Zhongxin Heavy Industrial Machinery Co.,Ltd.
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Hydrocyclone

Capacity
0.1-900m³/h
Inlet re
0.04-0.4mpa

Metallic & Non-Metallic Mineral Beneficiation: Essential classification stages in processing plants for iron ore, copper, gold, zinc, lead, phosphate, bauxite, and silica sand.

Closed-Circuit Grinding Systems: Working in tandem with rod mills and ball mills to classify mineral slurries, returning oversized particles for regrinding while passing appropriately sized material downstream.

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Premium wear-resistant industrial hydrocyclone isolated on a clean white background for mineral classification.
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Product Description:High-Efficiency Hydrocyclone Separator

◎A Hydrocyclone (Hydrocyclone Separator) stands as one of the most critical and cost-effective solid-liquid and solid-solid separation devices deployed in modern industrial processing. Operating entirely without moving parts, this dynamic piece of machinery relies on fluid kinematics and centrifugal acceleration to segregate particles suspended in liquid slurries based on their size, shape, and density.

◎As an indispensable cornerstone of modern mineral processing plants, metallurgical facilities, chemical processing lines, coal washing plants, and environmental tailing management projects, Zhongxin Heavy’s hydrocyclones are meticulously engineered to optimize closed-circuit grinding operations, particle sizing, desliming, slurry thickening, and dry-stack tailings dewatering.

◎By harnessing advanced computational fluid dynamics (CFD) in our design phase, our hydrocyclones ensure uniform internal flow distribution, minimizing energy consumption while maximizing sharp cut-points. Whether deployed as a standalone unit or integrated into a multi-hydrocyclone cluster, our equipment consistently delivers high processing capacities, small installation footprints, and exceptional reliability under the most abrasive operational conditions.

On-site installation of wear-resistant polyurethane hydrocyclones in an ore dressing plant.
Hydrocyclone

Sharp Particle Cut-Size & High Separation Efficiency

Optimized cone geometry generates a powerful centrifugal field to ensure precise particle size separation. This significantly reduces coarse particle bypass and maximizes overall classification efficiency.

Hydrocyclone

Superior Wear & Corrosion Resistance

Equipped with replaceable linings of high-grade rubber, polyurethane, or high-chrome cast iron. These durable materials protect critical wear zones and dramatically extend equipment service life.

Hydrocyclone

Modular Multi-Hydrocyclone Clusters

Individual cyclones can be easily manifolded into radial or parallel clusters for high-throughput plants. This allows operators to adjust capacity or isolate units without halting the production line.

Hydrocyclone

Zero Moving Parts & Low Maintenance

Operating entirely without moving parts, the stationary design minimizes mechanical failure rates and spare parts inventory. It ensures continuous, reliable operation with minimal downtime.

Hydrocyclone

Flexible Operational Adjustments

Performance can be easily fine-tuned on-site to adapt to changing slurry conditions. Operators can quickly adjust feed pressure or swap interchangeable apex nozzles and vortex finders.

Key Features & Technological Advantages: Engineered for Maximum Separation Efficiency and Durability

To withstand the rigorous demands of heavy-duty industrial applications, Zhongxin Heavy incorporates cutting-edge material science and structural engineering into every hydrocyclone

Fine sand recovery hydrocyclone unit operating in an aggregate and mineral processing line.
Mineral processing plant floor highlighting high-performance hydrocyclone separators in action.
Efficient particle cut-point separation using advanced hydrocyclones in an industrial plant.
Industrial hydrocyclones integrated into a closed-circuit rod mill and ball mill grinding system.
Industrial hydrocyclone system managing high-abrasion mineral slurry in a crushing plant.
Complete hydrocyclone battery system installed and running smoothly in a global mining facility.

Primary Industrial Applications

Zhongxin Heavy’s industrial hydrocyclones are versatile enough to serve a broad spectrum of global heavy industries:

◎Closed-Circuit Grinding Systems: Working in tandem with rod mills and ball mills to classify mineral slurries, returning oversized particles for regrinding while passing appropriately sized material downstream.

◎Tailings Management & Dewatering: Pre-conditioning tailings streams for thickeners, promoting water recovery in closed-loop water systems, and preparing feed for tailings dam construction or dry-stacking facilities.

◎Metallic & Non-Metallic Mineral Beneficiation: Essential classification stages in processing plants for iron ore, copper, gold, zinc, lead, phosphate, bauxite, and silica sand.

◎Coal Preparation & Mineral Washing: Used extensively in heavy media circuits, fine coal recovery, and desliming operations to upgrade coal quality.

◎Aggregates & Sand Washing Plants: Efficient sand-water separation, mud removal, and fine sand recovery in artificial sand-making lines.

