No. 1998.

100

Hydrocyclone Model Simulation: A Design Tool for Dewatering Oil

Sands Plant Tailings
A.I.A. Salama, CANMET, Devon, Alberta, Canada; and T. Kizior, Syncrude Canada,
Fort McMurray, Alberta, Canada

Abstract

Introduction

Design of classifying hyd rocyclone d ewatering ci rcuits for oil

sands plant tailings requi res careful evaluation of d ewatering
levels as a function of the cyclone cut size, variations in the
cyclone me chanical dimensions, and th roughput . The availability of reliable models can simplify this p rocess and p rovide
valuable information that enables the design engineer to
understand the p rocess and evaluate di fferent options ( e.g.,
single- or two-stage cyclone ar rangement, cut size, per cent
solids in underflow and feed, and number of cyclones).
A hyd rocyclone model simulation app roach has been
developed at the CANME T Western Resea rch Cent re (CWRC)
for designing d ewatering and fine particle sepa ration ci rcuits.
The app roach is based on an existing empirical model. Utilizing a cyclone manufactu rers published data, some modifications have been d eveloped and int egrated into the model.
Plant tailings characteristics, cyclone me chanical dimensions, and ope rating conditions a re utilized in the CWRC
modeling simulation . The computer results a re presented in 3D graphs and cor responding 2-D maps showing the cyclone
mass recover y, per cent solids by mass in underflow and ove rflow, and cut size as functions of the cyclone ap ex diameter
and cyclone th roughput (i. e., inlet p ressure or p ressure drop).
The g raphs and maps a re useful in visualizing and illust rating
the e ffects of ope rating conditions on cyclone performanc e.
The p roposed computer simulation app roach has been
demonst rated th rough the design of d ewatering ci rcuits for oil
sands plants . The design includes evaluation of hyd rocyclone
performance and d ewatering l evels. A summary of the results
is presented.

Conway, 1985 adopted an approach based on Plitts model

(Plitt, 1976), where the cyclone mechanical dimensions are
adjusted in a prescribed manner until the desired cut size is
achieved. Also the manufacturers cyclone capacity data are
used to determine the required number of cyclones. No
attempt was made to check the cyclone underflow per cent
solids (e.g., cyclone operating in rope mode or plugged).
While the approach may be valid in some cases, it does not
provide a thorough insight into cyclone performance as the
operating conditions are changed. Again, Plitts model is used
in the computer simulation approach adopted in this paper.
The cyclone mechanical dimensions are kept fixed except the
apex and vortex finder diameters are changed according to
selected manufacturer values. It is known that the apex diameter has significant effects on cyclone performance (per cent
solids and mass recovery). For a particular cyclone size, inlet
diameter, and overflow diameter, two sets of apex diameters
and feed volumetric flow rates are used to study their effects
on cyclone performance (cut size, underflow mass recovery,
and underflow and overflow per cent solids by mass).
In general, the hydrocyclone model simulation objective
may be stated as: start with given oil sands plant tailings characteristics and try to predict hydrocyclone performance, in
particular, cyclone underflow and overflow per cent solids by
mass, underflow mass recovery, and cyclone cut size. These
steps are summarized in the following table.

Input Data
Solids particle size distribution
Feed solids and fluid mass rates
Feed % solids (mass)
Solids specific gravity
Carrier fluid specific gravity
Carrier fluid viscosity
Desired cut size, D50 *

Model and Intermediate Data

Number of cyclones
Cyclone geometrical dimensions
Cut size range
Underflow/overflow mass split
Sharpness of separation
Pressure drop/capacity**
Model tuning parameters

Output Data
Overflow % solids (mass)
Underflow % solids (mass)
Overflow solids and fluid mass rates
Underflow solids and fluid mass rates
Underflow % mass recovery
Product particle size distributions

* D50 is the cyclone cut size (i.e., particle size which has a 5050 chance of reporting to either the underflow or the overflow streams).
**Pressure drop is defined as the difference between inlet pressure and overflow pressure.

CWRC Hydrocyclone Model

Simulation Approach

Svarovsky, 1984); however, the modifications are presented

next.

