Tag Archives: hydrocyclones

Weir to install ‘largest mill circuit pump in North America’ at Teck’s HVC mine

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

The Weir Group PLC has been awarded contracts to supply its WARMAN® slurry pumps and CAVEX® hydrocyclones to Teck’s Highland Valley Copper (HVC) Mine Life Extension (MLE) project in British Columbia, Canada.

Teck’s Highland Valley Copper Mine Life Extension Project aims to extend the mine’s operational life by enhancing existing site infrastructure, addressing the growing demand for copper driven by the transition to a low-carbon future. The project is expected to yield approximately 1.95 Mt of additional copper over its lifespan.

A cornerstone of this project is the WARMAN MCR® 760 pump, which will be the largest mill circuit pump in North America when installed. This addition complements Weir’s existing and planned installations of equivalent-sized pumps in South America and Australia.

The WARMAN MCR 760 pump was developed to meet the demand for mill circuit pumps that can handle unprecedentedly high flow rates, minimising the number of operating lines in a plant, and addressing the global trend of declining ore grades that require increased throughput for economical mineral recovery. The WARMAN MCR 760 pump is designed to maximise wear life in arduous mill duties and facilitate easy and safe maintenance, regardless of an operator’s maintenance schedule or approach.

In addition, Weir will supply CAVEX 800CVX and 650CVX hydrocyclones for the MLE Project. HVC, with its experience operating CAVEX hydrocyclones, has chosen this solution for its consistently high classification efficiency, capacity and low maintenance requirements, according to Weir.

The MLE project will be fully supported by the local Weir service centre in Kamloops, British Columbia, ensuring mission-critical equipment at the HVC mine operates efficiently, it says. The proximity of this service centre means any maintenance or support needs can be addressed promptly, minimising downtime and helping the mine maintain its targets. This local presence is crucial for the mine’s operations, providing reliable access to necessary parts and expert service.

Quinton Sutherland, Weir, Divisional Senior Product Manager, Pumps said: “Weir has a proven track record of supplying and supporting the largest, highest capacity mill pumps on the market. Designing, manufacturing and supporting pumps of this scale presents unique technical and engineering challenges, which is why Weir’s team of experts, drawing on decades of experience supporting customers across the globe, are the best choice when deciding who to trust with the most critical mill circuit operations.

“It’s an engineering and manufacturing feat that’s not easily replicable, which is why it’s important that we can demonstrate to our customers that we’ve done this before, and they know that they can have absolute confidence in us.”

Phil Blondin, Weir, Director, Capital Sales North America, added: “Weir prioritises being close to our customers wherever they are in the world. We have a service centre in Kamloops – a close drive to HVC – and a local team that can provide service and maintenance support, as
well as an inventory program that encompasses the lifecycle of the products we supply.

“This is the first mill pump this large in North America and, while Weir has manufactured and installed pumps this size in other parts of the world, we recognise that having a service network to support customers at every stage of the project is an essential part of what we’re offering.”

Jindex

Metso boosts slurry handling offering with addition of Australia-based Jindex

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Metso says it has signed an agreement to acquire Jindex Pty Ltd, a privately owned Australian company specialising in valves and process flow control, boosting its capacity to provide more comprehensive slurry handling solutions for the mining industry.

The company plans to combine its extensive experience and offering in slurry handling, hydrocyclones and mineral processing equipment solutions with Jindex’s valve offering as part of this transaction.

Tiago Oliveira, Head of Pumps business line at Metso, said: “This acquisition is yet another important step in the development of Metso’s Pumps business line offering to bring us closer to being our customers’ lifecycle partner of choice. Flow and isolation control play a vital role in ensuring smooth slurry handling to maximise the productivity and efficiency of minerals processing plants. In the past, we have collaborated with Jindex on many customer projects and are now glad to welcome the Jindex experts to the Metso team. Jindex has extensive expertise and strong capabilities in valve technology and control equipment, as well as in many types of slurry valve projects, and thus their products complement our offering well.”

Stephen Fowler, Managing Director, Jindex Pty Ltd, said: “This is a great development and an exciting next step. The Jindex product offering and our technical expertise in valves are an excellent addition to Metso’s Pumps business and will enable Metso to provide more extensive flow control solutions to the mining industry. We look forward to contributing our unique knowledge and experience as part of the Metso team, and providing enhanced outcomes to all our collective customers.”

