (lower portion) and a cover (top portion) which are secured to one another to form the upper chamber 12. The air core booster 26 may be secured to an outer upper surface of the cover of the upper chamber 12.

[0054] The air core booster 26 generally includes a lower base which is securable to the upper surface of the upper cylindrical chamber 12, an upper base longitudinally spaced from the lower base and which defines the upper opening therein, and a generally cylindrical body 29. The lower base of the air core booster may be in the form of an annular flange which extends from a lower portion of the generally cylindrical body and which surrounds a lower opening 31.

[0055] The interior of the cylindrical body of the air core booster 26 defines an inner cavity 32 which is generally in the shape of a volute for directing material entering the air core booster 26 through the lower opening 31 from the separation chamber 16 via the overflow outlet 24 towards the discharge outlet 28.

[0056] The vortex finder 14 may include a cylindrical body which extends from an annular base. In use, the annular base of the vortex finder 14 may be secured between the lower base of the air core booster 26 and an upper surface of the upper cylindrical chamber 12 with the cylindrical body extending into the upper chamber 12. The feed inlet 22 is configured to allow slurry (liquid containing suspended matter) to be pumped through the upper chamber 12 and into the separation chamber 18 to create one or more vortices therein and to create an air core to effect separation of the slurry into large particles reporting to the underflow outlet 18 and small particles reporting to the overflow outlet 24 and outward via the discharge outlet 28. An overflow pipe (not shown) which is connected to discharge outlet 28 may lead to a tank (not shown) for accumulating fine particulate slurry for use in ore extraction (for example, via flotation).

[0057] A centrifugal pump 34 is used to pump the slurry received on an input hose (or pipe) 36 which feeds the feed inlet 22 of the hydrocyclone 10. Where the hydrocyclone 10 forms part of a hydrocyclone cluster the centrifugal pump 34 is used to pump the slurry received on an input 36 hose into a distributor 38 that separates the slurry into a plurality of different hoses 40 with each distributor hose feeding a hydrocyclone inlet 22. The centrifugal pump is driven by a motor (not shown for clarity) controlled by a conventional variable frequency drive (VFD) controller.

[0058] Although not shown in detail in the figures, the spigot 18 comprises a spigot holder, having a cylindrical and / or conical body which is secured to a lower portion of the separation chamber 16, and a replaceable spigot liner housed within the spigot holder. The spigot liner can be composed of loose ceramic, neoprene, urethane, or rubber, depending upon the abrasion and corrosion resistant properties needed for the material passing through the spigot.

[0059] To monitor the internal diameter of the spigot , spigot liner 18, and / or vortex finder 24 the hydrocyclone includes an image sensor assembly shown more clearly in Fig. 2 which is a simplified cross section view of part of the hydrocyclone, more specifically the air core booster 26 and image sensor assembly 41 , showing addition features of the image sensor assembly 41 in more detail. Alternative embodiments of the image sensor assembly 41a, 41 b is shown more clearly in Figs. 3-4.

[0060] The image sensor assembly 41 shown in Fig. 2 includes a image sensor housing 42 which is securable to the upper portion (more specifically an upper outer surface) of the air core booster. The image sensor assembly 41 further includes an image sensor 44 which is housed within the image sensor housing 42 and which is arranged to capture image data relating to internal surface configuration or internal diameter of the hydrocyclone without having to insert the image sensor into the hydrocyclone. The image sensor may be arranged to capture image data relating to the spigot and / or spigot liner 18 to calculate the internal diameter of the spigot and / or spigot liner 18 from the image data. Alternatively or in addition, the image sensor may be arranged to capture image data of the vortex finder 14 to calculate the internal diameter of the vortex finder from the image data. The image sensor housing 42 is secured to the upper portion of the air core booster 26 with the image sensor 44 secured to an interior of an upper surface 48 of the image sensor housing 42 so that the image sensor’s field of view is orientated through the lower opening 31 and upper outlet (vortex finder 14) towards the spigot 18. In the illustrated example of Fig, 2 the sensor housing comprises an inverted cup-shaped body 50 defining an internal cavity 56 in which the image sensor 44 is housed. The image sensor housing 42 furthermore includes an annular mounting flange 46 which extends radially outward from a lower portion of the body 50 and which is secured to a flange 47 (or upper surface) of the air core booster 26 via a plurality of bolts 49. The image sensor housing 42 defines an upper wall 48 which is longitudinally spaced from the annular mounting flange 46 and an central aperture 58 defined by the opening radially inward from the annular mounting flange. In the illustrated example, the body 50 has a general frusto-conical shape but other configurations are possible wherein the body 50 is substantially cylindrical. The internal cavity 54 of the sensor housing 42 defines a generally central mounting zone. More specifically, an interior surface of the upper wall 58 defines a mounting zone to which the image sensor 44 may be coupled. It is to be appreciated that various configurations of sensor assembly can be used.

