If you've noticed your hydrocyclone discharging an excessive amount of fine solids through the overflow—or worse, coarse particles "reporting" to the overflow where they don't belong—you're facing one of the most common and frustrating problems in mineral processing.

Overflow solids carryover (often called "overflow run coarse" or "fines misplacement") is not just a nuisance. It directly impacts downstream processes: fines in the overflow reduce water recovery efficiency, increase reagent consumption in flotation circuits, and can cause environmental compliance issues.

The good news is that most causes are identifiable and fixable—often without replacing the entire cyclone.