Metso’s Pumps business line offers complete solutions for slurry handling and hydrocyclones, including equipment, parts, aftermarket and lifecycle services and digital services, the OEM says. The equipment offering includes slurry pumps, pipes, hoses, valves and hydrocyclones.

The acquisition is expected to be closed in August 2024. The parties have agreed not to disclose the transaction value, which has no material impact on Metso’s financials.

Metso reflects on ‘benchmark’ contract win in Chile copper space

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Metso has been awarded a major order worth some €55 million ($59 million) to deliver key concentrator equipment for a copper mining project in Chile.

The Metso delivery scope consists of high-capacity Nordberg® MP1250 secondary cone crushers, MF Series™ vibrating screens and energy-efficient Vertimill® VTM1500 regrinding mills.

For the flotation and separation circuit, Metso will supply multiple TankCell® and ColumnCell™ flotation cells featuring several of the largest available 630 cu.m TankCell units, as well as HCT™ High Compression tailing thickeners. In addition, Metso’s scope includes four MHC hydrocyclone clusters, of which two will be among the largest in the world.

Most of the products in the delivery scope are part of Metso’s Planet Positive offering.

Fernando Samanez, Vice President, Minerals Sales for South America at Metso, said: “Working together with the customer and the engineering company on an open collaborative model has been an extraordinary experience. The model enhanced the efficiency of the engineering process and contributed to the alignment of all parties on the targets set by the end customer. This will be a benchmark to be followed in similar projects all over the world.”

WeirMinerals-Cavex

Weir Minerals Africa showcases engineering nous with Cavex cyclone cluster build

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Weir Minerals Africa has manufactured a 20-way cluster of Cavex® 500 CVX hydrocyclones for a gold project in West Africa.

This hydrocyclone delivers exceptional operational efficiencies, reduced wear and consistent metallurgical performance, the OEM said. With a design built for longevity, this unit is anticipated to exceed a 20-year lifespan because of its easily replaceable wear parts that ensure peak performance throughout its service life, it added.

The hydrocyclone cluster was specifically tailored to the classification and processing requirements the project, with Lerato Ramanala, Product Manager Hydrocyclones at Weir Minerals Africa, saying it will be used in a milling application as part of a flowsheet with an HPGR and ball mill – the Cavex hydrocyclones will classify the mill discharge. Operating at a relatively low pressure of 73 kPa, the hydrocyclones are engineered to minimise equipment wear under demanding conditions, the company says.

Ramanala said: “Our design process considered factors such as port sizes and pipe schedules, ensuring obstruction-free operation, even under challenging conditions in which the hydrocyclones have to contend with a wide range of particle sizes. The feed and discharge pipes were engineered to accommodate the required flow rate and pressure, maintaining a launder geometry that ensures optimal slurry levels during regular operation, without any spillage during normal and design operation.”

The hydrocyclone cluster operates efficiently: the overflow goes to the trash screen, the underflow launder diverts the discharge, returning some to the ball mill for further grinding, while the other portion is fed to a gravity circuit.

Ramanala says the hydrocyclone cluster is custom-engineered featuring Cavex hydrocyclones, Linatex rubber linings and Isogate WR valves. The Cavex hydrocyclone features a 360⁰ laminar spiral inlet that significantly enhances separation performance, she notes.

“To prolong wear life and reduce the need for frequent replacements, we’ve used R55 rubber, a patented Weir Minerals material, in the hydrocyclones’ rubber inserts,” she adds.

To address abrasion resistance, Linatex premium rubber, known to consistently outperform other rubber materials in abrasive wet processing applications, Weir Minerals says, was selected. The integration of Linatex rubber minimises maintenance requirements and guarantees optimal equipment performance.

The Isogate WR valve is a lightweight valve designed for a hydrocyclone cluster of this size, featuring advanced rubber sleeve technology for improved wear life and full bore design for unrestricted flow, the company says.