Working Principle: How Centrifugal Force and Dual-Vortex Dynamics Drive Precision Separation

The core separation mechanism of a hydrocyclone relies on centrifugal sedimentation:

◎Tangential Feeding & Pressure Conversion: The incoming mineral slurry—a mixture of liquid and solid particles—is pumped under a controlled, steady pressure into the cylindrical upper section of the hydrocyclone via a tangential or involute feed inlet. This high-speed tangential entry instantly converts the fluid's pressure energy into a rapid, powerful rotational kinetic energy.

◎Dual-Vortex Flow Field Generation: As the slurry rotates at high speeds within the chamber, it creates a complex, highly stable dual-vortex velocity profile. This dynamic flow field consists of an outer spiral vortex moving downward along the inner conical walls and an inner core vortex spinning rapidly upward toward the top center.

◎Centrifugal Stratification & Particle Segregation: Within this intense centrifugal force field, particles of varying sizes, shapes, and densities undergo precise physical segregation:

1.Coarse & High-Density Particles: Subjected to a significantly higher centrifugal force, these heavier particles are flung outward against the conical wall. They spiral downward along the walls and are continuously discharged through the bottom Apex (Underflow) as a dense, high-solids underflow slurry.

2.Fine, Low-Density Particles & Liquid: Pulled toward the low-pressure central air core by the inner upward vortex, these finer materials travel upward through the body and exit cleanly through the top Vortex Finder (Overflow) as the final overflow product.

Industrial hydrocyclones connected to slurry distribution manifolds in a mineral grinding circuit.

Product Photos

Industrial hydrocyclone manufacturing workshop showing heavy-duty polyurethane lining production.
Precision machining of hydrocyclone components in our heavy machinery factory.
Skilled technicians assembling industrial hydrocyclone separation units.
Industrial hydrocyclones securely packed and loaded for international shipping to mining clients
Ready-to-ship mineral processing hydrocyclone equipment at our logistics loading bay.
Hydrocyclone cluster operating in a closed-circuit ball mill grinding plant.
Industrial hydrocyclones installed in a large Latin American copper and gold mineral processing plant.
High-efficiency hydrocyclone separator performing mineral desliming and classification on-site.
ailings dewatering hydrocyclone system working in a mining tailing dry stacking project.

Specification


 

Model

 

 

Diameter (mm)

 

 

Angle of Cone (°)

 

 

Max Feed Size

(mm)

 

 

Inlet re

(mpa)

 

 

Capacity (m³/h )

Overall Dimension

Length

Width

Height

(mm)

(mm)

(mm)

 

FX840

840

20

18

0.04～ 0.2

500～ 900

1700

1500

3700

FX750

750

45

16

0.04～ 0.2

400～ 500

1210

910

2680

FX710

710

45

16

0.03～ 0.2

350～ 450

1255

1185

1040

 

FX660

 

660

20

16

0.03～ 0.2

250～ 350

1140

 

1000

2920

45

16

0.03～ 0.2

250～ 350

1140

2000

 

FX610

 

610

20

13

0.03～ 0.2

200～ 300

875

 

950

2560

45

13

0.03～ 0.3

200～ 300

875

1810

 

 

FX500

 

 

500

20

 

 

10

 

 

0.03～ 0.3

 

 

140-220

 

 

850

 

700

2050

15

2380

45

825

1630

 

FX350

 

350

20

 

6

 

0.04～ 0.3

 

60～ 100

 

775

 

620

1765

15

1970

 

FX300

 

300

20

 

5

 

0.04～ 0.3

 

45～ 85

 

498

 

485

1415

15

1642

 

 

FX250

 

 

250

20

 

 

3

 

 

0.06～ 0.35

 

 

40～ 60

 

 

410

 

 

380

1215

15

1405

10

1788


>>SPECIFICATIONS-2

 

 

Model

 

 

Diameter (mm )

 

 

Angle of Co n e (°)

 

Max Feed Size

(mm )

 

 

Inlet Pressure

(mpa)

 

 

Capacity (m³/h)

Overall Dimension

Length

Width

Height

(mm )

(mm )

(mm )

 



10






1788

 

 

FX200

 

 

200

20

 

 

2

 

 

0.06～ 0.35

 

 

25～ 40

365

 

330

1030

15

410

1083

10

400

365

1490

 

 

F150

 

 

150

20

 

 

1 .5

 

 

0.06～ 0.35

 

 

1 1～ 22

 

 

310

 

 

265

820

15

878

10

1160

 

FX125

 

125

17

 

1

 

0.06～ 0.35

 

8～ 15

 

 

260

 

218

620

8

870

 

 

 

FX100

 

 

 

100

20

 

 

 

 

1

 

 

 

0.06～ 0.35

 

 

 

5～ 15

210

525

15

268

215

720

8

 

365

 

