Tag Archives: filtration

TAKRAF’s first Dry Stack Tailings system commissioned in Brazil

The first DELKOR Dry Stack Tailings (DST) system to be supplied by TAKRAF Group in Brazil is being commissioned for one of the largest steel producers in the Americas, the company says.

The order for the key equipment for the DST system was awarded in January 2019 and was followed shortly by an order being placed for the supply of a TAKRAF stacker.

The project comprises the following equipment to process iron ore tailings:

  • Flocculant plant;
  • Coagulant plant;
  • 35 m diameter DELKOR high rate thickener;
  • 300 sq.m slurry tank with agitator;
  • Four double-stage centrifugal slurry pumps;
  • Four DELKOR overhead beam filter presses (FP OH): 2 m x 2 m plates;
  • Four compressors with tanks (process and instrument air); and
  • Four TAKRAF belt feeders.

As part of the client’s initiative to improve the sustainability of its operations, the DST system is being built to enable the filtering and stacking of tailings as the deposit area of the existing tailings dam reaches full capacity by year-end.

In addition, by removing most of the water present in the tailing slurry, enabling the material to be safely stacked, the client can benefit from a secure and environmentally friendly approach to tailings disposal.

“Not only does it obviate the risk of catastrophic tailings dam failures, but also maximises the water recovered for return to and re-use by the beneficiation plant,” the company said.

DST will be applied following beneficiation to treat the tailings generated during the iron ore concentration process by flotation. The raw tailings slurry will be first fed to the thickener where part of the water is already recovered. In the next process step, more water is recovered by the filter press to achieve a moisture level of about 14% (dry basis), thus creating a dry filter cake ready to be deposited.

DELKOR’s equipment is built to withstand harsh mining environmental conditions, with the filter presses designed as an overhead beam type suitable for the prevailing operational conditions, it said. These require, among other features, large volumes of material to be processed and easy access to the filter plates and filter cloths for maintenance.

In line with DELKOR’s holistic solutions approach, the DST system was designed as a fully-integrated dewatering process through sedimentation and filtration, with the material being tested in the lab prior to sizing the equipment.

Tiago Carvalho, TAKRAF Brazil Managing Director, said: “TAKRAF and DELKOR’s world-leading technology and expertise to offer a complete DST solution, together with our outstanding technical proposal, based on comprehensive DELKOR testing during the bid stage and collaboration with specialised partners, were undoubtedly convincing factors in the project award.

“All colleagues involved in this project should be commended for successfully bringing this important DST reference to commissioning. This project serves to reinforce TAKRAF Group as a leading global solutions provider and we look forward to successfully delivering future DST projects.”

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

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.”

Metso Outotec introduces new modular filter for battery chemicals sector

Metso Outotec says it is introducing a new modular filter to its Dual Media (DM) filter product family, with the compact Metso Outotec DM1000 polishing filter particularly suitable for removing and recovering organic compounds and solids in small stream feeds in battery chemicals processes.

Thanks to its modular design, the filter is easy to expand also for larger process flows, the company says.

The DM1000 can be used as a traditional electrolyte filter in the extraction processes as well as for feed flow purification before crystallisation in the metal crystallisation processes.

“Since the launch of our first DM filters some years ago, we have delivered almost 50 DM and DM AC filters for hydrometallurgical extraction and crystallisation processes,” Mika Vuorikari, Director of Industrial Filtration at Metso Outotec, says. “We have delivered hundreds of polishing filters to the mining, chemical and hydrometallurgical industries around the world.

“Adding the modular DM1000 filter to our offering caters to the special needs of the rapidly growing battery industry, where sustainable high-quality filtration is needed to ensure increased production capacities and high-quality end products.”

Coming with energy- and water-efficiency benefits, the Metso Outotec DM1000 polishing filter for battery chemicals is part of the company’s Planet Positive offering.

Metso Outotec invests in Lappeenranta filtration technology centre

Metso Outotec is opening a new laser welding unit, customised for demanding production conditions, at its filtration technology centre in Lappeenranta, Finland.

The new laser welding unit will add to the centre’s manufacturing capacity and enable the production of higher-quality welded structures in a safer and more environmentally friendly manner, the company says. The value of the investment is approximately €1 million ($1.2 million).

Markku Teräsvasara, President of Metso Outotec’s Minerals business, says: “Investing in an efficient laser welding unit is one example of our desire to focus on being an industry leader also in filtration technology.