“Notably, this is the first greenfield cluster to incorporate Synertrex IIoT technology for performance monitoring, specifically to detect any roping or splashing events,” Ramanala says. This proactive performance monitoring platform enhances the overall effectiveness of the Cavex hydrocyclones by providing accurate data on cyclone performance, supporting the operator in maintaining optimal operating conditions and enabling proactive intervention for unforeseen incidents, the company explained.

Ramanala added: “Synertrex is much more than a condition monitoring system for individual pieces of equipment. As the technology continues to develop and Weir Minerals works to leverage the equipment and process data it alone has as the OEM, its customers are increasingly seeing it as the preferred partner for intelligent solutions and digitally-enabled services.”

Even with its substantial size, a cyclone cluster of this magnitude maintains a more compact overall footprint, facilitating space optimisation within the process plant while still achieving the necessary cut point, according to the OEM.

Weir Minerals Africa says its experienced local team carefully analysed operational requirements, flow rates and pressure differentials when designing this Cavex hydrocyclone cluster to maximise efficiency and meet required throughput rates. Structural integrity was a primary focus due to the cluster’s large size, and extensive use was made of computer-aided design to ensure a robust design capable of withstanding demanding conditions. The structural design includes walkways, support beams and bracing mechanisms.

The large cluster was manufactured at Weir Minerals Africa’s facility, undergoing trial assembly and quality checks before being disassembled and packaged for shipment to the customer. Installation on site will be part of the greenfields process plant construction project, with Weir Minerals Africa specialists readily available for installation and commissioning support.

Weir Group marks Minerals and ESCO progress in H1 results

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The Weir Group has issued its half-year results to June 30, 2023, noting some significant achievements across its Minerals and ESCO divisions.

Headline numbers for the six-month period included a 19% year-on-year jump in revenues to £1.3 billion ($1.67 billion) and a 26% rise in operating profit to £212 million.

Weir Minerals continued to execute on key strategic growth initiatives, and during the first half gained market share in its core mill circuit product categories, it said.

The company said: “We converted 100% of our competitive field trials for large mill circuit pumps, and also rolled-out our latest cyclone technology.”

One highlight in the period came at a large Brazilian iron ore mine, where Weir Minerals upgraded the cyclones to its latest Cavex® 2.0 solution. The new cyclones, which are Synertrex®-enabled, have improved separation and increased mineral recovery by more than 400,000 t/y, according to the company.

Cavex 2 cyclones were launched in 2020, introducing new geometric features to offer performance unmatched by any cyclone in operation at that point, the company claimed. The advanced LIG+ design (patent pending) enables the Cavex 2 hydrocyclones to classify up to 30% more feed slurry, while occupying the same footprint as competitor hydrocyclones, according to Weir.

Weir Minerals says it also made good strategic progress in sustainable solutions during the six-month period and delivered year-on-year growth in comminution. New orders included a pebble crushing plant for a large copper mine in South America and a crushing solution for a potash mine in Canada.

The company also said it saw “very encouraging interest” from customers for its Redefined Mill Circuit, securing orders from large copper mines in South America for coarse particle flotation (CPF) pilot circuits, in partnership with Eriez.

“Through this strategic alliance, we have integrated CPF technology with our latest generation Warman® mill circuit pumps and Cavex cyclones to provide significantly improved recoveries and process efficiencies for our customers,” it said. “Once operational in the September quarter, these plants will be important reference sites for the industry.”

Around a year ago, Weir Minerals and Eriez Flotation announced a cooperative agreement to design and develop CPF systems. This allows both companies to better connect the Eriez equipment with the slurry classification and conveying expertise of Weir Minerals, according to Ricardo Garib, Division President of Weir Minerals.

Weir Minerals also launched its new, proprietary digital intelli-solutions for pumps, cyclones and high pressure grinding rolls which, coupled with its Synertrex 2.0 platform, captures critical machine health data and enables remote condition monitoring.

It concluded: “We continued to invest in research and development of our core technologies including new materials and polymers, and upgrades and range expansions for our industry leading Warman slurry pumps.”

Weir ESCO, meanwhile, reported that the number of mines using Motion Metrics™ AI-enabled vision technology increased during the first six months of the year, with new orders including a package of five ShovelMetrics™ and five LoaderMetrics™ systems to be deployed across all large mining machines at an iron ore mine in Western Australia.

