New CAVEX® 2 hydrocyclone increases volumetric capacity up to 30%

Almost 25 years after the original Cavex® hydrocyclone revolutionised classification, Cavex® 2 will introduce a step-change in performance and sustainability, with water and energy savings...

The launch of Cavex® 2 marks a new generation of hydrocyclones. Like the original Cavex® hydrocyclones did more than two decades ago, Cavex® 2 introduces new geometric features which offer performance unmatched by any cyclone in operation today.

“Our Cavex 1 design set an industry benchmark over two decades ago with its unique 360° laminar spiral inlet geometry, which significantly reduced turbulence. This design was so successful and desired by the market that it was widely replicated by competitors,” states Debra Switzer, Global Product Manager for Hydrocyclones at Weir Minerals. “Following years of research, development and trials, we have improved upon this design with the creation of LIG+ inlet and chamber design. This unique design produces a more stabilised flow pattern, further reduces turbulences and friction throughout the hydrocyclone and provides up to 30% additional capacity.”

The advanced LIG+™ design (patent pending) enables the Cavex® 2 hydrocyclones to classify up to 30% more feed slurry, while occupying the same footprint as competitor hydrocyclones. Ultimately, operators can now achieve more throughput with fewer operating hydrocyclones, reducing the upfront CAPEX.

The new design has taken into consideration the shape and angle of the hydrocyclone to ensure particles report to the correct stream. This reduces recirculation and misclassification, taking separation efficiency to the next level.  

“Cavex 2 allows our customers to do more. A more sustainable circuit, with lower energy and water requirements. Expand the capacity of their existing circuits, without increasing the footprint of the cyclones or clusters. It’s the kind of generational engineering leap that will change the way circuits are designed for decades to come,” says Debra Switzer.

Engineered for future mine, Cavex® 2 takes advantage of Weir Minerals’ Synertrex® IIoT technology, which enhances the overall performance of the hydrocyclone. Armed with this technology, operators are automatically alerted to roping or blockage conditions ahead of time, ensuring the hydrocyclone runs under the most optimal operating conditions.

“To minimise the amount of bypass that is produced in any hydrocyclone, it is favourable for it to operate in the semi-roping condition.  This is often difficult to do continuously because any upset in the hydrocyclone’s feed conditions could move it into the roping condition, but with Synertrex this balancing act can be closely managed,” states Debra Switzer.

Cavex® 2 hydrocyclones can be customised to suit almost any application, with a variety of spigots, vortex finders and liners. Liners are available in a range of material options, including Weir Minerals’ proprietary R55® rubber compound or Linatex® premium rubber, both of which have proven to outlast competitors elastomers in similar applications. Liners can be replaced via a “snap-in” system which requires zero adhesive, while smaller models (400CVD and below) are available with moulded fibreglass housings.

“Every stage of the Cavex 2’s design has been guided by the needs of our customers . As a consequence it has been tested in multiple mining applications throughout the globe. These tests revealed outstanding results of up to 30% additional capacity. Decreasing ore grades and increasing need to reduce both water and energy usage have created the need for a low maintenance, highly efficient hydrocyclone which can be readily retrofitted into existing circuits to increase throughput and maximise returns. I can’t wait for our customers to see what this new range is capable of,” concludes Debra.

Cavex® 2 hydroyclones are now available to increase capacity of mines across the globe. For more information, visit

Associated Businesses

  • Weir Minerals Europe Limited is part of the Minerals Division of the FTSE 250 Weir Group, specialists in providing engineering solutions to the minerals, power & industrial and oil & gas sectors.The Weir Minerals Division focus...