Innovative design features

New 650 model expands the Cavex® 2 hydrocyclone range

I‌‌‌mprovements in efficiency and bypass demonstrated by the latest addition to the Cavex® 2 hydrocyclone range translate to operational savings for brownfield sites and reduced capital expense for greenfield projects. The Cavex® 2 hydrocyclone marked a new era in separation technology, with its LIG+™ advanced laminar spiral inlet and size of the feed chamber, delivering 30 % more capacity. This latest generation of cyclones boasts innovative design features, delivering an improvement in volumetric capacity and reduced turbulence.


1 Model 650 of the Cavex® 2 hydrocyclone series
© Weir Minerals

1 Model 650 of the Cavex® 2 hydrocyclone series
© Weir Minerals
The Cavex® 2 650 is the new hydrocyclone size to be released in the Cavex® 2 product line, and it has undergone lab testing and in-field testing to ensure it can withstand the rigours of heavy-duty industrial and abrasive applications. The 650 model addresses the continual demand for increased operational and circuit capacity, and offers customers process improvements combined with digital technology.


By reducing bypass returning to the mill, fewer fines are returned back to the mill in closed-circuit milling process, thus reducing the need for energy to be used to further process particles that are already small enough to move on to the next stage. This frees up mill capacity for the size reduction of larger particles. As a hydrocyclone that can make a finer separation, the Cavex® 2 650 can operate at a lower pressure for further energy savings or a higher feed density for water savings while maintaining the existing cut size from the hydrocyclone. And finally, using equipment with a higher volumetric capacity required fewer units to be installed upfront as well as fewer consumable spare parts used over the life of the hydrocyclone.


2 With its LIG+™ advanced laminar spiral inlet and size of the feed chamber it delivers 30 % more capacity
© Weir Minerals

2 With its LIG+™ advanced laminar spiral inlet and size of the feed chamber it delivers 30 % more capacity
© Weir Minerals
The new Cavex® 2 650 hydrocyclone comprises a robust metal casing with an elongated chamber design. The additional length guarantees turbulence is decreased inside the cyclone, allowing for additional volume and increased efficiency during the process. To satisfy all process conditions and slurry types, the Cavex® 2 650 hydrocyclone comes with a range of material technology options including industry-leading Linatex® premium rubber, the industry standard and ever-reliable R55 rubber, and neoprene for high levels of hydrocarbon and ceramic. The Cavex® 2 650 hydrocyclone can be customised to suit almost any application with a variety of spigots, vortex finders and cone angles.


The latest Cavex® 2 650 hydrocyclone trial with a customer took place in a large copper ore mine Chile, which had a SAG mill in a closed circuit with the cyclone cluster. The trial tested one Cavex® 2 650 in a 6-place cluster of existing Cavex® cyclones and saw an improvement of up to 48.5 % in circulating load and 31.7 % in water bypass versus the original cluster. A lab water test with the same hydrocyclone fittings as above also yielded positive results: a 211 mm inlet and 260 mm vortex finder delivered 16 % more capacity at 100 kPa, and 17 % more capacity at 250 kPa.


The Cavex® 2 650 hydrocyclone is the second in a range of standard sizes that Weir Minerals are planning to release, with the commitment to onsite trials, research and development means the expert Weir Minerals team always pursues new improvements to ensure that Cavex® hydrocyclones stay at the forefront of the industry.


The new Cavex® 2 650 hydrocyclone will be available globally, with assembly in local regions. In addition more sizes are in development to expand the current product range.

Advanced benefits

As with all Cavex® 2 hydrocyclones, the 650 delivers significant benefits to mining customers including:

· Increased operational and circuit capacity up to 30 %

· Maximised plant recovery by reducing the quantity of misclassified particles with an average improvement of the alpha parameter more than 10 %

· Improvements in bypass with an average of over 15 %

· Opportunity to retrofit Cavex® 2 650 cyclone into existing cyclone cluster footprints

· Less turbulence during the separation process due to the LIG+™ inlet and elongated chamber design

· Enhanced performance with a Synertrex®-enabled monitoring system which can detect roping or blockage conditions in advance for continuous, efficient operation of the hydrocyclone

· Improvement of environmental footprint

Applications and industries

The new Cavex® 2 650 hydrocyclone is ideally suited for use in a range of industries, including:

· Mining

· Aggregates

· Utility/FGD/General industrial

· Classification and separation (Mining)

· Classification and separation (Aggregates)

· Mine dewatering systems

· Tailings management


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