“The division made excellent progress in growing market share in mining attachments, with a 37% year-on-year increase in orders,” it said. “A particular highlight included converting four cable shovel buckets from competitor products to ESCO technology for a large North American copper miner.”

The division also provided an update on trials of its proprietary ore characterisation technology, which has been leveraging the BeltMetrics™ solution from Motion Metrics positioned above a conveyor directly after the crusher in the flowsheet at an unnamed mine. As well as using the rugged vision technology Motion Metrics has previously used, the company is also incorporating hyperspectral imaging into the mix for this trial.

It reported: “Field trials of our proprietary ore characterisation technology were successfully completed during the first half. Tests enabled critical data to be collected and validated the performance of the technology in a real-world environment.”

Development has now progressed to the next phase focused on exploring “novel illumination” technologies to enhance minerals characterisation, it added.

New Motion Metrics capabilities and functions were launched during the six-month period, including an upgraded lens cleaning solution that enhances machine vision capability and improves response times.

“Other technology investments included development of a new series of mining attachments that, once launched, will expand our addressable market,” it said.

FLSmidth out to optimise closed-circuit grinding operations with KREBS SmartCyclone tech

Automation, Comminution of minerals, Mineral processing, Mining equipment, Sustainable mining, , , , , , , , ,

Efficient operation and minimal downtime are crucial for maintaining productivity and profitability in grinding circuits and, to address these challenges, many operations are opting for the KREBS® SmartCyclone™ technology from FLSmidth, according to the OEM.

Abrie Schutte, Senior Applications Engineer at FLSmidth responsible for the KREBS pumps cyclones and valves product business line, says this innovative technology combines advanced monitoring and automation features to optimise closed-circuit grinding operations.

“SmartCyclone integrates various components and software to provide a comprehensive solution for grinding circuit management, and significantly incorporates roping sensor technology, wear detection technology, a wireless controller system and ECS/ProcessExpert® process control software,” Schutte says. “End-users have found that by leveraging these elements, maintenance planning is enhanced, wear reduced and there is an overall improvement in grinding circuit performance.”

The wear detection technology of SmartCyclone employs specialised sensors to monitor the wear status of cyclone components. This real-time information enables operators to proactively plan for part replacements and schedule maintenance activities, minimising unexpected downtime caused by component failures.

Schutte further explains that an automated monitoring system is a key feature of SmartCyclone.

“This is important as it allows operators to detect wear and troubleshoot issues from a centralised control room, eliminating the need for manual equipment inspections with a reduction in associated risks,” he says.

By promptly identifying and addressing potential problems, process disruptions are minimised, ensuring optimal performance of the grinding circuit.

The SmartCyclone system also includes a roping detection feature, which identifies and corrects disturbances known as “roping”. Overloaded cyclones or those experiencing roping can lead to increased bypass of coarse solids to the overflow and greater particle size variation.

“This accumulation of slurry can adversely affect downstream equipment, such as flotation cells,” Schutte says. “By monitoring and detecting roping, operators can confidently operate the plant closer to its limits, thereby increasing production capacity and improving mineral recovery.”

By integrating SmartCyclone with ECS/ProcessExpert software, the grinding circuit’s performance can be further optimised, according to FLSmidth. The system dynamically adjusts variables such as water addition, pump speed and the number of operating cyclones based on real-time data from SmartCyclone sensors. This continuous optimisation enhances particle size distribution, maximises mineral recovery and improves the overall efficiency of the grinding circuit, it says.

SmartCyclone offers a comprehensive solution for closed-circuit grinding operations, FLSmidth says. By leveraging advanced sensor technologies, automated monitoring and process control software, this system empowers operators to enhance maintenance planning, reduce wear and optimise the performance of their grinding circuits.

Schutte concluded: “With its ability to detect early warning signs, troubleshoot potential issues and dynamically adjust variables, SmartCyclone sets a new standard for smart and efficient grinding circuit management.”

Weir Minerals expands the Cavex 2 hydrocyclone range with 650 model

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Weir Minerals, building on over 20 years of Cavex® hydrocyclone experience, has added the Cavex 2 650 to its product line, with the cyclone set to deliver unparalleled results, the company says.