In Plitts model, the cyclone model predictions can be determined by utilizing four fundamental parameters expressed in
terms of the operating design variables (Plitt, 1976). These
parameters are:
Separation cut size D50

Pressure Flow Rate Cyclone Size

Correlation
Based on Krebs published data the following correlation has
been derived

Flow split between overflow and underflow

Sharpness of separation
Capacity/pressure drop
By determining these parameters, a complete mass balance
together with size distribution of the cyclone products can be
achieved. Plitts empirical model was developed based on a
large amount of data collected over wide ranges of operating
conditions. The CWRC computer simulation utilized Plitts
model with some changes. These changes were derived based
on Krebs Engineers (KE) published data. The details of Plitts
model are given elsewhere (Plitt, 1971, 1976, and further
work by Plitt and Kawatra, 1979; Flintoff et al, 1987, see

Q = K c D 2.12
c Dp

0.498

(1)

where Kc is a coefficient and is dependent on the cyclone size

and p (pressure drop across the cyclone) and Q (cyclone feed
volumetric flow rate) are expressed in psi and USgpm, respectively. However, it is straightforward to adjust Kc so that p and
Q can be expressed in different units. A set of nominal values
of Kc are given in this table.

Dc

4"

6"

10"

15"

20"

26"

30"

33"

44"

50"

Kc

0.481

0.603

0.417

0.374

0.468

0.527

0.619

0.616

0.475

0.539

Cyclone Cut Size Correlation

Based on KE published data and using nonlinear regression, a
correlation for the corrected cut size D50c can be determined
as

The Kc values could be changed around the nominal values

to give similar relationships between p and Q for the same
cyclone size. If, for a given cyclone size and known p and Q at
a particular operating conditions, then by back substitution of
these values in Equation 1 a new Kc can be determined. Mular
and July 1978 (and reported in Wills, 1992) utilized Krebs

D50c = F D50c .

2.12

Dp

0.498

0.5

(3)

where a viscosity term is added and FD50c includes units conversion. KE engineers have derived a similar form with slight
changes to the powers (Gottfried et al, 1982). The difference
between the actual cut size D50 and the corrected cut size D50c
is the actual cut size obtained using the actual classification
curve (i.e., including water bypass to underflow).

published data and derived a similar form for determining the

cyclone maximum capacity as

Q = K c Dc

0.6 83

m
Dc
0.5
0.301
(1 - 1.9C )1.48 Dr
Dp

(2)

where Kc = 9.4 x 10-3 and using SI units.

Case Study

and apex diameters. The corrected D50c is dependent on the

actual cut size D50 and the water split (bypass) to the underflow.
A selected set of three-dimensional (3-D) graphs and corresponding two-dimensional (2-D) maps (for single-stage 15"
and 20" cyclones and 40% and 50% feed solids by mass) are
presented in Figures 1-6. These figures are typical of the computer results obtained and are presented to demonstrate the
effects of apex diameter and cyclone pressure drop (feed volumetric flow rate, Equation 1) on cyclone performance. Figures
1 and 3 are 3-D graphs for the 15" cyclone with 40% feed solids and overflow diameters of 5" and 6", respectively. Figure 2
is the 2-D map corresponding to the 3-D graph in Figure 1.
Figures 4 and 5 are 3-D graphs for the 20" cyclone with 50%
feed solids and overflow diameters of 7" and 8", respectively.
Figure 6 is the 2-D map corresponding to the 3-D graph in
Figure 5.
In general, the simulation results for the 10-inch cyclone
showed flat surfaces for the underflow per cent solids (i.e.,
constant high values) over the selected ranges of feed volumetric flow rate and apex diameter. This is because the 10inch cyclone tends to separate at a low cut size and, as a result,
the apex becomes overcrowded resulting in higher underflow
per cent solids. The underflow mass recovery and per cent solids over the selected ranges of apex diameters exhibited
opposing trends (see Figures 1, 3, 4, and 5). The underflow
mass recovery and cyclone actual cut size D50a over the
selected ranges of apex diameters exhibited opposing trends
(see Figures 1, 3, 4, and 5). Cyclone performance (in particular the underflow mass recovery, underflow per cent solids,
and cut size D50) is strongly affected by the apex diameter. In
the selected range of 20% of the nominal feed volumetric flow
rate, the model predictions show unexpectedly small effects of
the feed volumetric flow rate (see Figures 1, 3, 4, and 5). Low
settings of overflow diameters and high settings of apex diameters produce higher underflow mass recovery with lower per
cent solids. This is due to forcing more solids and water to the
underflow stream. On the other hand, low settings of overflow
and apex diameters produce higher underflow mass recoveries
and per cent solids. Furthermore, as the feed per cent solids
increases the underflow mass recovery decreases.
A two-stage cyclone circuit was simulated where the overflow of stage I is fed to stage II. Stages I and II underflows
were combined to form the circuit underflow. Based on the
results of single-stage cyclone simulation the suitable apex
settings did not change very much in relation to the feed per
cent solids. As a result, the same settings used in the singlestage simulation were repeated for the two-stage simulation.
The two-stage cyclone circuit performance predictions at the
selected settings are summarized in Table 3. The results indicated that the two-stage cyclone circuit mass recoveries are
much higher than the single-stage cyclone recoveries; however, the underflow per cent solids is lower in the two-stage
cyclone circuit than in the single-stage cyclone. The per cent
solids differential decreases as the feed per cent solids

