Hydrocyclones Silicon Carbide Liners

Our Hydrocyclones Silicon Carbide Liners are engineered to solve the critical challenge of abrasion, corrosion, and geometric degradation in high-velocity slurry processing systems. Crafted from ultra-high-purity SiC (99%+ purity for sintered grades), these liners deliver unmatched durability, dimensional stability, and performance consistency—outperforming rubber, polyurethane, and alumina alternatives in the most aggressive mineral processing environments. Designed to line the cylindrical, conical, apex, and vortex finder sections of hydrocyclones, they preserve the critical geometry of your equipment, ensuring precise particle classification and long-term operational reliability.

Core Functions

1. Extreme Wear & Corrosion Resistance: SiC’s Mohs hardness of 9.5 (near-diamond) and chemical inertness (resistant to pH 1–14 slurries) prevent erosion from high-velocity, abrasive particles (e.g., quartz, feldspar) and corrosion from acidic/alkaline mining fluids, maintaining hydrocyclone integrity for years.

2. Dimensional Stability: Rigid SiC structure resists deformation under pressure (0.1–0.35 MPa operating pressure) and temperature fluctuations (0–100°C), preserving critical design parameters (cone angle, apex diameter, vortex finder dimensions) to ensure consistent cut size (d50) and separation sharpness.

3. Efficiency Preservation: By eliminating liner wear-induced geometry changes, our SiC liners keep hydrocyclones operating at optimal classification efficiency, reducing overgrinding, slime generation, and energy waste in wet ball mill circuits.

4. Impact Resistance: Reinforced SiC composites (for hot-pressed grades) withstand impact from coarse particles (>5mm) without cracking, avoiding unplanned downtime from liner failure.

Application Scope

Our SiC hydrocyclone liners are indispensable for industries and processes where abrasive slurry flow is constant:

• Mining & Mineral Processing: Iron ore, copper, gold, zinc, and coal mines (wet ball mill circuits, flotation pre-classification, tailings dewatering). Ideal for quartz-rich ores (≥15% quartz content) and high-velocity slurry (≥10 m/s flow speed).

• Aggregate & Construction: Sand and gravel washing, concrete recycling, and crushed stone classification systems.

• Chemical & Industrial Processing: Slurry separation in fertilizer production, wastewater treatment, and pigment manufacturing (corrosive slurry environments).

• Metallurgy: Smelter slag processing, leaching circuit classification, and metal ore beneficiation.

Case-proven performance at leading operations: Brazil iron ore mines, Nevada gold mines, Chile copper mines, and Australian coal processing plants.

Size & Customization

Standard Dimensions (Reference Only)

We offer pre-engineered liners for common hydrocyclone models (Krebs, Multotec, Weir, Metso) with the following range:

• Cylindrical section diameter: 50mm–1200mm

• Cone angle: 10°–40°

• Apex diameter: 20mm–200mm

• Vortex finder length: 50mm–500mm

100% Customization (Our Core Strength)

95% of our orders are custom-tailored to meet your unique requirements—no two mining operations have identical slurry characteristics, hydrocyclone designs, or wear patterns. Our customization process is guided by:

• Equipment Specifications: Exact hydrocyclone model, shell dimensions, and installation constraints.

• Work Conditions: Slurry particle size distribution, solids concentration, flow velocity, and chemical composition (pH, corrosive agents).

• Performance Goals: Target cut size (d50), circulating load, and desired liner lifespan (3–5 years typical for sintered SiC).

Our engineering team uses 3D modeling and CFD simulation to design liners that fit perfectly and optimize separation efficiency. Custom options include:

• Tapered cone profiles for enhanced particle segregation

• Reinforced apex liners for high-wear zones

• Grooved surfaces to reduce slurry turbulence

• Flanged designs for easy installation

Core Advantages vs. Alternatives

Additional Benefits:

• Downtime Reduction: Eliminates 4–8 unplanned shutdowns yearly (liner replacement takes 4–8 hours per hydrocyclone).

• Energy Savings: 10–18% lower mill energy consumption via stable circulating load control.

• Sustainability: 100% recyclable, reduces waste from frequent liner replacements, and cuts water/energy usage.

Why SiC Liners Are a Must-Have

In abrasive mineral processing environments, subpar liners lead to catastrophic losses:

• A worn hydrocyclone liner can reduce mill throughput by 25%, cut mineral recovery by 5–10%, and increase energy costs by 15%—costing a 10M ton/year mine $1–2M annually.

• Rubber/PU liners require quarterly replacement, with each change causing 4–8 hours of downtime (valued at $5,000–$10,000/hour in lost production).

• Alumina liners crack under impact, leading to sudden failures and safety hazards.

Our SiC liners eliminate these risks: they pay for themselves within 1–2 years via reduced maintenance, higher productivity, and lower energy costs. For mines targeting sustainability and profitability, SiC hydrocyclone liners are not an upgrade—they are a non-negotiable investment.

Customization Process & Ordering

1. Share Your Requirements: Provide hydrocyclone model, slurry data, and performance goals (via our technical questionnaire).

2. Engineering Design: Our team creates 3D models and CFD simulations to optimize liner geometry.

3. Sample Confirmation: We produce a prototype for fit and material testing (optional).

4. Manufacturing: Precision production via reaction bonding, pressureless sintering, or hot pressing (per your needs).

5. Installation Support: On-site guidance for liner installation and alignment (available globally).

Contact Us

Ready to upgrade your hydrocyclones with durable, custom SiC liners? Our technical team is available 24/7 to assess your needs, provide a personalized quote, and design a solution that maximizes your operational efficiency.