The release follows the recent launch of the Cavex 2 hydrocyclone, which brought with it the introduction of a LIG+™ inlet and chamber design that, the company says, produces a more stabilised flow pattern, further reduces turbulences and friction throughout the hydrocyclone and provides up to 30% additional capacity.

The latest 650 model has undergone years of research, lab testing and in-field testing to ensure it can withstand the rigours of heavy-duty industrial and abrasive applications. It also addresses the continual demand for increased operational and circuit capacity, and offers customers process improvements combined with digital technology, Weir Minerals said.

“It is important to note that enhancements of the hydrocyclone performance go hand in hand with improving the environmental footprint of the equipment,” the company said.

“By reducing bypass returning to the mill, fewer fines are returned back to the mill in a closed-circuit milling process, thus reducing the need for energy to be used to further process particles that are already small enough to move on to the next stage. This frees up mill capacity, previously used up with fine particles, for the size reduction of larger particles.”

As a hydrocyclone that can make a finer separation, the Cavex 2 650 can operate at a lower pressure for further energy savings or a higher feed density for water savings, while maintaining the existing cut size from the hydrocyclone, according to the company.

And, finally, using equipment with a higher volumetric capacity requires fewer units to be installed upfront as well as fewer consumable spare parts used over the life of the hydrocyclone.

Significant benefits to mining customers include:

  • Increased operational and circuit capacity up to 30%;
  • Maximised plant recovery by reducing the quantity of misclassified particles with an average improvement of the alpha parameter of more than 10%;
  • Improvements in bypass with an average of over 15%;
  • Opportunity to retrofit Cavex 2 650 cyclone into existing cyclone cluster footprints;
  • Less turbulence during the separation process due to the LIG+ inlet and elongated chamber design;
  • Enhanced performance with a Synertrex®-enabled monitoring system, which can detect roping or blockage conditions in advance for continuous, efficient operation of the hydrocyclone; and
  • Improvement of environmental footprint.

To satisfy all process conditions and slurry types, the Cavex 2 650 hydrocyclone comes with a range of material technology options including Linatex® premium rubber, R55 rubber, neoprene for high levels of hydrocarbon and ceramic.

The Cavex 2 650 hydrocyclone can be customised to suit almost any application with a variety of spigots, vortex finders and cone angles, according to the company.

These new hydrocyclones have already been put to the test, with the latest Cavex 2 650 hydrocyclone trial taking place with a customer in Chile. The testing was conducted in a large copper ore mine which had a SAG mill in a closed circuit with the cyclone cluster. The trial tested one Cavex 2 650 in a six-place cluster of existing Cavex cyclones and saw an improvement of up to 48.5% in circulating load and 31.7% in water bypass versus the original cluster, according to Weir Minerals.

A lab water test with the same hydrocyclone fittings as above also yielded positive results: a 211 mm inlet and 260 mm vortex finder delivered 16% more capacity at 100 kPa, and 17% more capacity at 250 kPa.

“These improvements in efficiency and bypass translate to increased savings for brownfield sites where the existing hydrocyclones do not have enough capacity and are maxed out, while greenfield projects benefit from savings in capital expense,” the company said.

The Cavex 2 650 hydrocyclone is the second in a range of standard sizes that Weir Minerals is planning to release, with more sizes in development to expand the current product range.

Cedric Minería selects CDE EvoWash wet processing tech for Buin sand, gravel ops

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Chilean mining and aggregates company, Cedric Minería, has announced a major overhaul of its aggregates business following a significant investment in advanced wet processing technology from CDE, the Belfast-based company says.

The family business, which expanded into aggregates production in 2003, has revealed plans for a new wet processing solution at its Buin operation.

Established in 1981, Cedric Minería specialised in the production of calcium carbonate and sulphur products before diversifying its interests and launching its silica operation, Mina Nancy, near the city of Calama in Antofagasta Region.

It soon secured listing as a strategic supplier of silica to state-owned copper mining company Codelco for its copper smelting plant in Chuquicamata, northern Chile.

Following the success of its silica business, Cedric Minería soon after commissioned its first aggregates processing plant in Buin which supplies the local market with a range of washed sand and gravel products for pre-cast concrete, asphalt, pipe bedding and more.

