Continuous Control of Dense Medium Cyclone Separation Density

This paper describes the development and installation of equipment for continuously measuring separating density in the dense medium cyclone circuits of the four million tpa Port Kembla B/C plant coal washeries. Monitoring equipment consisting of magnetic coils and differential pressure cells were installed in U-tubes taking the full flow of magnetite from the drain sections of the product drain and rinse screens. The monitoring equipment measures overflow magnetics concentration and overflow density continuously and has operated since 1989. From these measurements and calibration trials, the separating density of operating cyclone modules can be inferred reliably. Variographic analyses of the data show that medium density control to +/- 0.002 RD units and separation density control to +/- 0.007 RD units are achievable. Either method for measuring separation density can be used with approximately the same accuracy, although the overflow density measurement technique suffers from the need to have regular flushing of the Dp cells which complicates the signal analysis. Data from the plant shows that separation density can be controlled by regulating medium density, but the assumption of a constant offset between medium density and separation density is erroneous.