[0061] The image sensor housing 42 and image sensor 44 may be removably secured to the flange 47 of the air core booster to allow the image sensor housing 42 and image sensor 44 to be removed from the hydrocyclone when it is in operation and re-installed once the hydrocyclone is switched off and image data is required to be obtained.

[0062] Referring to Fig. 3 which shows a perspective sectional view of an image sensor assembly 41a in accordance with an alternative embodiment. The image sensor assembly 41a includes a image sensor housing 42a having a generally cylindrical body 50a defining an interior cavity 56a within the circular body in which the image sensor 44 is housed. The image sensor housing 42a further includes an annular flange 46a extending radially outward from a lower portion of the body 50a around the lower opening 58a for mounting against flange 47 of the air core booster. The image sensor housing furthermore include a removable top cover 48a which is securable to the body 50. More specifically the body 50a includes an upper annular flange 60a extending radially inward from an upper portion of the body 50a against which the removable top cover 48a can be mounted with suitable fasteners. The image sensor 44 may be secured to an interior surface of the removable top cover 58a so that the image sensor’s field of view is orientated through the lower opening 58a, upper opening 30 and upper outlet 14 towards the spigot 18.

[0063] In an alternative embodiment shown in Figs. 4A and 4B, the image sensor is displaceable relative to the upper portion of the hydrocyclone 12 between a first position (as shown in Fig 4A) wherein the image sensor 44 is positioned so that it is not exposed to the fluid when the hydrocyclone is in operation and a second position (as shown in Fig 4B) when the hydrocyclone 12 is turned off wherein the image sensor’s 44 field of view is orientated towards the spigot to capture image data relating to internal surface configuration or internal diameter of the hydrocyclone.

[0064] The image sensor housing 42b is similar to the image sensor housing 42a shown in Figure 3, and includes a generally cylindrical body 50b defining an interior cavity 56b within the circular body 50b. The image sensor housing 42b further includes an annular flange 46b extending radially outward from a lower portion of the body 50b around a lower opening 58b for mounting against flange 47 of the air core booster. The image sensor housing 42b furthermore includes a top wall 48b extending radially inwards from an upper portion of the body 50b.

[0065] In this alternative embodiment, the image sensor assembly 41b includes a displaceable support member 62 housed within the interior cavity 56b and which defines an upper and lower surface with the image sensor 44 secured to the lower surface. The image sensor assembly 41b includes a drive mechanism which is secured to the displaceable support member 62 to impart rotational movement to the displaceable support member 62. In this embodiment, the drive mechanism includes a shaft 64 secured to the displaceable support member 62 with an opposed end of the shaft 64 extending through the body 50b where it is coupled to a motor 66. In use, the motor 66 is arranged to rotate the displaceable support member 62 between the first position wherein the image sensor 44 is orientated away from the spigot 18 and the second position wherein the image sensor 44 is orientated towards from the spigot 18 as required. The displaceable support member 62 may be substantially disc shaped and dimensioned to fit within the interior cavity 56b of the cylindrical body 50b. The displaceable support member may include sealing members 68 positioned around an outer periphery of the displaceable member 62 which creates a fluid tight seal between an interior surface of the cylindrical body 50b and the displaceable member 62. Alternatively or addition the sealing members 68 may be positioned on an interior surface of the cylindrical body 50b to create a fluid tight seal between the interior surface of the cylindrical body 50b and the displaceable support member 56 to prevent fluid coming into contact with the image sensor 44 when in the first position. The sealing member 68 may be in the form of an annular sealing member. Preferably, the sealing members 68 may be in the form of two semi annular sealing members with one sealing member positioned below and the other sealing member positioned above the displaceable support member 62.

