Tag Archives: Filter Press

Sandfire welcomes new Larox filter press at Motheo copper mine

Base metals, Comminution of minerals, Mineral processing, Mining equipment, , , , , ,

Sandfire says it has successfully commissioned a Larox permanent filter press at its Motheo copper mine in Botswana, as part of a planned debottlenecking process.

On May 25, Sandfire announced that it had successfully produced first copper concentrate at Mothe, with construction of the mine nearing completion and equipment commissioning activities over 92% complete for the initial 3.2 Mt/y processing capacity.

During the initial ramp-up of the Motheo process plant in the September quarter of 2023, it was identified that the OEM filter press installed during construction was unable to achieve design parameters, the company explained in a July 22 release. An interim solution using mobile filter units was implemented, enabling the operation to safely ramp up the production of copper concentrate at planned rates and specifications.

In parallel, an $8 million capital investment secured the procurement, installation and commissioning of a Larox filter press from Metso to support the long-term operational requirements of Motheo.

Sandfire Chief Executive Officer and Managing Director, Brendan Harris, said: “Commissioning of the new filter press concludes a challenging period for the Motheo operations team, and I congratulate them on their hard work and ingenuity. The new filter press removes significant complexity at the ‘back end’ of our processing circuit and provides the capacity needed to test higher rates of production as we debottleneck the operation.”

CDE unveils ProPress high-performance filter press at Hillhead

Comminution of minerals, Environmental, Mineral processing, Mining events, Water management, , , , ,

CDE, a leader in the design and engineering of sand and aggregate wet processing solutions for the waste recycling and natural minerals processing sectors, has unveiled its new ProPress high-performance filter press at Hillhead, in the UK, adding to its state-of-the-art water management and recycling systems.

Developed to meet the evolving needs of the construction and demolition (C&D) waste recycling, quarrying and mining sectors, the ProPress integrates the latest technological advancements to deliver exceptional operational efficiency and maximum water recovery, according to the company.

CDE’s ProPress, which features patent-pending technology, benefits from a flexible design and variable throughput that can be scaled to fit the processing volume of any operation.

Unlike traditional filter presses, the system is dual feed, meaning sludge is fed from both sides of the ProPress for improved efficiency and faster cycle times. Optimised sludge feed pressure also allows for faster dewatering to increase overall throughput, CDE says. This is further supported by an overhead beam design that ensures reliability by reducing stress on the unit and improving its durability.

The ProPress features plates that are 25% larger (2.5 m x 2 m), while greater chamber volume and fewer plates serve to provide maximum capacity on a smaller footprint and improve mechanical cycle times, according to the company.

Safe and efficient maintenance is made possible by integrated plate-shaking technology which addresses filter cake build-up within chambers to help reduce the need for manual intervention. An access walkway provides clear and unobstructed means to carry out maintenance safely and efficiently, and flush mounted drip trays reduce material entrapment and lock in place to provide a secure maintenance platform for operators, CDE says.

The design is supported by an innovative, multifunctional robot, which serves as the main workhorse for the ProPress, controlling plate opening, plate shaking, cloth washing, plate winch and the maintenance platform.

The CDE ProPress is available in a range of different sizes to suit markets and applications. It is also largely pre-assembled to expedite commissioning, allowing operators to get up and running quickly.

ProPress process

As materials are washed and graded, the water from that process accumulates silt and other residues to form a sludge. A challenging material to process, that sludge is pumped under high pressure into the CDE ProPress, which consists of a sequence of plates, the composition of which forms a series of chambers.

As sludge is pumped under high pressure through the press, solid materials build within the chambers to form a filter cake which is dewatered to maximise water recycling and recover a by-product with multiple applications.

With the CDE ProPress, owners and operators can recycle up to 95% of process water for immediate reuse in their wash plant while simultaneously cutting waste disposal fees by recovering a filter cake product that can be used for pipe bedding and landfill capping, according to CDE. This eliminates the need for settling ponds which typically require extensive maintenance, consume labour resources and incur significant costs.

Owners and operators can cut waste disposal fees by recovering a filter cake product that can be used for pipe bedding and landfill capping, according to CDE

CDE’s Business Development Director, Darren Eastwood, said: “Tackling the most challenging of materials is our expertise. We’ve poured over 30 years of engineering excellence into the development of the ProPress. We’ve listened to and worked alongside our customers around the globe to design a solution that is adaptable to their needs, be they in the waste recycling or natural minerals processing sectors.

“Those needs were clear: sustainable water management was key to minimise fresh water dependency and maximise water recycling, all while improving processing capacity, reducing operating costs, and minimising maintenance downtime. The ProPress is our response to all of this and more and it is already delivering for our customers. By the end of the year, the ProPress will be found on eight plants across three regions, processing around 1000 t/h of material.