150

1065

5

1505

 

FX75

 

75

15

 

0 .6

 

0. 1～ 0.4

 

2～ 5

 

240

 

230

420

5

778

 

FX50

 

50

15

 

0 .3

 

0. 1～ 0.4

 

1～ 2

 

160

 

137

400

5

680

FX25

25

5

0.2

0. 1～ 0.4

0.8～1.2

130

85

495

FX10

10

4

0 .2

0.2～ 0.4

0.1～0.2

30

30

195


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Common Problems

This section is designed to address the most pressing inquiries customers may have regarding the daily operation, maintenance, product advantages, and after-sales service of our machine. Our aim is to help you gain a comprehensive understanding of our overall capabilities and enable you to make informed decisions for your projects.

A hydrocyclone (hydrocyclone separator) is a high-efficiency mineral classification equipment that utilizes centrifugal force to separate solid-liquid mixtures based on particle size and density. Slurry is fed tangentially into the cylindrical chamber under pressure, creating a dual-vortex flow field. Coarse particles are thrown outward and discharged through the bottom apex (underflow), while fine particles and liquid exit through the top vortex finder (overflow).

Industrial hydrocyclones are widely used across multiple heavy-duty sectors. Their primary applications include closed-circuit grinding systems (working alongside ball mills), tailings dewatering, slurry concentration, desliming, fine sand recovery, and coal washing circuits in metallic and non-metallic mineral processing plants.

Selecting the correct hydrocyclone separator depends on several operational parameters, including total feed throughput, feed solid concentration, desired separation cut-size ($d_{50}$), and slurry viscosity. For high-volume processing plants, multiple individual cyclones are typically integrated into parallel or radial hydrocyclone clusters to meet specific capacity demands.

Because mineral slurries are highly abrasive, key internal components of a polyurethane hydrocyclone—such as the feed chamber, vortex finder, and apex nozzle—are subjected to severe wear. High-grade natural rubber, high-performance polyurethane (PU), or high-chrome cast iron linings are utilized to drastically extend equipment service life, reduce maintenance downtime, and lower operating costs.

The separation efficiency of a grinding classification hydrocyclone is influenced by both design and operational variables. Key factors include feed pressure, feed solids concentration, inlet and outlet dimensions (such as apex and vortex finder diameters), and slurry rheology. Fine-tuning these parameters allows operators to optimize the cut-point and minimize misplaced particles.

In a hydrocyclone separator, the underflow is the heavy, coarse fraction discharged through the bottom apex nozzle (containing high-density solids and less liquid), while the overflow is the light, fine fraction that travels upward and exits through the top vortex finder (containing fine particles, clay, and the bulk of the carrier liquid).

In modern tailings dewatering systems, hydrocyclones act as an essential pre-treatment stage. They separate coarse sand fractions from fine slime tailings, producing a high-density underflow suitable for dry-stacking or dam construction while returning clarified water back into the plant's closed-loop water system.

One of the greatest advantages of a hydrocyclone is that it features zero moving parts, making mechanical maintenance minimal. Routine maintenance primarily involves regular inspection of high-wear components (such as apex nozzles and vortex finders) and replacing worn-out rubber or polyurethane liners before wear reaches the structural steel shell.

COMPREHENSIVE SERVICE & GENUINE SPARE PARTS

Zhongxin Heavy Industry provides not only high-performance equipment but also full life-cycle support solutions.

Hydrocyclone
Hydrocyclone
Comprehensive Lifecycle Technical Support

From the initial stage of mineral processing plant design and equipment selection to professional on-site installation guidance, commissioning, and operational troubleshooting, Zhongxin Heavy’s dedicated engineering team delivers full-lifecycle technical support. We work closely with your plant operators to analyze slurry characteristics, fine-tune operating parameters, and ensure your hydrocyclone systems consistently achieve peak separation efficiency, maximum throughput, and long-term stable performance.

Service
Premium Wear-Resistant Replacement Parts & Precision Components

Because heavy industrial mineral processing subjects equipment to severe abrasion, we manufacture and supply factory-direct, high-precision replacement parts designed specifically for rigorous duty cycles. Our inventory includes highly durable apex nozzles, vortex finders, feed chambers, and replacement liners crafted from premium-grade polyurethane (PU), molded natural rubber, and high-chrome alloys, engineered to dramatically extend service life and protect your structural investments.

Service
Rapid Global Logistics & Tailored Custom Engineering Solutions

We understand that unplanned equipment downtime can result in massive financial losses for processing plants. Backed by robust global logistics networks, responsive customer service teams, and flexible manufacturing capabilities, we deliver rapid-response spare part replacements and custom-engineered hydrocyclone cluster solutions directly to your project sites worldwide—ensuring your operations remain uninterrupted and highly profitable.

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