Abstract: To address the low classification efficiency of hydrocyclones in a concentrator and overcome the limitations of single-parameter optimization, this study systematically investigated the coupling effects of operating parameters, such as feed flow rate, feed concentration, and feed fineness, and structural parameters, including spigot diameter and vortex finder insertion depth. The effects of each factor on classification efficiency were determined through single-factor experiments, and an L16（4⁵） orthogonal experimental design was then adopted to investigate the synergistic effects of structural and operating parameters. The results show that the order of influence of each factor on classification efficiency is: feed fineness > spigot diameter > feed flow rate > feed concentration > vortex finder insertion depth. The optimal parameter combination is a feed flow rate of 152 m³/h, feed concentration of 39%, feed fineness of 37% （−38 μm fraction）, spigot diameter of 16 mm, and vortex finder insertion depth of 105 mm, resulting in a hydrocyclone classification efficiency of 66.27%, which is 22.86 percentage points higher than that of the original process. This research provides a theoretical basis and practical reference for the optimization of grinding and classification processes in similar concentrators.