Custom Hydrocyclone Spare Parts
Whether you operate a Cavex unit or an FLSmidth/KREBS design, DEF Rubber offers a reliable one-stop solution for all your hydrocyclone rubber parts needs.
Contact us today to discuss your project or request a free quote on custom-made hydrocyclone spares.
Hydrocyclone Types and Spare Parts We Provide
We support a wide range of hydrocyclone separators used in mining and industrial processes. In particular, DEF Rubber manufactures parts compatible with Cavex hydrocyclones (known for their innovative curved inlet geometry) and FLSmidth’s KREBS series hydrocyclones (like the gMAX® line). Each brand and model has unique design features, but they all rely on high-wear components that periodically need replacement. Our team is experienced in fabricating Cavex hydrocyclone parts and FLSmidth hydrocyclone parts that fit seamlessly into your existing equipment.
Typical hydrocyclone separator spare parts we supply include:
Feed chamber and cover liners
Protective rubber linings for the feed inlet area and upper housing, engineered to withstand intense erosion from incoming slurry.
Cone section liners (upper and lower cones)
Durable rubber linings for the conical sections of the cyclone, preventing abrasion of the cyclone body and maintaining separation efficiency.
Vortex finders
Replacement upper pipes/tubes (often rubber-lined) that channel overflow; our custom-molded vortex finders resist wear and maintain the correct flow geometry.
Apex/spigots
Precision-made underflow orifices (spigots) in natural rubber or polyurethane, ensuring a consistent underflow spray and longer life before needing change-out.
Overflow elbows and pipes
Rubber-lined overflow outlet components that carry fine product away, built to fit your model and avoid premature failure.
Other custom hydrocyclone parts
Whatever part of your Cavex or FLSmidth hydrocyclone requires replacement (whether standard or non-standard), we can design and manufacture a robust solution.
DEF Rubber’s capabilities span across the mining process. In addition to cyclone components, we also produce custom slurry pump spare parts and other rubber wear components. This enables our clients to streamline procurement and trust that all their critical equipment – from hydrocyclones to pumps – is protected by the same quality DEF Rubber material.
By covering all key internal components, we offer a complete aftermarket solution for your cyclone. Each replacement part is custom-molded to exact dimensions and quality-checked to ensure it meets or exceeds original OEM specifications. If you have an older or modified cyclone, our engineers can adapt designs to match any custom configurations.
(For more background on improving cyclone longevity, see our Rubber Lining for Hydrocyclone guide.)
Advantages of DEF Rubber’s High-Performance Material
DEF Rubber’s custom-molded wear parts are made from premium natural rubber, delivering superior durability and toughness in aggressive slurry conditions. All our hydrocyclone spare parts are constructed from DEF’s proprietary ultra wear-resistant rubber compound. This material is a result of advanced nano-engineered natural rubber processing, giving our parts exceptional physical properties:
Extreme Wear Resistance:
Our special rubber formulation significantly outlasts conventional materials. Independent tests show DEF’s liners achieve up to 3 times longer service life compared to standard polyurethane or rubber liners. This means far fewer shutdowns for maintenance and lower long-term costs.
High Strength and Tear Toughness:
With a tensile strength over 24 MPa and tear strength above 42 N/mm, our rubber even surpasses the industry-leading Linatex® rubber in key metrics. In practical terms, this high strength prevents cracks or premature failures, while the excellent tear resistance stops sharp particles from ripping the liner. Your cyclone can operate longer under heavy wear without unexpected breakdowns.
Elasticity for Energy Absorption:
DEF Rubber’s natural elasticity helps absorb impact and vibration inside the cyclone. The rubber flexes to dissipate forces from fast-moving slurry, protecting the cyclone structure. This resilience also ensures a snug fit of parts (maintaining sealing and efficiency) and quick recovery from each impact, which is crucial in maintaining performance over time.
Chemical and Temperature Resistance:
Our high-quality natural rubber is formulated to perform in the demanding environments hydrocyclones face. It endures continuous exposure to abrasive ores, water, and chemicals commonly found in mineral processing. The material remains stable in a broad temperature range and is resistant to acids or alkalis often present in slurries. (For operations involving oil or high temperatures, we can also offer specialized synthetic rubber or polyurethane options to suit your needs.)