“Our most significant product launch in recent years, the ProPress really encapsulates CDE’s purpose: to create our best world, a ton at a time. It represents a constant push for improvement to make our equipment, our customers’ operations and the sectors we operate in more efficient and less wasteful. We’re very pleased to finally bring this latest innovation to the wider market to help maximise the availability of our natural resources and reduce the industry’s waste burden.”

Hillhead 2024 is being held in Buxton, in the UK, and runs from June 25-27.

Zululand Anthracite Colliery commissions Filtaquip filter press at coal operations

Coal technology, Mining equipment, Water management, , , , , , , , ,

Zululand Anthracite Colliery (ZAC) says it has commissioned a new 25 t/h filter press at its coal washing plant, in Emakhalathini, KwaZulu-Natal, South Africa.

The filter press, from South Africa-based Filtaquip, removes slurry from the water used in the coal washing process. It will aid in preventing incidents such as the coal slurry spill, which occurred at ZAC after the end wall at Slurry Pond 3 failed on December 24, 2021, the company noted.

ZAC Engineering Production Superintendent, Howard Atkinson, explained: “The filter press filters slurry-laden water and removes all the ultrafines from the water to enable reclaimed water to be reused in the beneficiation process.”

The filter press plant, which cost R14.5 million ($933,660), was commissioned on May 10, 2022, and was in full production by May 16.

Filtaquip says its filter presses have high pressure technology for up to 21 bar feed pressure; Q-Shift plate movement technology for efficiency; external filtrate discharge; and an automated and maintenance free shaker system.

The conservation, protection and management of water is a top priority for ZAC, it said.

ZAC GM, Wayne Rowe, said: “The principal aim of ZAC’s sustainable water management policy is to minimise and reduce freshwater consumption in all our operations.”

ZAC operates an underground, deep level, narrow seam operation, using both continuous miners and drill and blast mining techniques. ZAC’s current life of mine is up to 2027, but there are undeveloped known resources still to be considered in future, it says.

New Ishigaki filter press starts up at Pilbara Minerals’ Pilgangoora operation

Energy minerals, Mineral processing, Mining equipment, Mining services, Water management, , , , , , , ,

Pilbara Minerals Ltd says it has commenced concentrate production from its newly installed filter press at the Pilgan Plant. The development is part of the Plant Improvements Project being undertaken at its 100%-owned Pilgangoora lithium-tantalum operation in Western Australia’s Pilbara region.

The filter press in question is provided by Ishigaki and will handle approximately 1,500 t/d of concentrate, Pilbara Minerals’ Managing Director and CEO, Ken Brinsden, confirmed.

The Pilgan Plant Improvements Project is expected to de-bottleneck the facility to increase plant operating time and throughput, reduce final product moisture (minimising solar drying) and further manage product recovery performance. These improvements are ultimately expected to realise additional production capacity from the facility, and particularly from the fines flotation circuit.

A total of approximately A$22 million ($16 million) of capital will be invested, with the project expected to be fully ramped-up during the December quarter 2021 to 360,000-380,000 t (dry) of spodumene concentrate. When combined with Ngungaju Plant’s ramped-up capacity of 180,000-200,000 t (dry), which is expected from mid-2022, the total annual production capacity across the entire Pilgangoora operation is expected to increase to circa-560,000-580,000 t/y.

Brinsden said the commencement of production from the Pilgan Plant Improvements Project marked another significant and exciting milestone in the rapid growth of the Pilgangoora project.

“The team has done another amazing job in delivering this project on time and in line with budget,” he said. “Keeping it on track, in combination with the restart of the Ngungaju Plant, is testament to the delivery capability of our team – particularly considering that these works were achieved during a period when the resources industry is under considerable pressure in terms of securing people, resources and equipment.”

Abra Mining selects CITIC HIC ball mill, Ishigaki filter press for base metals project

Base metals, Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, Mining services, Water management, , , , , , ,

Abra Mining has placed orders for two key long-lead items for the processing plant at its namesake base metal project in Western Australia, tapping CITIC-Heavy Industries for the ball mill and Ishigaki for the horizontal filter press.

The project, owned 77.28% by Galena Mining, is set to turn into a mine and processing facility with a 16-year life producing a high-value, high-grade lead-silver concentrate containing around 95,000 t/y of lead and 805,000 oz/y of silver after ramp-up. First production is scheduled for 2023.

Abra Mining, the joint venture company for the Abra base metals project, confirmed it had placed orders for the ball mill and the concentrate filter for the 1.2 Mt/y plant; items that have a combined order value of approximately A$9 million ($6.6 million).

Abra’s ball mill will be manufactured by CITIC-Heavy Industries Co Ltd (CITIC HIC) in Luoyang, Henan, China. The mill ordered is a 5 m diameter x 5.6 m effective grinding length fixed speed, single-pinion driven 2.5 MW ball mill.