This summer, CDE will commission the EvoWash™ sand wash plant and an AquaCycle™ water management system at the company’s Buin site, replacing their existing washing screws.

Using CDE cyclone technology, the new plant will enable Cedric Minería to produce two grades of high quality, in-spec fine sands: 0-5 mm and 0-8 mm.

A compact, modular sand washing system, CDE’s EvoWash screens and separates the smaller sand and gravel fractions through an integrated high-frequency dewatering screen, sump and hydrocyclones which provide control of silt cut points and eliminates the loss of quality fines with significant commercial value.

An alternative to water extraction and the costly process of pumping water to the plant, CDE’s AquaCycle significantly reduces costly water consumption by ensuring up to 90% of process water is recycled for immediate recirculation, the company says. It helps to accelerate return on investment by maximising production efficiency, minimising the loss of valuable fines and reducing water and energy costs. A single, compact and user-friendly unit, it can be applied to high and low tonnages across many market sectors.

Cedric Minería owner, Cedric Fernández, says the investment in CDE technology is a significant step forward for the company.

“We’re making a huge technological leap forward with this new plant. Cedric Minería branched into the aggregates business almost two decades ago and throughout that time we have operated a traditional system,” Fernández said. “The existing plant has served us well, but we need a modern solution that is future-ready. Our latest investment in CDE wet processing technology represents the beginning of a new chapter for our company.”

Fernández says the COVID-19 pandemic had a significant impact on the construction industry but anticipates strong future demand for sand and aggregates to support the country’s public works investments.

CDE Business Development Executive, Gustavo Brasil, says older technology is very much under the spotlight for materials processors as they work to remedy inefficiencies.

“Recognising the limitations of the existing setup, the team at Cedric Minería are setting out on an ambitious transformation project to replace a traditional processing plant with a much more advanced and efficient technological solution,” he said.

The CDE solution engineered for Cedric Minería will revolutionise its current process, he added.

“CDE’s Evowash solution will enable Cedric Minería to produce superior fine sands with less moisture content while the AquaCycle water management system will deliver massive efficiency gains by recycling process water and driving down operational costs,” he said.

Weir releases new gate valve as it advances Terraflowing, ToolTek solutions

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Weir Minerals has released a new Isogate® WR knife gate valve to reduce cycling discharge while improving wear life.

The lightweight, long-lasting Isogate WR knife gate valve offers miners and aggregates operators alike a step change in valve performance, according to Weir Minerals.

The release came on the same week Weir Group announced its 2020 financial results, which saw the company report revenue and adjusted operating profit of £1.97 billion ($2.73 billion) and £305 million from continuing operations, respectively. These figures were down 4% and 3%, respectively, from 2019 totals.

On the new valve, Weir said: “Incorporating the latest advances in design and materials technology from Weir Minerals’ expert engineers, the range of Isogate WR knife gate valves are more reliable, while producing minimal fluid discharge and weighing considerably less than equivalent mining valves.”

John Abbott, Global Product Manager – Valves & Tailings, said: “Drawing on decades of wear analysis, we’ve optimised the Isogate WR knife gate valve’s body design, by reinforcing the areas subjected to the harshest wear and pressure. At the same time, we have reduced the weight elsewhere to produce a robust, long-lasting mining valve that’s significantly lighter than comparable products.

“The weight reduction can be especially significant in situations where a number of valves are used on a specific installation, such as in a hydrocyclone cluster, or where lightweight piping systems are used.”

The gate has also been redesigned, with stronger materials resulting in a thinner gate that can still withstand the pressure of mining slurries. This combines with the valve’s unique gate guide that, Weir says, reduces deflection by ensuring smooth gate movement and less strain on the sleeve elastomer during blade transition.

The Isogate WR knife gate valve uses Weir Minerals’ new Isogate WSL sleeve, which comes with proprietary Linard® HD 60 silica-reinforced natural rubber to solve the three most common problems with sleeved knife gate valves: leakage during cycling, tearing and load distribution ring (LDR) failure due to corrosion and erosion, the company explained.