By utilizing a perfect alternative to Linatex rubber in our products, DEF Rubber helps you avoid the steep costs of OEM branded spares while actually improving on their longevity. You get top-tier quality without the “brand-name” price premium. In fact, many clients find that switching to DEF Rubber parts cuts their consumable spending by 30–50% due to the combination of competitive pricing and extended wear life.
Typical Applications and Industries
Our custom hydrocyclone parts are used across numerous industries and applications where liquid-solid separation is critical. Some of the areas and sectors that benefit from DEF Rubber’s high-performance cyclone spares include:
No matter the industry, if your operation uses hydrocyclones for separation, DEF Rubber’s parts are designed to maximize uptime. We work closely with clients to select the best rubber compound and design features for their specific application, ensuring the spare parts deliver optimum performance under those conditions.
Mining & Mineral Processing
Hydrocyclones are essential in mining for classifying and separating ores (gold, copper, iron, etc.). DEF Rubber parts thrive in grinding circuits, mineral classification, tailings thickening, and desliming duties, handling abrasive mine slurry with ease.
Alumina Production (Bauxite Refining)
Alumina refineries use hydrocyclone separators to classify bauxite slurry in the Bayer process. Our rubber linings and spigots in these cyclones resist the heavy wear from bauxite particles, ensuring reliable operation in alumina plants.
Sand & Aggregates
In sand washing and aggregate classification plants, hydrocyclones remove fines and separate sand by grain size. Our replacement cone liners and vortex finders help aggregate producers maintain consistent gradation and throughput, even with silica sand’s highly abrasive nature.
Coal Preparation
Coal mines and prep plants deploy hydrocyclones for desliming and dense media separation. DEF Rubber’s wear parts (especially for apex and cone sections) extend the service life in coal slurry applications, where mixed sharp particles and high slurry flows quickly erode standard parts.
Chemical & Industrial Processes
Many chemical processing facilities, fertilizer plants, and industrial minerals operations (phosphate, potash, etc.) utilize hydrocyclone separators in their processes. Our custom parts, with optional chemical-resistant rubber formulas, support these industries by providing reliable separation in corrosive or high-temperature slurries.
Water Treatment & Others
Even in dredging, wastewater treatment, and other fields where hydrocyclones or sand separators are used for removing solids, our robust rubber components can significantly improve equipment lifespan and reduce maintenance frequency.
Case Study: Vietnam Alumina Plant Saves $30,000 Annually
Background & Requirements: A large alumina production plant in Vietnam was experiencing frequent hydrocyclone maintenance and high consumable costs. The facility’s hydrocyclones (used to separate bauxite slurry in alumina refining) required new cones and spigots every few months due to extreme abrasion. The client’s goals were clear:
- Extend the wear life of hydrocyclone liners and parts
- Reduce unplanned downtime and maintenance labor
- Lower the annual spending on spare parts without sacrificing separation efficiency
Solution: DEF Rubber partnered with the alumina plant’s engineers to develop a custom replacement parts kit for their existing FLSmidth/KREBS hydrocyclones. We analyzed the operating conditions (slurry density, particle size, operating pressure) and identified that the underflow spigot and lower cone area were the primary failure points. Our team then formulated an upgraded natural rubber compound specifically for this application, enhancing the tear resistance to handle the sharp bauxite particles. We manufactured custom-molded cone liners and spigots to exact dimensions so they could be installed seamlessly in place of the OEM parts. The new parts featured thicker cross-sections in known wear spots and utilized our ultra-wear-resistant rubber for maximum longevity. Installation was straightforward, and the components fit perfectly, requiring no modifications to the cyclone assembly.
Results:
- Doubled the service life of critical hydrocyclone parts (2x longer lifespan).
- Halved the frequency of maintenance, significantly reducing downtime.
- Maintained consistent separation efficiency with less performance drop-off over time.
- Saved the plant over $30,000 per year in spare parts and labor costs.
Ready to Improve Your Hydrocyclone Performance?
DEF Rubber is committed to helping you maximize the efficiency and lifespan of your Cavex or FLSmidth hydrocyclones. From initial consultation to final production, our experts ensure you get the right material and design for your specific needs. If you’re looking to reduce costs and downtime with custom hydrocyclone parts, we’re here to make it happen.
Contact us today to request a quote or talk with our engineering team. Let DEF Rubber be your partner in keeping your separation equipment running stronger, longer – so you can focus on productivity and profit.