In late 1997, Syncrude Canada Ltd. decided that the hydrocyclone could be a viable process technology for dewatering
plant tailings. The plant approached CWRC to carry out a
computer modeling simulation and preliminary engineering
design, and to produce in-depth data that would provide a
basis for the engineering and installation phases of the development.
The plant tailings sand has a typical direct particle sizemass distribution as shown in Table 1. This particle size distribution is used as part of the input files to the CWRC modeling
simulation. Note that a top particle size of 250 mm is used in
the cyclone computer models. The direct mass distribution is
used to generate the cumulative mass distribution. Close
examination of the cumulative mass distribution indicates that
the desired cut size is in the range of 2040 mm.

Computer Input Data

Based on the tailings characteristics, slurry flow rate, and particle size distribution, a set of cyclone sizes (10", 15", 20")
and a set of feed per cent solids by mass (35%, 40%, 50%,
60%) were selected. The solids and liquid specific gravities
are 2.65 and 1, respectively. Using a nominal pressure drop
across the cyclone, a set of feed volumetric flow rates (using
Equation 1) was selected. This allowed better presentation of
the results and facilitated visualization of the effects of feed
volumetric flow rate and apex diameter on the underflow and
overflow per cent solids, cut size, and mass recovery. Using
plant tailings total volumetric flow rate in USgpm and Krebs
published data, the number of cyclones can be determined.
Such values are determined by assuming nominal values of
cyclone feed volumetric flow rate. There was no attempt to
adjust the calculated number of cyclones to meet KE design.
This adjustment can be made at the design stage.
KE cyclone mechanical dimensions, in particular, the vortex finderBapex distance and cyclone inlet diameter for the
10-, 15-, and 20-inch Krebs cyclones, were kept constant during computer simulation. Two settings around Krebs cyclone
overflow diameters were selected. A set of underflow diameters was selected rather than two settings around Krebs nominal values. This made it possible to evaluate the effect of
underflow orifice diameter on cyclone performance. Cyclone
performance is very sensitive to apex diameter and to lesser
extent to cyclone inlet pressure, as will be shown later.

Computer Simulation Results

The single-stage cyclone performance predictions at maximum underflow mass recoveries for different operating settings are summarized in Table 2, where * indicates that the
apex is overcrowded (small apex) and sends coarse particles to
the overflow stream, and recovery indicates mass recovery.
The maximum mass recoveries were obtained at low overflow

References

increases. Therefore, the two-stage cyclone circuit is recommended for feed with higher per cent solids (5060%).
The computer simulation results are predictive in nature
and supplementary experimental work is needed to support
the predictions

1.

2.

Conclusion

3.

A hydrocyclone model simulation approach for designing

dewatering and fine particle separation circuits has been
developed at the CANMET Western Research Centre
(CWRC). The approach utilizes an existing empirical model
and some modifications based on a cyclone manufacturers
published data are integrated into the model. The published
data on cyclone mechanical dimensions and operating conditions are used in the development of the modeling simulation.
The computer results are presented in 3-D graphs and corresponding 2-D maps showing the cyclone mass recovery, mass
per cent solids in underflow and overflow, and cut size as
functions of the cyclone apex diameter and cyclone throughput.
The results obtained from an oil sands plant utilizing this
computer simulation approach are briefly summarized and
presented.
The usefulness of the CWRC model simulation has been
demonstrated by the utilization of the results in the course of
full-scale implementation at several oil sand plants applications.

4.

5.
6.
7.

8.
9.

Acknowledgment
This work was supported in part by the Federal Panel on
Energy Research and Development (PERD). The authors
would like to thank Syncrude Canada Ltd. for permission to
publish the present work.