[0066] The image sensor 44 comprises a camera. A suitable camera for use in this embodiment is a BVS-E Universal vision sensor available from Balluff GmbH, SchurwaldstraBe 9, 73765, Neuhausen, Germany. It is to be appreciated that alternative cameras such as the IFM O2D514 may be used instead.

[0067] The image sensor 44 may be coupled to the image sensor housing or displaceable support member for example by using complementary formations on the image sensor and the sensor housing / displaceable support member such as a bayonet fitting or a screw thread fitting. Alternatively, the image sensor housing or displaceable support member can define a mounting bracket to which the image sensor can be attached using suitable fasteners.

[0068] An image sensor cable 52 provides an electrical connection between the image sensor and a controller 54.

[0069] In use, image sensor 44 is configured to capture image data which is sent to the controller 54 to calculate the internal diameter of the spigot, spigot liner, and / or vortex finder.

[0070] The controller 54 comprises an input interface for coupling to the image sensor cable, one or more processors for implementing various analytical functions, non-volatile storage and a user interface. The user interface may comprise an LCD screen.

[0071] Where the hydrocyclone forms part of a hydrocyclone cluster the image sensor assembly 41 may be secured to the flange of one of the hydrocyclone with the image sensor arranged to capture image data and send the image data to a mobile controller. Once the internal diameter of the spigot, spigot liner, and / or vortex finder is calculated the image sensor assembly 41 can be removed and secured to the flange of another hydrocyclone.

[0072] In the alternative embodiment, where the image sensor is displaceable the input interface may comprise a plurality of input modules with each image sensor having a unique identification, and the unique identification is mapped to a particular hydrocyclone (only one is illustrated in Fig. 1 , but a cluster of hydrocyclones is typically provided, each hydrocyclone having a dedicated image sensor). The controller may be in the form of a central controller which controls the displacement of the image sensor of each of the hydrocyclone as well as receiving image data from the various image sensors.

[0073] The hydrocyclone enables the internal diameter of the spigot, spigot liner, and / or vortex finder to be measured to ensure the internal diameter is within predefined ranges without the need for a service engineer to enter into the discharge tank and provide a suitable alternative to known methods. The hydrocyclone further enables the internal diameter of the vortex finder to be measured without disassembling the hydrocyclone. The image sensor assembly provides a useful solution to measure the internal diameter of the spigot, spigot liner, and / or vortex finder without having to insert the image sensor into the hydrocyclone which requires a more complex design of the image sensor assembly. Reference numerals