“In Lappeenranta, we produce several types of filters used in demanding industrial applications. We have systematically developed our capabilities in Lappeenranta over the years. Today, the technology centre for solid-liquid separation, which we opened in 2015, serves customers around the world.”

In addition to Lappeenranta, Metso Outotec provides filtration technology to customers worldwide from its Turku and Suzhou facilities in China, Jussi Venäläinen, Vice President of Metso Outotec’s Filtration Business Line says.

“Our filtration equipment is used, for example, in the mining, chemical and food industries,” he says. “All of them require reliable filtration to ensure high quality of their end products.”

Metso Outotec says its filtration technology centre in Lappeenranta plays an important role in the development of industry innovations. In addition to manufacturing, the centre operates a Dewatering Technology Center, which is focused on solid-liquid separation. It also has continuous cooperation with the Lappeenranta-Lahti University of Technology, among others.

Venäläinen added: “We have a long legacy of filtration expertise – our first filters were made as early as the 1930s in Sala, Sweden. Our selection of filtration technologies is the largest in the field, and their energy, emission and water efficiency is in a league of its own.

“Most of the filtration solutions are part of our Planet Positive range of products. Our filters are safe, easy to use, and quick to maintain, and their high level of automation enables continuous optimisation and remote support. We also provide comprehensive filter maintenance, including lifecycle services.”

Metso Outotec has carried out more than 14,000 filtration tests and delivered more than 5,000 filters for various applications worldwide. Most of the filters are sold under the Larox® product name along with Metso Outotec corporate branding.

In Finland, industrial filter production began in 1977 in Lappeenranta under Larox Oy. In 2009, it continued under Outotec (Filters) Oy, and, after the Metso Minerals and Outotec merger, the filtration technology centre became a part of Metso Outotec. The Lappeenranta site employs around 200 people.

Albarrie Tandem filter bags to receive MINExpo airing

Particulate filtration leader, Albarrie, is set to showcase its exclusive Tandem™ Nonwoven Baghouse Filter Bags at MINExpo 2021 in Las Vegas, USA, next month.

The company’s Tandem filter bags are used in some of the largest mining sites, under some of the most demanding conditions all over North America, the company claims, with the bags offering improved operating capabilities and excellent filtration abilities by combining high-performance P84® polyimide fibres with conventional fibres like PPS or polyester.

“The result is a highly efficient baghouse with lower energy requirements and a higher output,” Albarrie says. “This OEM-tested product has good chemical resistance and can withstand high operating temperatures ranging from 260°F (125°C) to 400°F (200°C), making it suitable for many applications.”

MINExpo 2021 is set to run from September 13-15, 2021, at the Las Vegas Convention Center.

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

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.

ANDRITZ ups the filtration ante with new ME2500 filter press

ANDRITZ has introduced a new filter press, the ME2500, to complete its range of “proven” A4F and the SE series filter presses for the mining and minerals industry.

The ME2500 is the best-fit for fast processing of tailings (also with high clay content) or mining concentrates like iron, copper, lead or zinc, the company says. The new model has an hourly processing capacity of up to 450 kg/sq.m, a filtration area of up to 840 sq.m, and features chained plates for faster filter cake discharge. These attributes enable the highest throughputs without compromising on safety, while reflecting a customer focus on saving water, ANDRITZ says.

The innovative closure system on the ME2500 largely replaces hydraulic components with electrical ones and further reduces cycle times, thus increasing capacity and operating availability.

“The increased use of electrical components enables highly sustainable operation of the filter press by reducing the amount of hydraulic oil needed, as well as improving safety thanks to more precise control and less reliance on high-pressure lines that are susceptible to leaks,” the company said.

In addition, and to further optimise the productivity of single machines or plants with multiple filter presses, all modules of the ANDRITZ intelligent filter press – controlled by the Metris addIQ control system – are also available for the ME2500 filter press and can be provided with the full range of options. This draws on smart sensors, data analytics and augmented reality, including multiple sensors to allow for online safety monitoring of the plate package and moveable parts.

The company concluded: “The safe disposal of tailings generated by the mining and minerals sector is a significant cost factor for the industry. ANDRITZ is known for its innovative range of overhead and sidebar filter presses that meet the industry’s most stringent requirements with regard to fast cake discharge and saving water and costs. The maintenance-friendly equipment from ANDRITZ is easily upgradeable, with a modular design for customised process solutions.”

ALROSA looks to ABEL HM pumps for filter press feeding

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.

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

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

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.