The concentrate filter (horizontal filter press) will be manufactured by Ishigaki Co Ltd at its manufacturing facility in Sakaide on Kagawa Island, Japan. The unit ordered is a LASTA MC fully automated horizontal batch pressure filter.

Galena Managing Director, Tony James, said: “Ordering this equipment now is a key step in the plant build program for Abra. The ball mill and the concentrate filter are internationally-sourced long lead-time items required for the plant and the company, in consultation with GR Engineering, has chosen trusted, industry-leading suppliers for both items.”

Metso Outotec to help Karara Mining expand tailings filtration at iron ore mine

Mine operation news, Mineral processing, Mining equipment, Mining services, Steel and iron ore, Water management, , , , , , , , , ,

Metso Outotec has signed a contract with Karara Mining Limited for the design of its tailings filtration plant expansion project at its iron ore mine in Western Australia.

This agreement includes the delivery of key filtration and material handling equipment and associated services, with the typical value for an order like this is in the range of €15-20 million ($11-15 million) depending on the scope of delivery. The order has been booked in Minerals’ June quarter 2021 orders received.

Karara produces a premium, high-grade (65-68% Fe) magnetite concentrate at a design production rate of 8 Mt/y, Metso Outotec said. With this expansion, the operation will increase the current tailings filtration capacity from 30,000 t/d to over 45,000 t/d enabling safe and sustainable storage of the process mine waste, with improved utilisation and recovery of water.

Kai Rönnberg, Vice President, Minerals Sales − Asia Pacific, said: “The Karara mine represents one of the largest filtered tailings facilities in the world. We are very proud that Karara Mining Limited has chosen Metso Outotec to deliver the plant design and key equipment in this expansion project. This is a continuation of earlier delivered proprietary key process equipment and long-term on-site maintenance service agreements.”

Metso Outotec’s scope in this expansion will include the Larox® FFP3512 filter press as primary filtration equipment, material handling conveyor systems and peripheral items. Additionally, spare parts and supervisory services will be supplied to support commissioning and plant ramp-up. Delivery will take place during 2022, and the plant is expected to start production late in the December quarter of 2022.

ALROSA looks to ABEL HM pumps for filter press feeding

Diamond mining, Mine operation news, Mining equipment, Mining services, Water management, , , , , , , , ,

Piston diaphragm pumps from ABEL are helping Russia’s ALROSA with its filtration process at one of its diamond mines in the country.

In Spring 2021, ABEL received an order for the delivery of six of these piston diaphragm pumps, HM pumps, following an initial HM pump order in 2020. This inaugural pump was delivered to ALROSA in February 2020 as replacement for a centrifugal pump previously used for filter press feeding. At the beginning of August, the ABEL pump was commissioned at the diamond producer’s plant. The dewatering result (higher solids content, shorter filtration time) was so convincing that ALROSA decided to feed all filter presses in this plant with the pumps, ABEL said.

The latest delivery is being facilitated by ABEL’s official distributor in Russia, SibComplectService.

ABEL’s HM pumps are available as single- or double-acting versions. They come with a high flow rate, reliable function and particularly low operating and maintenance costs, the company says.

In addition to filter press feeding, the hydraulic diaphragm pumps are also used for sludge transport, spray dryer feeding, rotary kiln feeding, autoclave feeding, and sealing/rinsing water supply, among other applications.

BHP Mitsubishi Alliance tasks Jord International with filter press maintenance challenge

Equipment maintenance, Mine operation news, Mineral processing, Mining equipment, Mining maintenance, Mining services, Steel and iron ore, Water management, , , , , , , , ,

Jord International has been tasked to develop a safer solution to filter press maintenance at BHP Mitsubishi Alliance’s Caval Ridge metallurgical coal mine, in Queensland, Australia, as part of BHP’s Supplier Innovation Program challenge, launched in partnership with Austmine in 2020.

The program follows a model that has operated successfully in BHP’s Minerals Americas business for the last decade, the miner says.

In January, Jord signed a Collaborative Agreement with BHP – the first under this new challenge – to design and construct the first prototype of this idea, working hand-in-hand with the maintenance team at BMA’s Caval Ridge metallurgical coal mine, near Moranbah.

Jord is proposing a safer way to perform maintenance on filter presses that removes moisture from coal rejects at the wash plant. It comprises a belt cartridge installer within a self-contained steel frame that holds a new belt and removes the old damaged belt.

The first belt installer is expected to be in use by July, according to BMA, with the pilot to run for six months. If successful, the new approach will be implemented permanently at Caval Ridge, and potentially at other BMA sites using filter presses to remove moisture from coal rejects, BMA added.

Jord’s Mechanical Engineer for Aftermarket and Reliability, Craig Samuel, developed the concept and says it eliminates the need for operators to be in physical contact with the filter press.

