GIW Industries, a leader in the design, manufacture and application of heavy duty centrifugal slurry pumps, has announced a groundbreaking new hydrocyclone design that reduces rebuild time by as much as 75%. The GIW Hydrocyclone, covered by more than 20 U.S. and global patents, has significantly longer wear life and shorter maintenance times than traditional hydrocyclones, according to GIW.

The innovative design reduces downtime by up to six hours. Most hydrocyclone manufacturers are basically producing the same designs they have been using for the past 50 years, GIW explained. In contrast, the GIW Hydrocyclone is the result of a fresh, original look at mining-processing needs and modern technology. A straightforward tie-bolt and clamp design is a breeze to install and maintain. Seven fasteners are all that is needed for a complete rebuild. A twist-to-lock option simplifies apex removal and service, and drop-in, glue-free liners reduce build time. By adding weep holes for early wear detection, customers can virtually eliminate unplanned outages.

“We offer a lot of features that no one else can,” said Mark Davis, GIW mill products manager. “An unplanned outage can cost anywhere from $50,000 to $150,000 per hour in terms of lost production, labor and other overhead. We offer a longer wear life, and our cyclone takes a quarter of the time to rebuild, when compared with competitors’ cyclones.”

That equals a typical rebuild time of just two hours—a time savings of up to six hours and a potential financial savings of hundreds of thousands of dollars.

The GIW Hydrocyclone is made for high-wear environments. Aside from its simple installation and fast, easy maintenance, this hydrocyclone is built to last. Tongue-and-groove mating surfaces foster precision alignment. Long-lasting urethane and ceramic cones and powder-coated steel construction resist corrosion and damage from abrasion, acid, oil, hydrocarbon, phosphate, potash and high temperatures, increasing the life of the product.

This hydrocyclone has superior resistance to tramp and oversize materials, thanks to its reaction bonded silicon carbide (RBSiC) and polyurethane construction. The patented design makes the GIW Hydrocyclone perfect for use in primary ball mill, aggregate, tailings, regrind, coal-preparation, dewatering and phosphate/potash processes.

The GIW Hydrocyclone is available in eight sizes, ranging from 2.5 inches to 33 inches. Repairs and rebuilds can be performed in place or on a build stand.

“The cyclone market is ready for better products,” Davis said. The GIW Hydrocyclone is ready to meet that demand.