Conway, T.M., 1985. A computer program for prediction

of hydrocyclone performance, parameters, and productsize distributions, Mintek-Report No. M233, Randburg,
South Africa.
Flintoff, B.C., Plitt, L.R., and Turak, A.A., 1987.
Cyclone modeling: a review of present technology,
CIM Bulletin 80:905, 3950.
Gottfried, B.S., Luckie, P.T., and Tierney, J.W., 1982.
Computer simulation of coal preparation plants, U.S.
Dept. of Energy, DOE/PC/30144-T7, DE 83004279,
December.
Mular, A.L. and Jull, N.A., 1978. The selection of
cyclone classifier, pumps and pump boxes for grinding
circuits, Mineral Processing Plant Design, AIMME,
New York.
Plitt, L.R., 1971. The analysis of solid-solid separation
in classifiers, CIM Bulletin 64:70: 4247.
Plitt, L.R., 1976. A mathematical model of the hydrocyclone classifier, CIM Bulletin 69:776: 114123.
Plitt, L.R. and Kawatra, S.K., 1979. Estimating the cut
size of classifiers without particle size measurement, Int
J Min Proc 5: 369378.
Svarovsky, L., 1984. Hydrocyclones, Holt, Reinhart,
and Winston, New York.
Wills, B.A., 1992. Mineral Processing Technology, 5th
Edition, Pergamon Press, New York.

Size
(mm)

Cumulative Mass
(%)

Size
(mm)

Direct Mass
(%)

- 10

9.02

- 10

9.02

- 20

12.54

10 - 20

3.52

- 40

20.15

20 - 40

7.61

- 80

26.54

40 - 80

6.39

- 90

32.46

80 - 90

5.92

- 100

39.31

90 - 100

6.85

- 150

78.69

100 - 150

39.38

- 200

95.77

150 - 200

17.08

- 250

100.00

+ 200

4.23

Total

100

Table 1: Sand Cumulative Mass and Direct Mass Distributions With Particle Size

Cyclone Feed
Solids %

35 %

40 %

50 %

60 %

Cyclone
Diameter

Cyclone
Underflow

Cut Size D50a

(mm)

Solids %

Recovery %

10"

75.3

82.8

38

15"

63.3

87.2

37

20"

64.7

79.1

52

10"

77.2

74.1

65*

15"

67.3

82.3

42

20"

69.4

76.3

60

10"

78.0

57.6

117*

15"

75.1

75.7

62

20"

75.8

67.6

87

10"

79.1

46.9

158*

15"

76.3

61.2

109

20"

73.7

50.8

150

* Overcrowded apex (small apex)

Table 2: Single-Stage Simulation Results

Cyclone
Feed Solids
%

Cyclone

Stage I

Stage II

Diameter

Cyclone
Underflow

Cyclone
Underflow

TwoStage
Cyclone
Circuit

Solids
%

Recovery
%

D50a
mm

Solids
%

Recovery
%

D50a
mm

Solids
%

Recovery
%

35%

10"
15"
20"

75.3
63.3
64.7

82.8
87.2
79.1

38
37
52

15.9
11.4
18.1

45.2
53.3
50.7

26
23
36

57.0
47.6
49.6

90.6
94.0
90.0

40%

10"
15"
20"

77.2
67.3
69.4

74.1
82.3
76.3

65*
42
60

31.8
18.5
24.3

57.7
55.5
52.9

29
25
39

62.3
52.6
54.9

89.0
92.1
88.8

50%

10"
15"
20"

78.0
75.1
75.8

57.6
75.7
67.6

117*
62
87

61.0
33.8
42.1

66.5
61.1
57.5

41
30
49

71.5
62.5
64.6

85.8
90.6
86.2

60%

10"
15"
20"

79.1
76.3
73.7

46.9
61.2
50.8

158*
110
150

75.3
58.3
63.3

60.6
64.2
55.3

70
53
97

77.5
70.0
69.7

79.0
86.1
78.0

Overcrowded apex (small apex)

Table 3: Two-Stage Simulation Results

Figure 1: 3-D Simulation Results for 40% Feed Solids, 15" Cyclone, 5" Do

Figure 2: 2-D Simulation Results for 40% Feed Solids, 15" Cyclone, 5" Do

Figure 3: 3-D Simulation Results for 40% Feed Solids, 15" Cyclone, 6" Do

Figure 4: 3-D Simulation Results for 50% Feed Solids, 20" Cyclone, 7" Do

Figure 5: 3-D Simulation Results for 50% Feed Solids, 20" Cyclone, 8" Do

Figure 6: 2-D Simulation Results for 50% Feed Solids, 20" Cyclone, 8" Do