“Creating a safer environment is the pinnacle of an engineer’s ethos and it’s incorporated in everything we design,” Samuel said. “We know from experience that efficiency and reliability are critical to mining operations, so I’m proud that this idea will make a traditionally time-consuming task much faster and I’m looking forward to working closely with the Caval Ridge team.”

When developing the award submission, Samuel consulted with Jord’s field service team to ensure the concept was practical and rigorous enough to meet the demanding operating conditions.

Jord’s General Manager of Resources, Kevin Barber, said he is proud of his team for having the drive and innovative thinking required to solve this long-standing industry challenge.

“We would like to thank BHP for their recognition and for the opportunity to participate in genuinely collaborative discussions about real challenges faced in the industry,” he said. “At Jord, we live by the motto ‘ideas engineered’, which means we encourage our people to share new ideas. We often invest in research and development initiatives with a goal to commercialising new products.

“We look to add value in all our projects, whether it’s increasing safety, reducing risk, producing a higher-grade product, increasing plant capacity, minimising environmental impacts, or conclusively proving new industrial processes.”

BHP says its Procurement Innovation & Community team is currently developing another six Supply Innovation Program challenges across Minerals Australia, with the goal of announcing more pilot contracts in coming months.

Metso Outotec tackles long-term tailings management task with Larox FFP3716 filter

Automation, Environmental, Mining equipment, Mining services, Sustainable mining, Water management, , , , ,

Metso Outotec says its newest addition to the FFP filter range, the Larox® FFP3716 filter, comes with compact plate pack design and smart automation, redefining the overall standard in reliability, capacity and safety in tailings filtration.

Combined with Metso Outotec’s optimised filtration plant design, the FFP3716 filter offers a reliable and cost-efficient long-term solution for tailings management, even in challenging environments, the company claims.

Geoff Foster, Head of Tailings Filtration at Metso Outotec, said: “Responsible usage of water in the mining industry is the primary driver for increasing interest in tailings dewatering. At Metso Outotec, our goal is to provide holistic tailings management solutions by bringing a step change in the way we view, handle, and manage tailings.

“Backed by proven technology and industrial knowledge, our efficient dewatering solutions help in maximising water recovery and reuse. The Larox FFP3716 filter represents the most advanced technology currently available for safe and efficient dewatering.”

The Larox FFP3716 comes with a substantial increase in total filtration volume, using an optimised plate pack design to reduce wear on the plate pack and cloth components, along with ease operation and spares holding.

The new design of the closing and sealing mechanism, with individual controlled sealing cylinders, ensures a squared plate pack at any time, resulting in long lifetime of the pack, the company says. The filter, which comes with a 2,000 sq.m filtration area, 44 cu.m of chamber volume and up to 16 bars of operating pressure, has been designed from bottom to top with optimal safety in mind, Metso Outotec added.

Metso Outotec gains more control over solid/liquid separation with Filter Optimizer

Environmental, Mineral processing, Mining equipment, Mining services, Mining software, Sustainable mining, Water management, , , , , , , ,

Metso Outotec has introduced a Filter Optimizer to further boost the performance of its Larox® PF filter in the mining and chemical industry processes.

The optimiser improves the PF filter performance by enabling more precise control over the solid/liquid separation process, according to the company. It is intended to stabilise the effect of upstream process variations, provide tools for improved process control and reduce the need for manual intervention.

In mining processes, the new Filter Optimizer complements Metso Outotec’s other advanced control solutions for concentrator plants consisting of the Grinding Optimizer, Flotation Optimizer and Thickener Optimizer, the company says.

The Filter Optimizer enables automatic adjustment of filtration as well as pressing and air drying setpoints based on filter performance. Compressed air usage is optimised in the controlled air-drying sequence, resulting in optimised energy consumption, Metso Outotec says.

Leena Tanttu, Senior Manager, Process and Testing of Filters at Metso Outotec, said: “The new Filter Optimizer automatically adjusts the filter’s process performance, adapting to upstream process variations. Instead of relying on manual moisture sampling and cake-weight monitoring, new setpoints are calculated on the go and adjusted automatically.”

Thanks to the optimiser’s remote connectivity, rapid OEM expert support is available for fine-tuning of the system parameters and further optimisation of performance, the company says. An integrated historical database increases process visibility and provides a powerful tool for performance evaluation.

Metso Outotec’s Filter Optimizer typical scope of supply includes:

  • Moisture analyser;
  • APC system (server, control room operator interface, VPN router for remote connectivity);
  • Engineering and project management including control design and set up;
  • Comissioning including system implementation, start-up and controller fine tuning; and
  • Operator training.

In addition to filters, Metso Outotec says it provides a full scope of services for filters, including process optimisation services, optimiser performance reporting, annual on-site maintenance visits, remote and on-site support, and more.