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BHAJJANKA SIMLAB

Multi-Ore Hydrocyclone
PU Liner Wear Simulator

Iron Ore · Coal · Gold Ore · Clay · Sand · Tailings · Mineral Processing

Model Ref
SIMLAB-HC-MINERAL-2026
Planning model – recalibrate with site life data
Simulator
Ore Library
Model Logic

1. Duty Selection

Simulation-Backed Liner Selection
m3/hr
30%
High SG ore at high Cv increases density and separation load. Clay has viscosity risk.
micron
90A
9000h
INR/kg
Critical Zone
–
–
PU Weight
–
–
Wear Cost
–
–
Zone-by-zone liner thickness map–
 
Zone Radius V Tang Wear Total Wear Required Mfg Thk Engineering Action
Commercial use: This model is intended for preliminary thickness selection, quotation support and sales engineering. For guaranteed life commitments in iron ore, gold ore, abrasive tailings or high-value cyclone banks, use site life data / CFD validation before final sign-off.

Ore / Mineral Library – Editable Assumption Base

Factors are starting engineering assumptions for PU liner planning. They are intentionally editable in the Excel generator and should be recalibrated with actual BHAJJANKA field life once the customer site history is available.

 
 

Model Logic – Multi-Ore Wear Correction

1. Formula

Wear = K x V^1.5 x (Cv/25) x Shape x Abrasion x SlurrySG x HardnessFactor x d50Factor x ZoneImpact x ViscosityFactor

Interpretation: velocity drives wear, but ore type changes the result through density, angularity, mineral hardness, abrasiveness and slurry rheology. Gold-quartz and iron ore duties therefore require a stronger liner strategy than coal or clay at the same hydraulic duty.

2. Design Verdict Rules

  • Apex >= 80 mm: do not simply cast thick PU. Use replaceable spigot/apex insert.
  • Lower cone >= 50 mm: consider segmented liner, premium PU or ceramic check for highly abrasive ore.
  • Feed velocity > 6 m/s: upsize cyclone or reduce per-cyclone flow.
  • Clay / sticky ore: wear may be low but classification and choking risk can dominate the design.

3. BHAJJANKA SIMLAB Positioning

This tool converts customer enquiry data into a defendable preliminary liner design within minutes: duty input, ore behaviour, zone-wise wear, thickness, PU weight, cost, and commercial recommendation.

BHAJJANKA® SIMLAB – Simulation · Research · Engineering. Planning model only; not CFD. Calibrate with actual field life for final warranty / guaranteed life commitments.