[0074] 10 hydrocyclone

[0075] 12 upper chamber of hydrocyclone

[0076] 14 overflow cap or vortex finder

[0077] 16 frusto-conical shaped lower portion

[0078] 18 spigot

[0079] 20 longitudinal axis

[0080] 22 feed inlet

[0081] 24 overflow outlet

[0082] 26 air core booster or overflow outlet control chamber

[0083] 28 discharge outlet

[0084] 29 cylindrical body of air core booster

[0085] 30 upper opening of air core booster

[0086] 31 lower opening of air core booster

[0087] 32 inner cavity of air core booster

[0088] 34 centrifugal pump

[0089] 36 input hose

[0090] 38 distributor

[0091] 40 hose

[0092] 41, a, b image sensor assembly

[0093] 42, a image sensor housing

[0094] 44 image sensor

[0095] 46 mounting flange

[0096] 47 flange of air core booster

[0097] 48, a, b upper surface of sensor housing

[0098] 49 bolts

[0099] 50, a body of sensor housing

[0100] 52 sensor cable

[0101] 54 controller

[0102] 56a, b internal cavity of sensor housing

[0103] 58, a, b central aperture of sensor housing

[0104] 60a upper annular flange

[0105] 62 displaceable support member

[0106] 64 shaft

[0107] 66 motor

[0108] 68 sealing members

Claims

CLAIMS1. A hydrocyclone for separating fluid into a plurality of streams, the hydrocyclone comprising: a main body having a separation chamber therein, the separation chamber having an inlet for receiving the fluid, an upper outlet and a lower outlet, the separation chamber in communication with the inlet, upper outlet, and lower outlet to deliver a first fluid stream to the upper outlet and a second stream to the lower outlet, the lower outlet defined by a spigot attached to a lower end of the main body with the separation chamber and spigot coaxially aligned to define a central longitudinal axis; an overflow outlet control chamber mounted to the main body and in fluid flow communication with the separation chamber via the upper outlet, the overflow outlet control chamber further including a tangentially located discharge outlet and an upper opening remote from the overflow outlet in an upper portion of the overflow outlet control chamber; and an image sensor assembly including a sensor housing securable to the upper portion of the overflow outlet control chamber, the image sensor assembly further including an image sensor housed within the sensor housing so that the image sensor’s field of view is orientated through the upper opening and upper outlet towards the spigot to capture image data relating to internal surface configuration or internal diameter of the hydrocyclone.

2. The hydrocyclone according to claim 1 , wherein the overflow outlet control chamber comprises a lower base which is securable to an upper surface of the main body, an upper base longitudinally spaced from the lower base and which defines the upper opening therein and a cylindrical body extending between the upper and lower base wherein the discharge outlet is located in the cylindrical body and the sensor housing is secured to the upper base.

3. The hydrocyclone according to claim 1 or 2, wherein the sensor housing comprises an inverted cup-shaped body defining an internal cavity in which the image sensor is housed.

4. The hydrocyclone according to claim 3, wherein the sensor housing comprises an annular flange which extends radially from a lower portion of the body and which is securable to the upper base around the upper opening.

5. The hydrocyclone according to any one of the preceding claims, wherein includes a removable upper portion which is removably secured to the remainder of the sensor housing and wherein the image sensor is secured to the removable upper portion of the sensor housing.

6. The hydrocyclone according to claim 3, wherein the sensor housing includes a displaceable support member on which the image sensor is secured and which is rotatably displaceable within internal cavity of the sensor housing between a first position wherein the image sensor is positioned so that it is not exposed to the fluid in the overflow outlet control chamber when the hydrocyclone is in operation and a second position wherein the image sensor’s field of view is orientated towards the spigot to capture image data relating to internal surface configuration or internal diameter of the hydrocyclone.

7. The hydrocyclone according to claim 6, wherein the displaceable support member is in the form of a circular disc shaped and dimensioned to fit within the internal cavity of the sensor housing with the image sensor secured to one side of the displaceable support member.

8. The hydrocyclone according to claim 6 or 7, wherein the displaceable support member includes sealing members positioned around an outer periphery of the displaceable support member or to an interior sidewall of the sensor housing to create a fluid tight seal between an interior sidewall of the sensor housing and the displaceable support member.

9. The hydrocyclone according to any one of claims 6 to 8, which further includes a drive mechanism connected to the displaceable support member to rotationally displace it between the first and second positions.

10. The hydrocyclone according to claim 9, wherein the drive mechanism includes a shaft secured to the displaceable support member at one end with an opposed end extending through the sensor housing and coupled to a motor to impart rotational movement to the displaceable support member between the first and second position.

11. The hydrocyclone according to any one of the preceding claims, further including a controller in communication with the image sensor to receive image data from the image sensor, and wherein the controller is arranged to calculate the internal diameter of the hydrocyclone at a fixed location along the central longitudinal axis while the image sensor remains housed within the sensor housing.

12. The hydrocyclone according to claim 11 , wherein the controller includes an input interface for coupling to the image sensor, one or more processors for implementing various analytical functions, non-volatile storage and a user interface.

13. The hydrocyclone according to claim 12, wherein the controller is arranged to receive the image data, in the form of two-dimensional images of the spigot, spigot liner, and / or vortex finder and calculate the internal diameter of the spigot, spigot liner, and / or vortex finder.

14. The hydrocyclone according to any one of claims 1 to 10, wherein the image sensor is a camera housed within the sensor housing and arranged to capture image data relating to internal surface configuration or internal diameter of the spigot, a spigot liner, and / or a vortex finder positioned in the upper outlet.

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