Leveraging the Linard HD 60 rubber’s high resilience against cut, tear and abrasive wear to improve wear life, the new Isogate WSL sleeve fully encloses the LDR to prevent corrosion. By allowing the rubber to move with the blade cycles, the design reduces the chance of tearing while reducing slurry discharge by up to 75%, according to Weir.

The Isogate WSL sleeve can also be used in existing Isogate WS knife gate valves, improving wear life and decreasing discharge on cycling.

Abbott added: “When designing the Isogate WR knife gate valve, we focused on features that improve the everyday experience of working with our valves. This includes important things like improved grease distribution and improved body flushing when used on high solids concentration applications.

“In-depth finite element analysis enables us to ensure the product’s integrity, while making it lightweight. There are also a lot of smaller features to make life easier, such as a larger grease reservoir, ISO mount standardisation and an external visual indicator for the valve’s status.”

Other notable developments from Weir Group’s 2020 financial results included the first order for ESCO’s ToolTek™ system.

This collaborative effort with key mining customers provides enhanced safety for maintenance personnel during the replacement of worn Nemisys® points and adapters, according to ESCO. It features a hydraulic crane mounted tool that is remotely operated, well out of harm’s way during the replacement of worn components. New parts are pre-staged on racks  positioned on the flatbed truck outfitted with the hydraulic crane. The truck also features a recycle bin for safer disposal of worn parts.

Alongside this, Weir said in 2020 it installed the first pilot Terraflowing® plant at a customer’s mine site designed to cost-effectively reduce water in tailings, enabling this waste product to be safely stored or repurposed.

Terraflowing incorporates a two-stage cyclone dewatering process followed by centrifugation of the final stage of cycloning overflow. In the process, three dewatered tailings streams are produced: a primary cyclone underflow, a secondary cyclone underflow and a centrifuge pulp. These three streams can be combined or used in different configurations depending on the end use of the tailings stream, according to Weir Minerals.

This three-stage system offers the flexibility to make provision for variations in mineralogy and particle size distribution as well as the opportunity to recover ‘tailings as a resource’, it added.

Multotec looks for increased resistance, longer wear life from new ceramic-based solution

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A new ceramic-based solution from Multotec has opened the door for a range of componentry to be shaped using pressed alumina ceramics for high wear resistance and longer wear life, the South Africa based company reports.

According to Boyd Butterworth, Sales Engineer at Multotec Wear Linings, the opportunity arose when a chrome smelter in the Steelpoort area of South Africa’s Limpopo province was searching for a more cost-effective solution for certain wear parts in their rotary dryer multi-cyclone arrangement.

“The customer initially required the fabrication and ceramic lining of steel components in the multi-dryer cyclones,” Butterworth says. “The units are employed in the process of drying chromite ore particles and other feed material on its way to the pelletising section of the plant.”

The units are essentially dust cyclones – rather than the process or separation cyclones Multotec supplies – and are subject to aggressive wear. The feed to these multi-dryer cyclones typically consists of chromite ore, reductants such as anthracite, char, coke and coal, and fluxes like quartzite, dolomite and lime.

“The multi-dryer cyclone has four main components, made initially of steel and later lined with ceramics in response to the rapid replacement rate,” Butterworth says. “The wear rate is exacerbated by the high velocity of the material, which is required in order for it to remain in suspension while passing through the system.”

The customer’s eagerness to find a more effective solution allowed Multotec to present an unusual – perhaps unique – concept: solid ceramic components custom-shaped for this specific purpose, the company said.

Butterworth noted that the previous installation of standard ceramic tiles by a competitor did not adequately protect the components from the highly abrasive material which, moving at about 18 m/s, was still leading to frequent component replacements.

“Our proposal was to produce a solid ceramic blade and dome arrangement, as well as to provide the rest of the tube and inlet sections with engineered ceramics, installed at a very high standard,” he says.

Paving the way for this solution was a highly specialised and innovative new fabrication technique that saw the ceramics shaped into various complex and intricate designs while they are in the ‘green phase’ of production, using state-of-the art CNC technology.

“Thanks to this technique, we can produce solid alumina ceramic machine components,” Butterworth says.

The company’s research to date suggests that this might be the first time components like these have been produced from pressed alumina ceramics – making them a pioneering achievement.